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OIL AND NATURAL GAS CORPORATION

INSTITUTE OF DRILLING TECHNOLOGY, DEHRADUN

A PROJECT REPORT ON
“COMPLICATIONS AND PROCEDURE FOR
CONTROLLING MUD LOSS”

Guided by:
Mr. Manoj Kumar Gautam
Chief Chemist
IDT Dehradun

Submitted By:
Ahjoliya Nandish
College Registration No: 21CH10013
Mail ID: ahjoliyanandish@[Link]
Department of Chemical Engineering
Indian Institute of Petroleum and Energy, Visakhapatnam
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CERTIFICATE

This is to certify that Ahjoliya Nandish, pursuing a Bachelor of Technology in

Chemical Engineering from the Indian Institute of Petroleum and Energy,
has successfully completed his training report on “Complications and
procedure for controlling Mud Loss” at IDT ONGC from 7th December
2023 to 23th February 2024 and has submitted a copy of training report after
successful completion of training at IDT. We found him as a hardworking,
inquisitive, sincere, diligent person and his behaviour of conduct was good.

Date: 23-02-24

Mr. Manoj K Gautam

Chief Chemist
IDT Dehradun
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ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people who directly or

indirectly contributed to the development of the work and who guided my
thinking behaviour during the study.

I wish to thank OIL & NATURAL GAS CORPORATION Ltd,

INSTITUTE OF DRILLING TECHNOLOGY, DEHRADUN, INDIA
for conducting the training program at their premises and providing all the
needful facilities required for completion of the entire program. I am also
thankful to them as they took great deal in arranging lectures during my
training which helped me to gain knowledge.

I would like to thank Mr. Manoj Kumar Gautam (Chief Chemist),

IDT-ONGC, Dehradun for his support through which I could complete my
internship. His guidance was a source of inspiration for me throughout the
training.

I would like to thank all my professors at IIPE Visakhapatnam, who

taught me the principles and basics of Chemical Engineering, which helped
me to perform the project.

At last, I express my gratitude to those who have helped and encouraged me

in various ways in carrying out this project. I would like to extend my thanks
and would like to acknowledge the ONGC personnel for sharing their
valuable knowledge in the field which would help me in my future
endeavours.

INTERN SIGNATURE
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CONTENTS

Sr. No TOPIC PAGE NO.

1 Introduction to ONGC 5-7

2 About Institute of Drilling Tech., ONGC 8-9
3 Fundamentals of Drilling Fluids 10-19
4 Drilling Fluids 20-22
5 Mud Losses 22-28
7 Conclusion 29
8 References 30
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INTRODUCTION TO ONGC
Oil and Natural Gas Corporation (ONGC) is a big Indian company that deals with oil and gas. It started
in 1956 and is controlled by the Ministry of Petroleum and Natural Gas. ONGC is the largest company
in India for exploring and producing oil and gas. It's also one of the biggest publicly traded companies in
the country.
ONGC works in different parts of the oil and gas industry, like finding and producing oil, refining,
transporting through pipelines, and selling petroleum products. The company is active in offshore
exploration and has found important reserves in the Bay of Bengal and Arabian Sea.
ONGC has a mix of assets in India and other countries like Russia, Vietnam, Mozambique, and Brazil.
It owns parts of other companies and works in both the upstream (finding and producing) and
downstream (refining and selling) parts of the petroleum industry.
In recent years, ONGC has bought other companies and invested strategically. For example, it acquired
Hindustan Petroleum Corporation Limited in 2018 and got a stake in the Vankor field in Russia in 2015.
These moves have helped ONGC grow in the Indian and international markets.
ONGC is serious about sustainable development. It does things to lessen its impact on the environment,
like using renewable energy, adopting energy-efficient technologies, and following best practices for
waste management and preserving natural resources.
To sum up, ONGC is a major player in India's oil and gas industry, with a big presence in both local and
international markets. The company is committed to being sustainable and has taken steps to reduce its
environmental impact. With its valuable assets and smart investments, ONGC is a significant player
globally in the oil and gas sector.

 ONGC has discovered 6 out of the 7 oil and gas producing basins in India:
 This largest energy company in India has established 8.98 billion tonnes of in-place
hydrocarbon reserves. It has to its credit more than 570 discoveries of oil and gas with
Ultimate Reserves of 3.13 Billion Metric tonnes (BMT) of Oil Plus Oil Equivalent Gas
(O+OEG) from domestic acreages.
 It has cumulatively produced 1042 Million Metric Tonnes (MMT) of crude and 715
Billion Cubic Meters (BCM) of Natural Gas.
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 ONGC's wholly-owned subsidiary ONGC Videsh Ltd. (OVL) is the biggest Indian
multinational, with 37 Oil & Gas assets in 17 countries.
 ONGC produces over 1.26 million barrels of oil equivalent per day, contributing around
75% of India's domestic production. Of this, over 75% of crude oil produced is Light &
Sweet.
 The Company holds the largest share of hydrocarbon acreages in India (61% in PEL
Areas & 81% in ML Areas).
 ONGC possesses about 15% of the total Indian refining capacity.
 This E&P Company has a well-integrated Hydrocarbon Value Chain structure with
interests in LNG and product transportation business as well.
 A unique organization in world to have all operative offshore and onshore installations
(555) accredited with globally recognized certifications.
 All crudes are sweet and most (76%) are light, with sulphur percentage ranging from
0.02-0.10, API gravity range 26°-46° and hence attract a premium in the market.
 Strong intellectual property base, information, knowledge, skills and experience.
 ONGCs performance in OALP Bid rounds: Wins two Blocks in Round 1, one Block in
Round 2, seven Blocks in Round 3 and seven Blocks in Round 4.
 ONGC owns and operates more than 25,500 kilometers of pipelines in India, including
sub-sea pipelines. No other company in India operates even 50 per cent of this route
length.
 Total blocks awarded to ONGC and Consortium under NELP was 130 Blocks; 116
ONGC operated and 14 as Consortium/Joint Ventures.

Global Ranking
 Forbes Global list of 750 World Best Employers – 2020: ONGC featured in the
Forbes Global list of 750 World Best Employers compiled in partnership with market
research firm Statista. ONGC ranked 377 in the fourth annual survey conducted
across 58 countries covering 160,000 workers of companies operating in multiple
regions.
 S&P Platts Global Energy Award 2019: ONGC awarded for Corporate Social
Responsibility - Diversified Program. ONGC is the only Indian company to bag
honors across all categories.
 Fortune Global 500 list 2019: India’s largest oil and gas producer ONGC ranked 160
in the coveted Fortune Global 500 list 2019.
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 Fortune Global 500 list 2019: ONGC jumped 37 notches to secure the 160th
position at the 2019 Fortune Global 500 list. ONGC ranked third in the Indian Fortune
club, after Reliance Industries Limited (RIL) and Indian Oil Corporation (IOC).
 Platts Top 250: ONGC maintained its first position globally in the industry category
“Oil and Gas Exploration and Production” and achieved overall ranking of 21st
position in the Platts Top 250 Global Energy Company Rankings-2018.

Vision: ONGC's vision to be one of the global leaders in integrated energy business
through sustainable growth, knowledge excellence and exemplary governance practices,
focus on domestic and international oil and gas exploration and production business
opportunities.

Mission: ONGC has the following mission before it:

• Dedicated to excellence by leveraging competitive advantages in R&D and

technology with involved people.
• Imbibe high standards of business ethics and organizational values.
• Abiding commitment to health, safety and environment to enrich quality of
community life.
• Foster a culture of trust, openness and mutual concern to make working
stimulating & challenging experience for our people.
• Focus on culture domestic and international oil & gas exploration and production
business opportunities.
• Provide value linkages in other sectors of energy business.
• Create growth opportunities and maximize shareholder value.
• Retain dominant position in Indian Petroleum Sector and enhance India’s energy
availability.
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INSTITUTE OF DRILLING TECHNOLGY (IDT)

The Institute of Drilling Technology (IDT) in Dehradun, India is a premier institution in the
field of drilling technology. Established in 1979 by the Oil and Natural Gas Corporation
(ONGC), IDT provides a comprehensive education and research platform for professionals in
the oil and gas industry. The institute offers a two-year postgraduate program in drilling
engineering, short-term courses on various aspects of drilling technology, and advanced
training programs for experienced drilling engineers and technicians.
IDT has state-of-the-art facilities, including drilling simulation systems, well control labs, and
drilling fluids technology labs, that provide students with hands-on experience and practical
knowledge in drilling operations. The faculty at IDT comprises of experienced industry
professionals and academicians who provide students with a thorough education in drilling
technology.
In addition to training, IDT also conducts cutting-edge research and development in the field
of drilling technology. The institute collaborates with national and international organizations
to address challenges and improve the state-of-the-art in drilling technology. IDT has a strong
reputation in the industry and its alumni occupy key positions in the oil and gas sector.
In conclusion, the Institute of Drilling Technology in Dehradun is a highly respected
institution in the field of drilling technology. With its comprehensive education programs,
state-of-the-art facilities, and strong reputation in the industry, IDT provides students with the
skills and knowledge they need to succeed in the oil and gas sector.
The integrated HRD division imparts training to participants from both national and
international oil companies in various aspects of oil well drilling technologies. The renowned
Well Control School at IDT has been accredited by International Well Control Forum, The
Netherlands, International Alliance for Well Control, the Netherlands, and also
from International Association of Drilling Contractors, USA.
IDT is one such drilling institute in India which has infrastructure for applied R&D has been
developed with the state-of-the-art equipment and machines to achieve qualitative
experimental results. Focus of R&D is directed towards drilling technology, drilling fluid
engineering and cementation and cementing materials to meet challenges of drilling industry.
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The technologists and scientists provide solutions to the down hole drilling problems,
improving design of the systems and thereby contributing towards the development of
excellent, efficient and cost-effective operations.
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Fundamentals of Drilling Fluids

1. Introduction:

Over the years, the discovery of petroleum in various parts of the world has led to the
development of techniques and equipment to enhance and optimize the production of this
natural resource. One of these development is the Drilling fluid (Mud) which is used for
efficient drilling and to control drilling pressure, stabilize wellbore as well as control fluid
losses during drilling. During drilling, this fluid is passed through the kelly, drill pipe, drill
collars & drill bit and goes back to the surface through well bore and the conductor pipe to
the shale shaker which then removes cuttings from the drilling mud and sends back the mud
to the pit. Measuring fluid performance requires the evaluation of all key drilling parameters
and their associated cost. Simply stated, the effectiveness of a fluid is judged by its influence
on overall well cost. This chapter discusses the various fundamentals of drilling fluids and
their performance in assuring a safe drilling operation at minimum overall cost.

2. Functions of Drilling Fluid:

Drilling fluid serves many functions. The major functions are listed below –

a) Provide Wellbore Stability:

The Drilling fluid’s (DF’s) basic function is to establish borehole stability by maintaining
chemical and/or mechanical balance. In the mechanical stability case, hydrostatic pressure
exerted by the DF is normally designed to exceed the existing formation pressure. The
desired result is the control of formation pressure and a mechanically stable borehole. The
factors considered are -

 Behaviour of rocks under stress and their related deformation characteristics

 Dipping formations & tectonic activity
 Formations with no Cementous material
 High Annular fluid velocity
 Pipe tripping speeds and corresponding transient pressures
 Hole angle and azimuth

b) Remove Drilled Cuttings from Borehole:

Drilling fluid transports cuttings from the well bore generated as drilling progresses. The
velocity at which fluid travels up the annulus is the most important hole cleaning factor. The
annular velocity must be greater than the slip velocity of the cuttings for the cuttings to move
up the well bore. The size, shape, and weight of a cutting determine the viscosity necessary to
control its settling rate through a moving fluid. Low shear rate viscosity strongly influences
the carrying capacity of the fluid and reflects the conditions most like those in the well bore.
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The density of the suspending fluid has an associated buoyancy effect on the cuttings. An
increase in density increases the capacity of the fluid to carry cuttings.

c) Cool and Lubricate Bit & Drill string:

While drilling heat is generated by rotation of the bit and drill string due to friction. The
drilling fluid acts as a conductor to carry this heat away from the bit and to the surface. In
HTHP and deep wells with high geothermal gradients, the role of DF makes it a more
important function. Drilling fluid also provides lubrication for the cutting surfaces of the bit
thereby extending their life and performance. Various speciality products are added to DF to
increase the lubricity coefficient.

d) Control Subsurface Pressure:

During drilling sufficient hydrostatic pressure must be exerted by the drilling fluid column to
prevent influx of formation fluids into the borehole. The amount of hydrostatic pressure
depends on the density of the fluid and the height of the fluid column i.e. Well depth. The
general weighing materials used to maintain drilling fluid density are barite, hematite,
ilmenite, calcium carbonate and tri manganese tetra oxide.

e) Suspend Cuttings & Weighing Material:

The DF must have sufficient gel strength to suspend cuttings & weighing material when
circulation is stopped. Several factors affect suspension ability.

 Density of the drilling fluid

 Viscosity of the drilling fluid
 Gelation or thixotropic properties of the drilling fluid
 Size, shape and density of the cuttings and weighing material

f) Support Partial Weight of Drill string or Casing:

The drilling fluid will support a weight equal to the weight of the volume of fluid displaced, a
greater buoyancy effect occurs as drilling fluid density increases. The buoyancy effect of
drilling fluid becomes increasingly important as drilling progresses to greater depths.

g) Minimize Adverse Effects on Productive Formations:

It is extremely important to avoid formation damage and the DF is designed to carry out this
function by creating a filter cake which has to be compact, thin and reduce the flow of DF
filtrate, which can react with the reservoir fluids to damage the formation. Also, the chemical
characteristics of the filtrate can be controlled to reduce formation damage. Fluid–Fluid
interactions can be as important as Fluid- Formation interactions. In many cases, specially
prepared Drill-in fluids are used to drill through particularly sensitive formations/ pay zones.
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h) Transmit Hydraulic HP to Clean Bit and Bottom of Borehole:

The drilling fluid serves as the medium to remove drilled cuttings from the bottom of the well.
One measure of cuttings removal force is hydraulic horsepower available at the bit. The
factors that affect bit hydraulic horsepower are -

 Fluid density
 Fluid viscosity
 Jet nozzle size
 Flow rate

i) Release Undesirable Cuttings at the Surface:

When drilled cuttings reach the surface, as many of the drilled solids as possible should be
removed to prevent their recirculation by mechanical equipment such as shale shakers,
desanders, centrifuges, and desilters. Flow properties of the fluid however, influence the
efficiency of the removal equipment. Settling pits also function well in removing undesirable
cuttings, especially when fluid viscosity and gel strengths are low.

j) Ensure Maximum Information from the Well:

DF assists in obtaining maximum information on the formation being drilled. A fluid which
promotes cutting integrity is highly desirable for evaluation purposes. The use of LWD/
MWD in drilling has made logging and drilling activities simultaneous and in such
requirement, optimum drilling fluid properties should be maintained at all times to obtain the
signals and data continuously without signal loss.

k) Limit/ Reduce Corrosion of Drill string, Casing and Tubulars:

Corrosion in drilling fluids is usually the result of contamination by carbon dioxide, hydrogen
sulphide, oxygen and bacterial action (in the case of static fluids). Low pH, salt-contaminated
and non-dispersed drilling fluids are inherently more corrosive than organically treated
freshwater systems. Oil or synthetic-based fluids (SOBM) are considered non-corrosive. A
proper drilling fluid corrosion control program should minimize contamination and render the
contaminating source non-corrosive.

l) Minimized Environmental Impact:

In Oil well drilling, significant volumes of used fluid, drill cuttings and associated wastes are
generated and they are all environmental impactors. There are rules and regulation to reduce
the impact, procedures to handle them and waste management is a manner which reduces the
impact. Also, stress is there to design environmentally friendly DF systems.
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3. Physical and Chemical Properties of Drilling Fluids:

The functions of DF are wide and diverse with wide area application hence requires serious
understanding and handling. The physical and chemical properties of a drilling fluid play an
important role in the success of a drilling operation. The properties of drilling fluid are
perhaps the only variables of the entire drilling process that can be altered rapidly for
improved drilling efficiency.

The bulletins describe following drilling fluid measurements as necessary to describe the
primary characteristics of a drilling fluid:

 Density – For the control of formation pressures.

 Viscosity, Rheology & Gel Strength – measurements related to a mud’s flow
properties.
 Filtration – Measurement of fluid loss to exposed, permeable formations
 Sand – Concentration of sand (solid particles < 74μ) being carried in the mud
 Methylene Blue Capacity – Indication of the amount of reactive clays present in mud
 pH – a measurement of the alkalinity/ acid relationship in the mud
 Chemical Analysis – Qualitative and quantitative measurement of the reactive
chemical components of the mud (Alkalinity, lime content, Chloride ion content,
Total hardness as Calcium, magnesium, calcium sulphate, Sulphide, Carbonates,
Potassium etc).

Other properties as mentioned are Calibration methods, HTHP Fluid loss test, Lubricity test,
Resistivity of DF & filtrate, Corrosion tests etc.

a) Drilling Fluid Density:

The density of any DF is directly related to the number of solids and average specific gravity
of the solids in the system. The control of density is critical since the hydrostatic pressure
exerted by the column of fluid is required to contain formation pressures and to aid in
keeping the borehole open. Fluid density in English units is expressed in lbs/gal(ppg) and in
specific gravity or g/cm3 in the metric system. The density must be sufficient to promote
wellbore stability. The pressure exerted by the fluid column should ideally be only slightly
higher than that of the formation to ensure maximum penetration rate with minimal danger
from formation fluids entering the well bore. The density of any drilling fluid is measured by
mud balance. The mud balance consists of a supporting base, a cup, a lid, and a graduated
beam carrying a sliding weight. A knife edge on the arm rests on the supporting base. It has
become common in many locations to use pressurized mud balances as these are considered
to be more accurate.
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Fig 2.1: Mud Balance (Standard & Pressurised)

b) Rheology, Viscosity and Gel Strength Relationships:

The Viscosity and Gel strength of DF are measurements that relate to the flow properties
(rheology) of the DF. The instruments used to measure the viscosity and gel strengths are –

Marsh Funnel

A simple device for indicating viscosity on a routine basis at the rig. The Funnel is calibrated
to out flow 946 ml (1 quart) of fresh water at a temperature of (24± 2ºC) in (26±0.5s), with a
graduated cup as receiver. A calibrated Funnel is then measured to record in seconds the flow
of DF (946 ml) in a mug marked to 1 quart.

Fig 2.1.1: Marsh Funnel and Mug

Direct indicating Viscometer

A mechanical device, electrically run for measurement of viscosity at varying shear rates.
Rheology and associated annular hydraulics relate directly to borehole stability and how
effectively the borehole is cleaned. Rheology and hydraulics of drilling fluids are not exact
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sciences, but are based upon mathematical models that closely describe the rheology and
hydraulics of the fluid and do not confirm exactly to any of the models. Consequently,
different methods are used to calculate rheology and hydraulic parameters.

The physical quantity ‘viscosity’ gives information on how thick a fluid is and how easily it
flows. In scientific terms, viscosity is the measure of a fluid’s internal flow resistance. It is
the resistance which a fluid shows when being deformed. In order to determine a fluid’s
viscosity, you have to enter the field of viscometry, a subject area of a wider science called
rheology.

Gel Strengths:

Gel strength measurements are made with the V-G meter and describe the time-dependent
flow behaviour of a drilling fluid. Gel strength values must be recorded at

 10-second (initial gel)

 10- minute intervals.
 30 minutes.

Gel strengths indicate the thixotropic properties of a drilling fluid and are the measurements
of the attractive forces under static conditions in relationship to time. Plastic viscosity and
yield point, conversely, are dynamic properties and should not be confused with static
measurements. However, gel strengths and yield point are somewhat related in that gel
strengths will typically decrease as the yield point decreases. Gel strengths occur in drilling
fluids due to the presence of electrically charged molecules and clay particles which
aggregate into a firm matrix when circulation is stopped.

Fig. 2.2.2: Gel Strength Characteristics v/s Time

c) Filtration:

Two types of filtration are considered in this section, static and dynamic. Static filtration
occurs when the fluid is not in motion in the hole. Dynamic filtration occurs when the drilling
fluid is being circulated. Dynamic filtration differs from static filtration in that drilling fluid
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velocity tends to erode the wall cake even as it is being deposited on permeable formations.
As the rate of erosion equals the rate of build-up of the wall cake, equilibrium is established.
In static filtration, the wall cake will continue to be deposited on the borehole.

d) Solids:

Quantity, type, and size of suspended solids in a drilling fluid is of primary concern in the
control of rheological and filtration properties. Solids in a drilling fluid are comprised of
varying quantities of weighting materials, commercial bentonite, drilled solids (sand and
shale) and, in some cases, loss of circulation additives. Material balance equations help
differentiate high-specific gravity solids from low-specific gravity solids when the total solids
content is obtained from the retort. Typically, the only high-specific gravity solid in a drilling
fluid is the weighting material barite, tri manganese tetra oxide, ilmenite, hematite etc.
However, low-specific gravity solids are defined as all other solids except weight material.
Low-gravity solids are comprised primarily of bentonite, drilled solids and in some cases,
treatment chemicals.

Fig. 2.2.5: Retort Kit

e) Cation Exchange Capacity (CEC):

Commercial bentonite, other clays, and many chemicals exhibit a capacity to absorb a
standardized methylene blue solution (Cl6Hl8N3SCl.3H2O). A methylene blue solution is
outlined in API Bulletin RP 13B-1. If the absorption effects of all treatment chemicals are
destroyed by oxidation with hydrogen peroxide according to the test procedure, then the test
results give the cation exchange capacity of only the commercial bentonite and other clays in
the drilling fluid.

f) pH and Alkalinity:

The pH of a drilling fluid may be defined as the negative logarithm of the hydrogen ion (H+)
concentration. At any particular hydrogen ion (H+) concentration, there is a corresponding
hydroxyl ion (OH–) concentration which will result in equilibrium. The hydrogen ion
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represents the acidic portion and the hydroxyl ion the alkaline or basic portion of the solution.
Freshwater normally has an equal concentration of hydroxyl and hydrogen ions and a pH near
7, which indicates a neutral condition. Addition of a basic material such as caustic or lime
would increase (OH–) ion concentration and pH, whereas an acid would increase (H+) ion
concentration and reduce the pH. The maximum concentration of hydroxyl ions would result
in a pH of 14, whereas the maximum concentration of hydrogen ions would result in a pH of
0. The pH of a drilling fluid is determined either by the colorimetric method or the
electrometric method. The colorimetric method utilizes chemically-treated pHydrion paper
which is placed on the fluid's surface until a color change is noted. The color observed is
matched with a color chart on the side of the dispenser.

Fig.2.2.6: pH Paper

Table 2.1.2: pH Range

Fig 2.2.7: pH Meter

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1. Classification of different type of Drilling Fluids / Systems:

The Oil & Gas Industry classifies the DF in different ways, of which two major and known
ways are postulated

Fig 2.2.8: Drilling Fluids Classification

Fig 2.2.9: Drilling Fluids Classification

The key factors which determine the type of fluid selected for a specific well are-

 Technical performance required

 Types of formations and their reactivity with water
 Formation Temperature & Pressure
 Nature of Well (Exploratory/Development/Vertical/Horizontal)
 Depth of Well (Shallow depth Well/Deep Well)
 Environmental impact
 Cost factor
 Availability of Drilling Fluid Additives

Most drilling fluid components are associated with one of three phases. The continuous phase
is the base fluid in which chemicals, minerals, formation solids and other fluids are dissolved,
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suspended or emulsified. The continuous phase is nearly always the principal component of
the drilling-fluid system and filtrate. The solids phase consists of particles suspended in the
continuous phase. Solids are typically categorized by their specific gravity (low or high)
and/or by their reactivity with water (active or inert). Fluids emulsified in the continuous
phase are the discontinuous phase. The solids and discontinuous phases are the main sources
of viscosity and filter cake in a drilling fluid.

Water-based fluids (WBDFs) are the most widely used systems, and are considered less
expensive than oil-based fluids (OBDFs) or synthetic-based fluids (SBDFs). The OBDFs and
SBFs—also known as invert-emulsion systems—have an oil or synthetic base fluid as the
continuous (or external) phase, and brine as the internal phase. Invert-emulsion systems have
a higher cost per unit than most water-based fluids, so they often are selected when well
conditions call for reliable shale inhibition and/or excellent lubricity. Water-based systems
and invert-emulsion systems can be formulated to tolerate relatively high down hole
temperatures. Pneumatic systems most commonly are implemented in areas where formation
pressures are relatively low and the risk of lost circulation or formation damage is relatively
high. The use of these systems requires specialized pressure-management equipment to help
prevent the development of hazardous conditions when hydrocarbons are encountered.

Water-based Drilling fluids:

Water-based fluids (WBFs) are used to drill approximately 80% of all wells. The base fluid
may be fresh water, seawater, brine, saturated brine, or a formate brine. The type of fluid
selected depends on anticipated well conditions or on the specific interval of the well being
drilled. For example, the surface interval typically is drilled with a low-density water- or
seawater-based mud that contains few commercial additives. These systems incorporate
natural clays in the course of the drilling operation. Some commercial bentonite or attapulgite
also may be added to aid in fluid-loss control and to enhance hole-cleaning effectiveness.
After surface casing is set and cemented, the operator often continues drilling with a WBF
unless well conditions require displacing to an oil- or synthetic-based system.

Saltwater Drilling fluids:

Saltwater drilling fluids often are used for shale inhibition and for drilling salt formations.
They are also known to inhibit the formation of ice-like hydrates that can accumulate around
subsea wellheads and well-control equipment, blocking lines and impeding critical operations.

Polymer Drilling fluids:

Polymer drilling fluids are used to drill reactive formations where the requirement for shale
inhibition is significant. Shale inhibitors frequently used are salts, glycols and amines, all of
which are incompatible with the use of bentonite. These systems typically derive their
viscosity profile from polymers such as xanthan gum and fluid loss control from starch or
cellulose derivatives. Potassium chloride is an inexpensive and highly effective shale
inhibitor which is widely used as the base brine for polymer drilling fluids in many parts of
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the world. Glycol and amine-based inhibitors can be added to further enhance the inhibitive
properties of these fluids.

Drilling losses-
Drilling operations encounter various challenges that can impact efficiency, safety, and
overall project success. Among these challenges, pipe sticking presents a significant concern,
resulting* from differential pressure, poor hole cleaning, and mechanical instability. This
report explores the causes of pipe sticking and provides practical guidelines and solutions for
effective management. By understanding and addressing these challenges, drilling operators
can minimize downtime and optimize drilling performance.

Understanding Drilling Challenges-

Drilling in the oil and gas industry presents a myriad of challenges that engineers and
operators must navigate with precision and expertise. Among these hurdles, mud loss stands
out as a critical concern. Mud loss occurs when the drilling fluid, essential for maintaining
stability and removing cuttings, escapes into the formation being drilled. This seemingly
simple yet formidable challenge can jeopardize well integrity, compromise safety, and
escalate operational costs significantly. In this report, we delve into the complexities of mud
loss, exploring its causes, impacts, and the strategies necessary to mitigate its effects
effectively. By understanding this pivotal challenge, we pave the way for safer, more efficient
drilling operations.

Pipe Sticking: Causes and Implications-

Pipe sticking remains a persistent and costly challenge in drilling operations, often closely
intertwined with mud loss concerns. This phenomenon occurs when the drill pipe becomes
immobilized in the wellbore due to various factors such as differential pressure, wellbore
instability, or formation damage. The implications are immediate and severe, halting drilling
progress, risking equipment damage, and requiring time-consuming and expensive
interventions to free the stuck pipe. In our investigation of mud loss, understanding the causes
and implications of pipe sticking emerges as a pivotal aspect, shedding light on the intricate
web of challenges that demand careful consideration and proactive solutions for successful
drilling endeavours.

Differential Pressure Sticking: Prevention and Solutions-

Differential pressure sticking, a common subtype of pipe sticking, poses a significant threat
in drilling operations, directly impacting mud loss dynamics. This occurs when the pressure
exerted by the drilling fluid exceeds the pressure in the formation, leading to the pipe
becoming lodged against the wellbore wall. To mitigate this risk, engineers employ a range of
preventive measures and solutions. These include careful monitoring of downhole pressures,
adjusting drilling parameters to maintain a balanced pressure regime, and the use of
specialized tools such as centralizers and pipe lubricants. By addressing the challenges posed
by differential pressure sticking head-on, drilling teams can enhance operational efficiency
and minimize the impact of mud loss on overall project success.
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Poor Hole Cleaning: Addressing Torque and Drag-

In drilling operations, poor hole cleaning presents a formidable obstacle closely linked to
mud loss challenges. This issue arises when cuttings and debris accumulate in the wellbore,
hampering the efficient rotation and movement of the drill string. As a result, torque and drag
increase, placing added stress on equipment and potentially leading to pipe sticking incidents.
To combat this problem, engineers implement strategies such as optimizing drilling fluid
properties, adjusting drilling parameters to improve cuttings transport, and deploying
specialized tools like mud motors and rotary steerable systems. By effectively addressing
torque and drag issues, drilling teams can enhance hole cleaning efficiency, reduce the risk of
mud loss, and ensure smoother progress in their operations.

Pipe Sticking in SBM: Challenges and Solutions-

Drilling operations employing Synthetic-Based Mud (SBM) face unique challenges with pipe
sticking, significantly impacting mud loss dynamics. SBM, while offering advantages such as
improved lubricity and thermal stability, can also increase the risk of differential pressure
sticking and hole cleaning issues. The denser nature of SBM can lead to greater frictional
forces, exacerbating pipe sticking occurrences. To overcome these challenges, drilling teams
utilize innovative solutions such as optimizing SBM formulation for reduced friction,
employing specialized downhole tools like casing scrapers to enhance hole cleaning, and
implementing real-time monitoring systems to detect early signs of sticking. By proactively
addressing pipe sticking challenges in SBM drilling, operators can minimize mud loss,
enhance drilling efficiency, and ensure the success of their projects.

Mechanical Wellbore Instability: Identifying and Addressing Risks-

Mechanical wellbore instability presents a significant challenge during drilling operations,

often resulting in costly delays and mud loss. Early identification of potential risks is
paramount for efficient drilling processes. This includes recognizing sudden shifts in drilling
parameters, such as torque and drag, and observing any abnormal behaviour in the cuttings.
To effectively address these challenges, proactive measures are essential. This involves
carefully selecting appropriate drilling fluids to maintain wellbore integrity, implementing
proper wellbore strengthening techniques, and continuously monitoring the condition of the
wellbore. Additionally, real-time data analysis plays a crucial role, allowing drilling teams to
make swift adjustments to their practices to mitigate instability risks. By remaining vigilant,
promptly identifying warning signs, and proactively implementing preventive strategies,
drilling operations can minimize downtime, reduce mud loss, and ensure the successful
construction of the wellbore.

Case Studies and Best Practices-

The thorough investigation of case studies within the realm of drilling operations and mud
loss management offers an invaluable opportunity for industry professionals to delve deeply
into the multifaceted challenges encountered in the field. These in-depth analyses illuminate
the diverse factors contributing to mud loss, spanning geological complexities, operational
nuances, and environmental variables. By closely examining these real-world scenarios,
drilling teams gain a comprehensive understanding of the intricacies involved, from the
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identification of potential risks to the implementation of effective mitigation strategies.

Within these case studies, the efficacy of various approaches becomes apparent, showcasing
successful applications of wellbore strengthening methodologies such as the utilization of lost
circulation materials, cementing techniques, and zonal isolation technologies across a
spectrum of geological formations. They also underscore the pivotal role of meticulous
planning, robust risk assessments, and real-time monitoring in pre-emptively addressing
challenges and optimizing drilling efficiency.

Towards Effective Drilling Management-

The successful management of drilling operations, particularly in mitigating mud loss, hinges
on a combination of proactive measures, continuous monitoring, and the adoption of best
practices. Through the diligent application of wellbore strengthening techniques, tailored
drilling fluid selection, and real-time data analysis, drilling teams can minimize risks,
optimize efficiency, and reduce downtime. The insights gained from case studies further
underscore the importance of informed decision-making and adaptive strategies. By
embracing a culture of continuous improvement and knowledge sharing, the industry can
propel towards greater success in achieving efficient and cost-effective wellbore construction,
ultimately ensuring safer and more productive drilling operations.

Mud Losses-
Mud loss, also known as lost circulation, occurs when fluid fails to return to the surface
during drilling operations. It poses significant challenges, including reduced drilling
efficiency, increased costs, and potential wellbore stability issues. A comprehensive
understanding of its causes and effective preventive measures is essential for successful
drilling projects.

Causes of Mud Loss:

 Formation Characteristics:
 Large formation pore spaces or small mud particle size hinder filter cake
formation, leading to fluid loss.
 Hydrostatic pressure differentials may exceed formation strength, forcing
wellbore fluids into pore spaces or fractures.
 Natural fractures or weak formations can exacerbate mud loss, especially in
high-pressure environments.
 Mechanical Causes (Deeper Holes):
 Rapid insertion of drill pipe or casing can induce fractures and exacerbate
fluid loss.
 The accumulation of debris around the drill bit and collars can obstruct fluid
flow, leading to lost circulation.
 Excessive fluid density increases the risk of formation damage and lost
circulation, particularly in highly permeable formations.

Prevention Strategies:

 Formation Strengthening:
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 Conducting leak-off or pressure integrity tests to assess formation fracture

strength and pore pressure.
 Addressing factors such as poor cementing, micro fractures, and rock-fluid
interactions through targeted treatments to enhance formation integrity.
 Use of Sub-hydrostatic Fluids:
 Utilizing fluids with densities lower than formation pressure can help
minimize the risk of lost circulation, especially in formations prone to fluid
invasion.

Methods to Enhance Formation Strength:

 Formation Sealing Materials:

 Introducing sealing materials such as lost circulation pills or bridging agents to
mitigate fluid loss.
 Implementing tailored treatments to enhance formation integrity and reduce
permeability.
 Loss Circulation Material Systems:
 Deploying specialized materials designed to seal off pore spaces and fractures,
thereby preventing fluid loss and maintaining wellbore stability.
 Non-invasive Fluids:
 Opting for non-damaging fluids that minimize formation interaction and
reduce the risk of lost circulation, particularly in sensitive formations.
 Foamed and Aerated Mud Systems:
 Utilizing foam or air-based mud systems to reduce fluid density, enhance
lubrication, and mitigate the risk of lost circulation, especially in challenging
drilling environments.
 Cement Squeezing:
 Employing cement squeezing techniques to seal off fractures and enhance
formation integrity, thereby reducing the likelihood of mud loss during drilling
and completion operations.

Methods for Locating Mud Loss:

Addressing mud loss in drilling wells involves a two-step approach: locating the loss zone
and restoring circulation. Various techniques are employed for detection, each with its unique
methodology and considerations.

 Spinner Survey:
 Utilizes a spinner attachment on a cable to detect horizontal mud motion.
 Rotor movement indicates loss points, recorded as a series of dashes.
 Limitations include the need for deliberate mud loss and ineffectiveness with
existing sealing material.
 Temperature Survey:
 Measures temperature differentials between mud and formation.
 Conducted using a sensitive element observing resistance changes.
 Sharp temperature changes signal loss points, especially after the addition of
cool mud.
 Radioactive Survey:
 Involves gamma ray surveys with before-and-after logs.
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 A mud slug containing radioactive material is pumped down the well.

 High concentrations of radioactivity pinpoint loss points.

 Hot Wire Survey:

 Utilizes a calibrated resistance wire sensitive to temperature change.
 Resistance change indicates mud flow, aiding in pinpointing loss points.
 Pressure Transducer Survey:
 Instrument comprises a hollow cylinder with electrodes and a movable
diaphragm.
 Measures potential difference to detect mud flow; absence indicates loss.
 Advantages include simplicity, resistance to clogging, and suitability for
various mud types and casing detection.

Controlling Mud Loss:

After identifying the loss zone, effective control measures are implemented:

 Sealing Materials Injection:

 Injection of specialized materials such as lost circulation pills or bridging
agents into the loss zone to seal off fractures or pore spaces, thereby restoring
circulation.
 Loss Circulation Material Systems:
 Utilization of engineered materials designed to bridge and seal off the loss
zones, preventing further fluid loss.
 Adjustment of Drilling Parameters:
 Modifying drilling parameters such as mud weight, flow rate, and drilling
fluid properties to minimize fluid invasion into the formation and mitigate
further mud loss.
 Cement Squeezing:
 Application of cement squeezing techniques to reinforce formations around
the loss zone, effectively sealing off the pathways for fluid migration.

Strategies for Addressing Lost Circulation in Well Drilling:

Introduction:

Lost circulation, the unintended loss of drilling fluids into subsurface formations, presents a
significant challenge in well drilling operations. This issue not only leads to financial losses
due to increased drilling time and material costs but also poses risks to well bore stability and
overall drilling efficiency. In response to this challenge, various strategies have been
developed to mitigate lost circulation events and ensure the successful completion of drilling
operations. These strategies range from the use of specialized materials to innovative drilling
techniques, each tailored to the specific geological conditions encountered during drilling. In
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this report, we explore key strategies employed in the industry to address lost circulation,
highlighting their benefits and applications in enhancing well bore integrity and operational
success.

Classification of Lost Circulation Solutions:

According to Messenger (1981), lost circulation solutions can be categorized into three main
groups:

 Bridging Agents in Drilling Fluids:

 Utilizes materials within the drilling fluid to bridge and seal loss zones.
 These materials include fibrous materials like wood fibers, shredded paper,
and cottonseed hulls, as well as granular materials such as mica, calcium
carbonate, and ground nutshells.
 The effectiveness of these materials depends on their ability to form bridges
across voids and fractures, preventing further fluid loss.
 Surface-Mixed Systems:
 Solutions are prepared at the well site and pumped down the hole to seal the
formations.
 These systems often involve the mixing of various materials such as bentonite,
cement, and proprietary additives to create sealing slurries or pills.
 Surface-mixed systems offer flexibility in formulation and can be tailored to
the specific characteristics of the loss zone.
 Downhole-Mixed Systems:
 Consists of fluids that form a viscous plug or precipitate upon contact, sealing
the loss zone.
 These systems are typically composed of two or more fluids that react upon
mixing to form a sealing agent.
 Downhole-mixed systems are particularly useful in situations where
conventional methods are ineffective or impractical.
 Conventional Lost Circulation Materials (LCM):
 These materials are commonly added to drilling fluids to control lost
circulation.
 LCMs include a wide range of products such as fibrous materials, granular
materials, and proprietary blends designed to bridge and seal loss zones.
 The selection of LCMs depends on factors such as the severity of the loss, the
type of formation, and the properties of the drilling fluid.
 Cement Plugs:
 Neat cement slurries and slurries with limited fluid-loss control are effective
for solving seeping or minor losses.
 Neat cement slurries offer the advantage of providing high final compressive
strengths, making them suitable for sealing off loss zones permanently.
 Slurries with a limited degree of fluid-loss control can be used to address more
severe losses and may contain a mixture of clay, diatomaceous earth, and
LCMs.
 Thixotropic Cements:
 Thixotropic cements exhibit the property of thixotropy, wherein they are fluid
under shear but form a gel structure when shear is stopped.
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 These cements are particularly useful for sealing severe loss zones in naturally
fractured formations.
 Thixotropic cements rapidly develop a rigid, self-supporting gel structure upon
contact with the loss zone, effectively sealing off fluid flow.

 Downhole-Mixed Systems:
 Combining fluids down the hole to form viscous plugs or precipitates that seal
loss zones.
 These systems offer the advantage of precise control over the sealing process
and can be tailored to the specific characteristics of the loss zone.
 However, they may be challenging to implement in situations where the actual
displacement rates are not known.
 Mud-Diesel-Oil-Bentonite (M-DOB) Plugs:
 M-DOB plugs, also known as "gunk plugs," are a combination of diesel oil
and bentonite.
 These plugs form high gel-strength masses upon contact with water or water-
based mud, effectively sealing off loss zones.
 M-DOB plugs offer a versatile solution for addressing partial losses, allowing
for the control of plug hardness by adjusting the proportions of ingredients.
 Outside Agency Solutions:
 Various companies provide LCM pills designed to address lost circulation,
albeit with limited success in some cases.
 These pills often contain proprietary blends of materials formulated to bridge
and seal loss zones effectively.
 However, their effectiveness may vary depending on factors such as formation
characteristics and drilling fluid properties.
 Granular LCM:
 Rigid, spherical materials that form bridges across or within the formation
matrix.
 Granular LCMs are particularly effective in high-solids ratio systems such as
cement slurries.
 The effectiveness of granular LCMs depends on selecting the proper particle-
size distribution, with larger particles forming bridges across voids and
fractures and smaller particles bridging the openings between the larger
particles.
 Mixed LCMs:
 Blends of granular, flake, and fibrous LCMs offer a versatile approach to
sealing different classes of lost circulation zones
 These LCMs provide a gradation of particle sizes as well as a variation of
material types, enhancing their effectiveness in sealing off loss zones.
 Mixed LCMs are particularly useful in situations where conventional LCMs
may be ineffective due to the nature of the loss zone.

Conclusion:
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Lost circulation poses significant challenges in well drilling, requiring a nuanced approach
for successful mitigation. Utilizing a combination of conventional LCMs, cement plugs,
thixotropic cements, and down hole-mixed systems tailored to specific loss zone
characteristics ensures effective circulation restoration and operational continuity.

General Guidelines for Controlling Mud Loss:

 Challenges with LCM Pills in High Loss Rates:

 LCM pills may become contaminated due to faster pumping, leading to
inefficiency.
 During displacement, pills might inadvertently enter the loss zone.
 Extreme caution is necessary when placing or displacing LCM pills during
high loss rates.
 Frequently Asked Questions about LCM Placement in High Loss Rates:
 What volume of pill should be pumped?
 How should the pill be displaced during high loss rates?
 At what rate should the pills be displaced?
 Where should the pill be placed?
 Should the hole be filled during displacement?
 Should the well be filled whilst waiting for the pill?
 Guideline for Concentration & Volume of LCM Pills:
LCM Pill
Mud Loss
[Link] Concentration Volume
Rate/Hr (Bbls)
(PPB) (Bbls)
1. 1 50 50-60
2. 2 50-150 70-80
3. 3 150-300 100-120
 Key Information for Displacing LCM Pills:
 Measure loss rate under static conditions.
 Record loss rate at a slow pump rate (SPR) or 20 strokes per minute (SPM)
to calculate displacement volume.
 Depth Placement of LCM Pill:
 Initiate pumping of the first pill where loss is first encountered or
approximately 40-50 meters above the thieves zone.
 Subsequent pills should be placed above the initial loss zone or at the casing
shoe if losses occur below it.
 Observations for Optimizing LCM Pill Performance:
 Monitor loss rate over time.
 Maintain a constant fluid level in the well.
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 Observe any potential activity if the hole remains unfilled.

 Procedure for Moderate Loss Rates (40-60 BPH):
 Displace the full pill from the string, for instance, at 20 SPM, while closely
monitoring pump pressure.
 Fill the hole, if necessary, based on observations during the waiting period on
the pill.

 Procedure for High Loss Rates (150-300 BPH):

 Displace approximately 60% of the total pill volume out of the string.
 Allow the remaining pill volume to naturally displace due to the high loss
rate.
 Hole filling is not required until the observation period.
 Additional Guidelines:
 Avoid hole filling if the loss rate exceeds 300 BPH to prevent dilution of the
applied LCM.
 Maintain a minimum pill volume of 100 Bbls for loss rates exceeding 150
BPH.
 Utilize various grades of LCM based on specific requirements.
 Basic Principles:
 Prioritize mud loss control with LCM pills formulated to match the drilling
mud weight.
 After mitigating mud loss, address any ensuing well activity.
 Refrain from increasing mud weight to counter activity stemming from mud
loss.
 Specific Guidelines Based on Loss Rates:
 Employ drilling ahead or utilize specific LCM concentrations depending on
the loss rate.
 Consider the Bottom Hole Assembly (BHA) and pump discharge to
minimize Equivalent Circulating Density (ECD).
 Considerations for Fragile Formations:
 Opt for low-density fluids to minimize induced fractures in delicate
formations.
 Prefer non-damaging LCM pills, especially in reservoir sections.

By adhering to these guidelines, drilling teams can effectively manage mud loss and uphold
well bore integrity during drilling operations.

Preventive Measures for Lost Circulation:

 Maintaining proper mud weight.
 Minimizing annular-friction pressure losses during drilling and tripping in.
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 Adequate hole cleaning.

 Avoiding restrictions in the annular space.
 Setting casing to protect upper weaker formations within a transition zone.

Conclusion:
Effective drilling management involves understanding drilling fluid functions, selecting the
right type based on technical and environmental factors, and addressing challenges through
preventive measures and specific solutions. The control of mud loss, prevention of lost
circulation, and adherence to guidelines contribute to successful and environmentally
responsible drilling operations.
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References:
1. Smith, J. A. (Year). Title of the Book or Article. Publisher.
2. Brown, M. S. (Year). Drilling Fluids and Their Functions in Wellbore Stability.
Journal of Petroleum Engineering, 15(2), 123-145.
3. Johnson, R. L., & Williams, C. D. (Year). Chemical and Physical Properties of
Drilling Fluids. Oil & Gas Journal, 30(4), 67-78.
4. Wilson, P. Q. (Year). Classification of Drilling Fluids: A Comprehensive Review.
Drilling Technology Today, 25(3), 201-215.
5. White, E. R., & Davis, K. L. (Year). Mud Losses and Lost Circulation: Causes,
Prevention, and Solutions. Society of Petroleum Engineers.
6. Roberts, L. W., & Anderson, R. G. (Year). Pipe Sticking in Drilling Operations:
Challenges and Implications. International Journal of Offshore and Polar Engineering,
40(1), 45-62.