Deep Water Drilling Fluid Design Example

Drilling FluidsPlanning Document
KDS Ltd.
Deepwater drilling
fluids design example
Rev: 1.1 09/03/01
Deepwater Exploration
KDS Ltd.
Deepwater drilling fluids design

Purpose
To ensure minimal operational time and risk exposure to personnel,
process, production and equipment during drilling operations.
The following operational well control procedures are to ensure drilling
fluids are properly managed, controlled and maintained during drilling,
tripping casing and cementing operations.
If problems occur, procedures in this document, service company, well
specific guidelines and other relevant documents should be followed.
Responsibilities
It will be the responsibility of the Operators drilling representative and
senior fluids representative to ensure that others with duties related to
drilling fluid management operations contained within this document are
aware of their responsibilities.
Scope
These procedures shall apply to all drilling personnel.
Further References
Drilling contractors, service company, and Operators mutually agreed
specific drilling fluids procedures.
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KDS Ltd.
Drilling and Completion Fluid

Design
Table of contents
DEEPWATER DRILLING FLUIDS DESIGN EXAMPLE.....................................1
DEEPWATER DRILLING FLUIDS DESIGN..........................................................2
PURPOSE..................................................................................................................2
RESPONSIBILITIES ...............................................................................................2
SCOPE .......................................................................................................................2
FURTHER REFERENCES .....................................................................................2
DRILLING AND COMPLETION FLUID DESIGN ................................................3
TABLE OF CONTENTS .........................................................................................3
DEEPWATER GLYDRIL SYSTEM ......................................................................4
HYDRATE SUPPRESSION ....................................................................................8
BENTONITE SYSTEM .........................................................................................11
NACL/KCL POLYMER SYS TEM.......................................................................13
INTERVAL DISCUSSION ....................................................................................17
SOLIDS CONTROL AND WATER BASED MUD ............................................55
CONTINGENCY SECTION .................................................................................58
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KDS Ltd.
Deepwater Glydril System

Application
The DEEPWATER GLYDRIL system is used to drill reactive clay and shale
formations in water depths greater than 1000 when hydrate suppression is a
major problem. This system uses NaCl and KCl salts, conventional polymers
and glycol to provide formation inhibition and hydrate suppression.
Primary inhibition is achieved with GLYDRIL MC, a polyalkylene glycol. The
glycol prevents water molecule interaction within the shale. Encapsulation
polymers, the potassium ion, and low water activity provide secondary shale
inhibition. Additions of POLYPAC and POL YPLUS polymers provide inhibition
through encapsulation; the polymers adsorb on the formation surface
preventing water from migrating into the shale structure. The cation exchange
of the potassium with the formation reduces the swelling tendency of the clay
by direct interference with the swelling mechanism. The high salinity further
ties up water molecules contributing to shale and hydrate inhibition.
The DEEPWATER GLYDRIL system is more inhibitive than a conventional
potassium polymer system. The system is run non-dispersed. The pH is
maintained from 89 to minimize swelling effects caused by the hydroxyl ion.
Soda Ash is used to control pH and to maintain the total hardness at levels
that do not interfere with the performance of the polymers.
The KCl concentration is maintained at 5% and the NaCl concentration is 1322%.
The concentration of GLYDRIL MC is 5 vol%. GLYDRIL MC contributes to
shale inhibition, reduced fluid loss, a quality filter cake, and improved the
lubricity. It has been shown that the GLYDRIL MC will drill gauge hole and
give excellent wellbore stability.
System Limitations
Temperature limitations of PAC polymers are theoretically 150C. However,
the use of GLYDRIL MC will extend the temperature limitations of the system.
Additives
ADDITIVE
NaCl
KCl
GLYDRIL
MEG
XCD
POLYPLUS
POLYPAC LV
SODA ASH
BARITE
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MATERIAL
Sodium Chloride
Potassium Chloride
MC Polyalklene Glycol
Monoethylene Glycol
Xanthan Gum
PHPA
Polyanionic Cellulose
Sodium Carbonate
Barium Sulfate
FUNCTION
Hydrate Suppressant
Shale Inhibitor
Shale Inhibitor
Hydrate Suppressant
Viscosifier
Shale Inhibitor
Fluid Loss Control Additive
Alkalinity Control
Density Control
KDS Ltd.
Mixing Procedure
If a mixing plant is in place, the brine will be shipped to the rig as a saturated
NaCl brine. The brine will be reduced to the required concentration with the
addition of polymer premixes formulated with drill water. KCl will then be
added to the specified concentration. The mixing order of the polymers is,
under normal conditions, not critical. The mixing of polymers depends more
on the mixing and shear facilities available on the rig. If possible, mix the
PHPA and PAC polymers in drill water, add to the brine, and then add the KCl
to the specified concentration. If this is not practical the procedure below is
recommended.
If possible, the polymers should be mixed slowly, 10 to 20 min/sack
depending on the viscosity of the mud, to prevent forming "fisheyes" in the
fluid.
Hole cleaning is an important consideration. The successful drilling of these
sections will, to a large extent, be dependent upon the ability of the drilling
fluid to clean the hole. Drilling practices designed to maintain a clean hole
enhances the hole cleaning ability of the mud. These may include; circulating
prior to connections and trips, controlled drilling rates, rotation and working of
the string, boosting the riser, and pumping of pills.
In such wells, XCD is the primary viscosifier, because of its shear thinning
characteristics. With XCD, viscosity at low shear rates can be increased and
maintained, without greatly affecting the viscosity at higher shear rates, thus
providing the desired 3 and 6 rpm readings.
If PHPA polymer is used in the active system, this will affect the viscosity. An
increase in the 3 rpm reading as well as Yield Point will occur. Addition of
POLYPLUS will provide better lubricity and encapsulation properties of the
fluid but the GLYDRIL MC system is the primary shale inhibitor.
The rheology and inhibition of the GLYDRIL sys tem can be controlled as
required with different combinations of XCD, GLYDRIL MC, POLYPAC LV,
and POLYPLUS.
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KDS Ltd.
Daily Maintenance
The specified mud properties should be maintained with special attention
being given to efficient use of the solids control equipment and controlled
dilution as required to maintain mud parameters within specifications.
Because of the higher cost of the liquid phase of this mud, relative to a
conventional polymer system, dumping volume to control solids is the last
alternative.
In and out viscosity checks of the fluid should be made regularly. A minimum
of one complete mud check (in and out) should be taken every tour while
drilling. This sample should be logged and coincide with a check on the same
volume prior to being circulated from the active pits. This will provide an
indication of the effect on the mud after circulating it through the well.
Pre-hydrate, if possible, all products before adding them to the active system.
Additions of products directly to the active system may reduce the efficiency
of the products and cause unstable properties
When drilling cement, the system should be pre-treated/treated with Citric
Acid and Bicarbonate to control the pH and calcium levels. Mud with pH
above 11 should be discarded. If there is available pit space this volume may
be stored for treatment at a later time. This option is practical when the liquid
phase of the mud is expensive and there is a high concentration of XCD,
PHPA and GLYDRIL MC. These polymers are less susceptible to degradation
from cement.
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Mud Parameters
Rheology - Control at programmed specification by adjusting the additions of
XCD and POLYPAC LV in the premixes. Control excessive rheology with
whole mud dilution.
API Fluid Loss - Experience has shown that the fluid loss is low, 2 - 4 ml,
because of the polymer concentration in this system. Also the GLYDRIL MC
will contribute to a low fluid loss.
MBT - The MBT reading should be controlled less than 17.5 ppb with whole
mud dilution and solids control equipment. If all other mud parameters are
acceptable and stable, an MBT of maximum 5 ppb above this limit can be
accepted. This will naturally also be dependent on the actual mud weight.
Inhibition - Maintain the specified GLYDRIL MC level for inhibition of the
system. The GLYDRIL MC will deplete from the system by adhesion to the
surface of removed drill solids. The premixes should always be made up with
slightly higher concentrations. The GLYDRIL MC can also be added directly to
the system as needed. A temperature-controlled retort will be used to distil out
the water and glycol separately.
Encapsulation - Even with the GLYDRIL MC in the system, POLYPAC LV
and POLYPLUS will encapsulate drilled cuttings and reduce the dispersion of
clay in the drilling fluid. This enhances solids removal and provides a cleaner
fluid. Premix for whole mud dilution should be made up with slightly higher
polymer concentrations to compensate for polymer losses due to adhesion to
the surface of drilled cuttings and Barite in the active system. Note that the
system can easily be run without any PHPA. In fact, this is most often the
case.
PH - Maintain PH at 8.0-9.2. Soda Ash should be added if alkalinity is
required
Bacteria Control - Polymer systems are subject to bacteria attack and
subsequent degradation. However, this is rarely a problem in high salinity
muds, due to the high chlorides level. Normally, there should be no need for
additions of biocide in the initial mix up of the system. However, Panatest
dipslide tests should be run occasionally, and treatment should be carried out
at any signs of bacterial growth.
Barite Addition - When the density in the active system is increased with
Barite, POLYPLUS should be added simultaneously in concentrations of 1.5
lb to 1 ton of Barite to maintain suspension. POLYPAC LV is required to
maintain fluid loss. If mixing large amounts of Barite, fresh premix or water
should be added at the same time to prevent dehydration.
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KDS Ltd.
Hydrate Suppression
Glydril suppression
The DEEPWATER GLYDRIL system will give a total protection against
formation of gas hydrates at the given well bore conditions. The formulations
are based on the M-I Hydrate prediction software, as well as laboratory
hydrate testing. The use of brine-based drilling fluids in deepwater areas has
not provided total hydrate protection; these fluids have used backup
procedures for displacement of the choke and kill lines, and riser to a fluid
which is fully hydrate inhibitive in the event of circulation shutdown, or a kick.
For the 22 and upper 17 sections, where the mud weight is low, it
becomes more difficult to use the hydrate suppression behavior of high salt
concentrations, due to the density contribution. In this case we formulate a
lower density fluid, using MEG in place of some of the salt to give the required
hydrate suppression.
The effect of each formulation for each section has been calculated, using the
lab results from Houston and the Stavanger technical centers along with the
prediction model calculations. Laboratory results on hydrate formation have
been compared with the calculated results. The following graphs summarize
the calculated data for various brines.
Based on these observations 13% NaCl along with 5% KCL and with the
addition of 10% by volume MEG is sufficient to prevent hydrate formation at
static conditions with a 200 psi kick margin in the 22 section.
An extra safety factor commonly used is to flush and spot the choke / kill lines
and BOPs during any shut-downs with a near or saturated pill with glycol. A
22%NaCl and 10% MEG formulation is recommended for this purpose.
Nature of Gas Hydrates / Basic Structure

Gas hydrates are solid inclusion compounds similar to ice in appearance, but
differing in crystal structure. The danger of hydrates comes from two basic
physical properties. The first, is the solid nature of the hydrate phase. The
second, is the large gas content of the hydrate phase, which upon melting,
can release up to 170 scf of gas per cubic foot of hydrates. Furthermore,
hydrate formation can cause the breakdown of a mud system by fresh water
extraction from the mud to form the hydrate structure.
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Crystal Structure
Under favourable conditions of high pressure and low temperature, water
physically entraps the molecules of a hydrate former inside a hydrogenbonded solid lattice. The hydrate former can be a vapour or a liquid state,
miscible or immiscible with the water. Methane, ethane, propane, butanes,
CO2, N2, H2S, and their mixtures are known hydrate formers. Currently, there
are three known crystal structures for gas hydrates. An example of one unit
cell of structure has a dimension of 12.03A and includes two small and six
large cages. It takes 20, 24, and 28 water molecules to form the small cage,
and the large cage of structure. Each water molecule is hydrogen bonded to
three neighbours within the cage and one neighbour outside the cage. The
water molecule accepts two hydrogens from two of the four neighbours and
donates two hydrogens to the other two neighbours.
Elements Necessary to Stabilize Hydrates

Four elements are necessary to form and stabilize gas hydrates. These are:
The hydrocarbon phase
The aqueous phase
Low temperature
High pressure
In the deepwater drilling environment, the open hole provides hydrocarbons
and the aqueous phase (water), while water-base muds provide another
source of water. Formation water is usually saline, which provides some
protection against hydrates. The pressure at the mud-line is dependent on the
mud weight, the magnitude of the circulating pressure losses in the annulus
and the choke-line, and the allowable kick margin.
Hydrate Phase Behavior and Inhibition

The three phase hydrate equilibrium (Gas-Water-Hydrate) of a given gas
composition and aqueous phase (drilling fluid for example) is defined by the
Pressure and temperature conditions at which the last hydrate crystal melts.
This phase equilibrium line is shown on the charts as the far right line (#1).
This gas-water-hydrate phase line is arrived at by taking hydrate
thermodynamic test. By repeating this test at several different pressures, the
entire Gas-Water-Hydrate line is generated. Along this line, the three phasesGas, Water, and hydrate coexist in equilibrium. At any pressure and
temperature conditions to the right of this line hydrates cannot form, while to
the left they can. Line #2 represents the limit of the metastable region, where
hydrate formation is possible. The metastable region reflects the degree of
sub-cooling can be looked at as a safety factor imbedded in the way we
estimate the pote ntial for hydrate formation. The probability of hydrate
formation increases as we move from line #1 to line #2. In the region to the
left of line #2, the probability of hydrate formation becomes definite. Without a
clear definition of the metastable region, it is not recommended to include the
sub-cooling in the mud designs for hydrate inhibition and leave that as a
safety factor.
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KDS Ltd.
Thermodynamic Inhibition
To de-stabilize or inhibit gas hydrates, one or more of the four basic elements
(gas, water, temp and pressure) must be eliminated from the system.
Removing all the water may not be possible even when using oil-base muds.
Instead, the water activity is normally lowered by adding salts or glycols to
suppress hydrates. Not encountering a gas kick, on the other hand, will
remove the hydrocarbon phase. Antifreeze chemicals such as salts, and
glycols are used to suppress hydrates. This is a direct utilization of the wellknown thermodynamic inhibitor; one can shift or move the hydrate phase line
to the left. If the anticipated operating pressure and temperature fall to the
right of the shifted phase line, hydrates should not form. Otherwise, more
inhibitor is needed to shift the phase line further left.
References
M-I Tech Centers in Houston and Stavangar
Gas Hydrates Workshop 1 prepared by Majeed Yousif with Westport
Technology Center Intl and Colin Leach with Well Control & System Design,
Inc. Sept of 1997.
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KDS Ltd.
Bentonite System
General
The hole cleaning ability of Bentonite spud muds is usually the main property
controlled, since surface hole is large and the annular velocities low. A funnel
viscosity of 100 sec/qt is normally regarded as sufficient. The mud weight is
low or un-weighted to reduce chances of lost circulation. Use of Seawater and
Bentonite, with returns to Seabed, has no significant impact on the
environment.
For drilling surface hole, seawater is used, circulating viscous pills on a
regular basis or as required to keep the hole clean. However, when drilling
through anomalies, which can contain gas, a weighted mud (10 ppg) is used.
Once through, with no signs of gas, return to using seawater and viscous pills.
If gas is encountered, casing is usually run.
Once the section is drilled, a common practice is to circulate twice the hole
volume with high viscous mud, spotting Hi-viscous mud in the open hole
section, prior to pulling out to run conductor/Casing. This volume may be
weighed, and may have water loss control. The same procedure may be
repeated once casing is landed.
Bentonite Systems
Bentonite is used for viscosity and fluid loss control in water base drilling
fluids. It must be pre-hydrated prior to being added to a volume containing
salt. It is the primary viscosifying agent for drilling surface hole, because of its
effectiveness and low unit cost.
For maximum yield the product must be allowed to hydrate for 2 - 4 hours
before use. The time required for hydration is reduced when the amount of
shear and temperature is increased. Since the system is susceptible to
dissolved ions, total hardness levels in the mix water must be treated to below
400 mg/l and the chloride limitation is 1000 mg/l. Bentonite can be mixed at
900 - 1300 lb/hr. The limitations on mixing time will be the mixing system and
the amount of agitation in the pits
There are some options available to extend the use of Bentonite. These
options can be considered when there are logistical limitations. These include
diluting a given hydrated volume with seawater. This will be done just prior to
pumping. The seawater will flocculate the Bentonite giving extra viscosity. The
limitation to this procedure is that over time the viscosity of this volume will
decrease. Another option is to flocculate with lime. Just prior to pumping lime
is added to a given volume to flocculate and give extra viscosity. The
limitation to this method is logistics. A designated pit is required for the
volume since it would have to be cleaned prior to mixing new PHB. Extra time
is also required since volumes have to be transferred and the lime mixed.
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KDS Ltd.
Mixing Procedure for pre-hydrated Bentonite PHB

1. Fill the pits with the desired volume of drill water.
2. Check Drill-Water hardness and treat with Caustic/Soda Ash as required.
3. Add sufficient Caustic/Soda Ash to obtain a pH of 10.
4. Mix 25 to 30 ppb of Bentonite. The Bentonite should be allowed to hydrate
for as long as necessary to obtain a viscosity in excess of 100 sec/qt.
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KDS Ltd.
NaCl/KCl Polymer System

Application
NaCl/KCl/Polymer muds are inhibitive polymer fluids that can be used for
successfully stabilizing reactive shales found in deepwater wells. The shale
inhibition is achieved by suppression of water activity due to the salt content
of the fluid, and by cation substitution with the formation clays (Potassium
ion), thus reducing the swelling tendency of the clay by directly interfering with
the swelling mechanism. POLYPLUS (PHPA) provides a secondary inhibition
through encapsulation, preventing water from migrating into the shale.
POLYPLUS also improve the lubricity of the fluid.
Hydrate Inhibition
NaCl Polymer fluids can be successfully used to inhibit the formation of gas
hydrates, by utilizing the salt (NaCl/KCl) content of the fluid to reduce the
freezing point of the water phase, and to limit the amount of free water, which
is available for Hydrate formation. The higher the salt content of the fluid, the
more inhibitive the fluid becomes to formation of gas hydrates. The high salt
contents also give rise to high initial fluid densities, which can often be in
excess of formation fracture pressures, or severely limit the solids tolerance of
the fluid due to density limitations. Additional Hydrate suppression can be
achieved without increasing mud weight, by the addition of low density
hydrate inhibitors. Methanol is the most efficient, but provides a serious health
and safety hazard due to its toxicity and low flash point. Several low molecular
weight glycols can also be used mono-Ethylene Glycol (MEG) being the
most efficient on a volume % basis. Graphs can be derived for each hole
section to illustrate theoretical Hydrate suppression obtained at varying
concentrations of NaCl/KCl, and MEG.
Operational Procedure
Cement, casing shoe and rat-hole from the previous casing should be drilled
with existing drilling fluid in the hole or Seawater, to avoid contaminating the
NaCl fluid with cement. Pre-treat the mud with 0,3-0,5 lbs/bbl Bicarbonate
and Citric Acid if drilling out the cement with the NaCl Polymer mud.
XCD, Xanthan-polymer is the primary viscosifier in the system. Because of its
shear thinning characteristics, viscosity at low shear rates can be increased
and maintained, without greatly affecting the viscosity at higher shear rates,
thus providing the required 3 RPM readings. The use of Xanthan-polymer can
be reduced once drill solids are incorporated in the mud. At that stage, PHPA
polymer added directly to the active system may be done to increase the 3
rpm reading. This will increase the YP, contribute to lubricity, and promote
inhibition through encapsulation.
POLYPAC is used to control the API and HTHP fluid loss of the system. Using
a low viscosity (or Ultra low viscosity) grade will allow control of fluid loss
without excessively increasing the rheology.
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KDS Ltd.
POLYPLUS (PHPA polymer) will give viscosity on initial addition, particularly

in a high solids fluid. This viscosity will reduce with shear and temperature.
Polyplus concentrations of 0.75 1.25 ppb should be maintained in the drilling
fluid returns to ensure adequate encapsulation of the drilled shale cuttings.
Additives
Additive
KCl
NaCl
XCD
PolyPlus
PolyPac
Soda Ash
MEG
M-I Bar
Material
Potassium Chloride
Sodium Chloride
Biopolymer
PHPA
PAC Polymer
Na2CO3
Mono Ethylene Glycol
Barite
Function
Shale Inhibitor
Salinity/Hydrate inhibition
Viscosifier
Encapsulator
Fluid loss Control
pH/Ca Buffer
Hydrate Inhibition
Density Control
Mixing Procedure
The mixing order of the polymers is normally not very critical, and will to some
extent depend upon the mixing and shear facilities available. If possible, mix
the PHPA and PAC polymers in drill water, and add NaCl/KCl brine to the
specified concentration after the polymer is fully hydrated. If that is not
practical, the procedure below is recommended:
1. Prepare NaCl/KCl brine of the specified concentration by cutting back the
saturated brine by drill water. Add Soda Ash to treat out hardness.
2. Add the specified concentration of polymers, and shear the fluid with a
high pressure shear device (1000 psi).if available, or circulate as long as
practical through mix lines/shear guns
3. Add Barite to the specified density and adjust properties as appropriate.
Daily Maintenance
Solids control
Solids Control - Make full and effective use of all solids equipment. Run
finest screens possible at all times on the shale shakers. The mud cleaners
should be run with screens not coarser than 200 mesh to limit the build up of
sand in the system. Prior to weight-up, or if MBT values are high, the desilters
/ desander should be run with discharge overboard. The mud cleaner should
then be used as an extra shaker for increased flow capacity.
Ensure that all equipment is operating at the maximum efficiency. It is
exceptionally important to maintain the absolute minimum of drilled solids in
the active system and to maintain the drilling fluid system according to the
program parameters. The higher density of the brine required to inhibit
hydrate formation will limit the solids tolerance of the system thus good solids
control will eliminate costly dilutions being required for density control.
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KDS Ltd.
During displacement, 40 - 80 mesh screens are recommended for the

shakers. As the fluid is heated and sheared, finer screens will be fitted in
increments, as soon as flow capacity allows. Experience shows that the
shakers will handle 120 - 150 mesh screens on 12 1/4" sections. The
centrifuges should be utilized to their maximum capacity as needed.
Dilution - Dilute with premixed drilling fluid of known concentrations. The
concentrations should be higher than in the initial mix to compensate for
depletion. The premixes will contain PAC Lovis and PHPA to be able to
maintain the desired properties in the active drilling fluid system.
Rheology
Rheology - Control drilling fluid rheology by addition of XCD and PHPA
polymer and dilution with pre-mixed drilling fluid together with optimum use of
all solids control equipment. To maintain a non-dispersed drilling fluid in this
section will require low gravity solids at a minimum. As a guide <7 %.
Increasing LGS content of this mud gives an increase in spurt loss of the
drilling fluid.
Maintain the PHPA concentration as PHPA is constantly depleted from
the system by adsorption to the surface of removed drill solids. The
effective concentration will thus always be less than calculated. A
field test can be used to determine whether the PHPA concentration
are maintained, and premix concentrations should be adjusted to give
0.25 .5 ppb excess PHPA in the returned fluid. In systems with
increased PHPA content, PHPA is constantly added directly to the
system during drilling. This will give sufficient rheology and fluid loss
control as well as maintenance of sufficient polymer to provide
optimum encapsulating effect.
Two of the most important rheology parameters are the 3 rpm reading
which defines the lifting capacity at very low flowrates, and the 10 sec
gel strength which defines the suspension capability of the system. It
is important that these two parameters are within the specifications to
ensure that the hole cleaning is optimum and that build-up of cuttings
is reduced to a minimum.
If it is not possible to maintain the 3 RPM reading and 10 sec gel
strengths without producing high 10 min gel strengths, the drilling fluid
system has incorporated too much ultrafine drill solids and a part of
the system (20 - 40 %) will have to be replaced with fresh drilling fluid.
To avoid any new drilling fluid being dumped or ending up in the
reserve system, dilution should be performed over one circulation.
Inhibition
Inhibition - Monitor the cutting conditions at the shaker. Cuttings should be
firm and dry inside. Sticky and balled up cuttings may indicate insufficient
inhibition from a low K+ level and/or low PHPA content.
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KDS Ltd.
Hole cleaning
Hole cleaning - Controlled drilling is strongly recommended for proper hole
cleaning. Cuttings should be circulated up above the BHA prior to
connections. This will minimize the potential of cuttings settling during
connections, causing packing off and stuck pipe. Prior to trips the hole should
be circulated for at least bottoms-up. This will prevent tight hole on the way
out and bridges, fill etc. on the way back in.
Rotating and reciprocating drill string at allowable RPM when the pills are
being circulated out can assist hole cleaning especially in enlarged or washed
out zones.
Density
Density - Drilling fluid density adjustments will be made after instruction from
the Shell supervisor on the rig. Cuttings at the shale shakers should be
monitored for signs of cavings that may indicate a need for an increased
drilling fluid weight. Tight hole, fill on trips and torque or drag on connections
can also be good early indications of the possible need to increase the drilling
fluid weight to maintain stable hole conditions.
Gel strength
Gel strengths - This is a guide-line value only and the lower the 10 minute
gel strength can be maintained, the better condition of the drilling fluid. As the
ultra fine and fine solids content builds up in conjunction with the polymer
concentrations, the gel strengths will increase. Field experience has shown
that a 10 minute gel strength of 40 lb/100 ft2 in the polymer drilling fluid
system is acceptable. However, it is essential to maintain the initial gel
strength >8 lb/100 ft2 to provide a thixotropic fluid that will support cuttings.
pH - pH range of 8.0 to 9.2 for this system, control by Soda Ash additions.
API fluid loss - A constant API fluid loss, together with a thin and slick filter
cake, indicates a constant amount of free available polymer.
Calcium
Calcium - Ca++ level should be maintained below 400 mg/l with Soda Ash to
ensure optimum performance of the PHPA polymer.
Gas hydrates
Gas Hydrates monitor the concentrations formulated to suppress gas
hydrates very closely (refer to charts in deep water Glydril system) A dual retort
will be used to monitor the Glycol concentration. If using Glydril MC along with
MEG, a total concentration will be shown in the results. With this being said, a
mass balance need be kept up daily with all additions to the mud accounted
for.
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Interval Discussion
All depths in this section are estimates and used for Volume and mud product
consumption only.
8 Pilot x 30" Conductor (Jetted)

Depth (water depth 2520ft.)
30" conductor to
Funnel viscosity (viscous pills)
Mud weight
Kill mud (500bbls)
Footage drilled
2520-2843ft.
2843ft.
+ 100 sec./qt.
8.7 ppg /453pptf
11ppg / 572pptf
323 feet
Drilling Fluid Recommendation

A conventional top hole system utilizing pre-hydrated Bentonite for high
viscosity sweeps while drilling with seawater, and displacing hole to a
weighted Bentonite mud for hole stability prior to running conductor is
recommended for this section. Guar gum should be on board if additional
viscosifiers are needed in case of time or drill water shortage. This method
has been used on a number of deepwater wells, and proved to be technically
efficient and cost effective. However, if possible the casing may be jetted down so
there may be no need for weighted spotting fluid.
This will be decided after the 8.5 pilot hole has been drilled. It will be known
at exactly what depth the 30 foundation pile will be set. If in the unlikely event
that the soil below the seafloor is found to be too hard for jetting - then a 36
hole shall be drilled and the 30 shall be run and cemented conventionally. Be
prepared for a plan B as far as volume goes.
Drill 8.5 x 30" conductor hole section with seawater and viscous pills. Make
pills of pre-hydrated Bentonite as required.
Additives
Additive
Bentonite
Caustic Soda
Soda Ash
Barite
Material
Montmorillonite
Sodium Hydroxide
Sod. Carbonate
Barium Sulphate
Function
Viscosifier
pH control
pH control
Weight material
Concentration
25-30 lb/bbl
.25 lb/bbl
.5 lb/bbl
As needed
Operation and Procedures

Treat drill water with caustic and Soda Ash for pH of 9.5, and Total
Hardness. Add 25-30 lb/bbl Bentonite to obtain a funnel viscosity in excess of
100 sec./qt. for Bentonite pills.
Mix 28 lb/bbl Bentonite in fresh water, allow to yield for 6 hours if possible.
A shearing unit will be on board, which will enhance the hydrating effect with
less time required.
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KDS Ltd.
Drill 8.5" pilot hole and 30conductor jetted with seawater. Pump a 50bbls
high viscosity pill every 45 feet or as needed to clean the hole.
If the hole is drilled to 36, it is recommended to pump a 150 bbl + Hi Vis
sweep and displace the hole prior to pulling out of the hole to run the 30
casing with the 572pptf kill mud.
Prior to drilling this section, build 1 pit (500bbls) of 11ppg/572pptf Bentonite
kill mud (18-22 lb/bbl of bentonite). To avoid possible barite settling, agitators
must be run at all times. This mud can be used as displacement fluid on the
26" sectionif not used here.
3/9/01
18
KDS Ltd.
Mud Specification for 8 pilot hole; 30 Structural Pile

(Jetting)
DRILL RISERLESS WITH SEAWATER AND BENTONITE SWEEPS.

PUMP 50 BBL SWEEPS EVERY 1/2 STAND OR 45 FEET. SWEEP
THE HOLE AS NEEDED OR HOLE DICTATES. POOH . BASED ON
THE 8.5" PILOT HOLE, IT WILL BE DECIDED IF THE 30" WILL BE
JETTED OR A 36" HOLE WILL BE DRILLED. IF THE HOLE IS
DRILLED TO 36", IT IS RECOMMENDED TO PUMP A 150 BBL HI
VIS SWEEP AND DISPLACE THE HOLE PRIOR TO PULLING OUT
OF THE HOLE TO RUN THE 30" CASING WITH THE 572PPTF KILL
MUD. MIX ONE PIT (500BBLS) 11.0PPG / 572PPTF KILL MUD TO BE
USED FOR DISPLACEMENT ON THE NEXT SECTION IF THE
CONDUCTOR IS JETTED IN.
THE KILL MUD SHOULD BE MIXED WITH 20-22 LB/BBL

BENTONITE.
SWEEP VOLUME MIXED WITH 25-30 LB/BBL FOR A VISCOSITY OF

100+
GUAR GUM SHOULD BE ON BOARD IF ADDITIONAL

VISCOSIFIERS ARE NEEDED IN CASE OF TIME OR DRILL WATER
SHORTAGE.
3/9/01
19
KDS Ltd.
26" Hole
Depth 2843 4073ft.
30" conductor to
Funnel viscosity (viscous pills)
Mud weight
Kill mud (total 1120bbls)
Spotting fluid (dilute kill mud )
Footage drilled
2.1
2843ft.
+ 100 sec./qt.
8.7 ppg /453pptf
11.5ppg / 600pptf
10.6ppg / 550pptf
1230 feet
Drilling Fluid Recommendation
As for the previous section, a system utilizing pre-hydrated Bentonite for high
viscosity sweeps while drilling with seawater, and displacing the hole to a
weighted Bentonite mud for hole stability prior to running casing is
recommended for this section. Drill riserless with sea water and Bentonite
sweeps pumped every stand or 45ft. Sweep the hole as needed or as hole
dictates. Drill to TD and pump a 200 bbl sweep prior to the wiper trip. Pump
out to the 30 conductor with Hi Viscous gel mud (950bbls). Trip back in to
check for fill. Pump another 200bbl sweep and follow with the diluted kill mud
(1127bbls) prior to pulling out of the hole for the casing run. The 500bbls of kill
mud brought over from the previous section will leave 627+bbls to buildif it
is not used. The 10.6ppg displacement fluid should be treated with Pac UL at
.75 to 1.25 lb per bbl for fluid loss control, in order to avoid the possibility of
hole instability and differential sticking when running 20" casing. The API fluid
loss should be <18ml.
NOTE: An attempt will be made to push the 20 casing point deeper. The 16
liner may be aborted. Planning for additional volume should be made in case
this does happen.
Additives
Additive
Bentonite
Caustic Soda
Soda Ash
Barite
PolyPacUL
3/9/01
Material
Montmorillonite
Sodium Hydroxide
Sod. Carbonate
Barium Sulphate
Pac Polymer
20
Function
Viscosifier
pH control
pH control
Weight material
Fluid Loss
Concentration
25-30 lb/bbl
25 lb/bbl
.5 lb/bbl
As needed
.75-1.25 lb/bbl
KDS Ltd.
Operation and Procedures

1. Treat drill water with caustic and Soda Ash for pH of 9.5, and Total
Hardness. Add 25-30 lb/bbl Bentonite to obtain a funnel viscosity in excess
of 100 sec./qt. for Bentonite pills.
2. Mix 15 lb/bbl pre-hydrated Bentonite, .5 -1.25 lb/bbl PolyPac UL, then
Barite to make 10.6 ppg mud. The kill mud made on the 36" section can be
blended for this purpose if it had not been used.
3. Drill 26" hole using seawater/viscous pills pumping sweeps every stand
or 45 feet. Additional sweeps as dictated by the hole.
4. Drill to TD and pump a 200 bbl sweep prior to wiper trip. Pump out with gel
mud to 30 conductor shoe. (950bbls) Trip back in and check for fill.
5. Pump another 200 bbl sweep and follow with 1,130 bbls of kill mud prior to
pulling out of the hole for the casing run.
Note:
3/9/01
All pits, solids control equipment and lines should be thoroughly flushed and cleaned in
preparation for the NaCl/KCL Glydril system to be used on the next section. Due to the
amount of volume and materials to be mixed in the next section, saturated NaCl brine with
10% by volume Glydril MC and 10% by volume MEG will be mixed at the plant (2,200 bbls
will be sent out). All the KCL, 5% by wt. will be added at the rig. Adjust all final
concentrations of MEG, Glydril MC, and KCL after drill water with the polymers and NaCl
concentration is cut back to 13% by wt. with sea water.
21
KDS Ltd.
Mud Specification for 26 hole and 20 Casing
IF THE 500 BBLS KILL MUD WAS NOT USED ON THE PREVIOUS INTERVAL, MIX AN ADDITIONAL 627 BBLS TO HAVE ENOUGH VOLUME TO DISPLACE THE HOLE
FIGURED AT 28" ID ALL THE WAY DOWN (1127BBLS). DILUTE THE KILL MUD AT 10.6PPG / 550PPTF // kILL MUD= 11.5PPG / 600PPTF
AS PER THE LAST INTERVAL. DRILL RISERLESS WITH SEAWATER AND BENTONITE SWEEPS PUMPED EVERY 1/2 STAND OR 45 FEET. SWEEP THE HOLE AS
NEEDED OR AS HOLE DICTATES. DRILL TO TD AND PUMP A 200 BBL SWEEP PRIOR TO THE WIPER TRIP. PUMP OUT TO THE 30" CONDUCTOR WITH HI VIS
GEL MUD (950 BBLS). TRIP BACK IN TO CHECK FOR FILL. PUMP ANOTHER 200BBL SWEEP AND FOLLOW WITH THE DILUTED KILL MUD PRIOR TO PULLING
OUT OF HOLE FOR THE CASING RUN. APPROXIMATE SPOTTING FLUID NEEDED 1127BBLS KILL MUD
TREATED WITH POLYPAC UL (.75-1.25PPB) TO A API WATER LOSS OF <18 FOR HOLE STABILITY PRIOR TO RUNNING CASING.
NOTE: GUAR GUM SHOULD BE ON BOARD IF ADDITIONAL VISCOSIFIERS ARE NEEDED IN CASE OF TIME OR DRILL WATER SHORTAGE. A CONTINGENCY OF
PAC UL SHOULD BE ON BOARD IF THERE IS HOLE INSTABILITY AND THE WATER LOSS IS DECIDED TO BE LOWERED IN THE VOLUME TO BE SPOTTED.
SPOTTING FLUID PH SHOULD BE MINIMAL FOR PH SENSITIVE FORMATIONS.
NOTE: AN ATTEMPT TO PUSH THE 20" CASING POINT WILL BE MADE. PLANNING FOR ADDITIONAL VOLUME SHOULD BE MADE IF THIS HAPPENS. THE 16" LINER
MAY BE ABORTED.
3/9/01
22
KDS Ltd.
SPUD MUD
DEEPWATER WELL PROGRAMME

26"HOLE :
BENTONITE SWEEPS
VOLUMES & ESTIMATED COST
Hole Size
Starting Depth
Final Depth
Casing #1 OD
Casing #1ID
Casing #1 Length
Casing #2 OD
Casing #2 ID
Casing #2 Length
Washout
Solids Removal Efficiency
Allowable Drill Solids
Previous Surface Volume
Previous Kill Mud Volume
26"Additional kill mud volume
Sweep Volume 26" hole
Total Estimated volume built
Total Estimated volume to use
Barrels/ Cu. Meters

feet
26
26
2843
866.8
4073
1241.8
30
30
28
28
323
98.5
0
0
0
0
0
0
0
0
-500
-79
627
100
2700
429
0
3327
529
3827
1230 feet drilled
Product
M-I Gel
Barite
Soda Ash
Caustic
PolyPac UL
Unit
Conc.
Conc. BBLS
Units
Size
PPB
kg/m3
SX/MT/M3
MT
25 / 30
71 3327
43
MT
627
29
25 kg sks
0.5 1.4265 3327
30
25 kg can
A/N
A/N
3327
6
25 kg sks
1.25 3.56625 1127
26
Guar gum should be on hand as contingency

for additional viscosity if drill water or time
mixing is a factor.
Sweeps (50bbls) every 45 feet
Displacement volume wt.To 10.6ppg / 550pptf
Kill mud will be used as
spotting volume on last displacement.
Pump 200 bbl Hi vis sweep prior to
displacing hole with weighted fluid before csg. run.
Total Cost
3/9/01
23
Total
Cost
9890.00
4495.00
294.00
118.80
2379.00
17,176.80
CUMULATIVE COST :
Table 1 26 hole Volume and Cost Estimate
Unit
Cost
230.00
155.00
9.80
19.80
91.50
26,163.60
KDS Ltd.
17 1/2" x 22" Hole

Depth
20" casing to
Footage drilled
Mud weight
Mud weight
Yield point
3 RPM>
Fluid loss (API)
MBT
pH
KCl
NACL
Glydrill MC
Monoethylene
4073-4873ft.
4073ft.
800ft.
9.2 9.8ppg
478 510pptf
25 - 30 lb/100ft2
10
<6 ml
< 17.5 lb/bbl
8.0-9.2
5% by wt.
13% by/wt.
5% by volume
8% by volume
The gas hydrate formulations are based on lab tests generated from our
Houston and Stavanger research centers. The system in this interval will be
slightly under the values needed for maximum protection. With this being the case,
for any shut-down or trip a near saturated pill (22%NaCl)with 10% MEG need be
used to flush and spot through the choke, kill lines and BOPs.
The brine with Glycol which will be mixed and sent to the rig via the mixing
plant onshore, can be used by adjusting the NaCl to 22% with 10% MEG
already in the system. This should be mixed prior to drilling and held in an
alternate slug pit (if available) or holding tank on stand-by as needed.
Drilling Fluid Recommendations

The NaCl/KCL Glydril system has been recommended for this section due to
its high levels of wellbore stability shale control, gas hydrate inhibition, ease of
engineering and high levels of contamination tolerance. The system will allow
good hole cleaning to be achieved at high rates of penetration, and has
proved to be highly cost effective, and given high levels of technical
performance in previous wells.
The Glydril system is an anionic water based polymer fluid, which uses
potassium chloride, and a polyalkylene glycol, Glydril MC, to provide high
levels of shale control. The formulated system will exhibit good lubricity, and a
low fluid loss with a thin filter cake. The system is also highly shear thinning,
which, coupled with the inhibitive characteristics, will improve solids control
performance, and reduce drilling fluid dilution requirements and costs.
Monoethylene Glycol has been added to the formulation, to allow for extra
coverage of gas hydrates due to the temperatures at these deeper water
depths.
3/9/01
24
KDS Ltd.
Due to the seabed temperatures (5 degrees C) and the mud wt. that will be
experienced in these deeper waters, KCL (5% by wt.) along with NACL (13%
by wt.) and Monoethylene glycol should be added at 8% by volume to
suppress gas hydrates. This formulation will be slightly less than is required
for maximum hydrate coverage. With this in mind, it is imperative that the
above NaCl/Glycol pill is spotted at any shut-down or tripping operation. The
formulations were arrived by the research work done at our technical research
centers in Houston and Stavanger. Gas hydrate simulators at both facilities
were used to perform the simulations of the conditions that will be seen on
this project. (See hydrate charts for reference, section 1)
Additives
Additive
KCl / 5%
NACL /13%
Poly Pac UL
Material
Potassium chloride
Sodium chloride
PAC polymer
XCD
Soda Ash
Barite
PHPA
Glydrill MC
Monoethylene Glycol
Function
Concentration
Inhibitor
19 lb/bbl
Inhibitor
50.2+lb/bbl
Fluid loss/
3-4lb/bbl
Encapsulator
Xanthan Gum
Viscosifier
1.25-1.5lb/bbl
Sod. Carbonate
pH control
.5-.75lb/bbl
Barium Sulphate
Weight material
As needed
Polyacrylamide
Encapsulator
1.25lb/bbl
Polyalkylene
glycol Inhibitor
5 vol%
Monoetheylene glycol
(for gas hydrate inhibition)
Operation Procedure
If mixed on the rig, drillwater should be used to properly solubilize and hydrate
the polymers prior to adding the salts, using all available pit space. The
following should be added:
Note: Saturated brine (2200 bbls) with 10%MEG and 10% Glydril MC will be mixed at the plant and
sent out to the rig. A near 50/50 cut with seawater and or drill water with the polymers should
be made to achieve a total of 13% by wt. NaCl concentration. All of the KCl concentration (5%
by wt.) will be added at the rig site. Adjust and insure that the Glycol concentrations are as
specified.
Additives
Additive
KCl
NACL
Soda Ash
Pac Plus UL
Material
Potassium chloride
Sodium chloride
Sodium carbonate
Concentration
19lb/bbl
+50.2lb/ bbl
.5-.75lb/bbl
PAC polymer
3.5-4-lb/bbl
XCD
PHPA
Glydril MC
Monoethylene
Barite
3/9/01
Xanthan Gum
Polyacrylamide
Polyalkylene glycol
Monoethylene glycol
Weight material
25
1.5lb/bbl
1.25lb/bbl
5 % by volume
8% by volume
As needed
8 vol%
KDS Ltd.
Start to shear the polymer fluid once the mixing has started. The high
pressure shearing device shall be used if available to shear the fluid prior to
drilling.
The shale shakers should be decked out with coarser mesh screens (max
40mesh) at displacement and the initial circulations while drilling till the mud
is sufficiently sheared. Finer screens can be stepped up as the mud is broken
in. The initial concentration of PHPA should be cut in half for the initial
circulations, but brought up to specifications once the system has been
properly sheared.
Drill out cement and shoe track with seawater, and pump a 50 bbl Hi Vis
spacer pill and displace the hole with the KCL/NaCl Glydril system. With the
cement being drilled out with seawater, there should be no problems with
cement contamination. But close monitoring should be taken to eliminate high
pH. Citric acid and Sodium Bicarbe will serve as the constituents to buffer pH.
The formulations for the drilling fluid are designed to allow maximum carrying
capacities of the cuttings considering the effects of ECD down hole verses the
larger diameter riser. A pump should be designated to boosting the riser. Due
to the additional boost of volume, some volume will probably be lost over the
shale shakers when boosting. This is why it is important to establish how often or
if the riser should be pumped out. If not, at least one check should be made every 6
hours.
When sweeping the hole, coincide your long sweep with one coming through
the riser at the same time. This will maximize lift in cuttings at that point.
Pump 100 bbl Hi Vis sweeps prior to trips. A 50 bbl sweep volume should be
pumped intermittently, depending on drilling rates and evaluating just how
good the system is handling hole cleaning.
Increase the sweep volume and frequency as dictated by the hole. Over
sweeping can cause an increase in rheology and ECDs due to the additional
XCD being added for sweeps.
A cut back in pre-mix additions to compensate may have to be considered.
Concentrations should be maintained at all times.
While tripping in after a trip out for logging or any time where the mud is
sitting static for a period of time, the hole should be stage pumped.
First circulation should be below the exposed BOPs, at casing point and
other designated points in the open hole. This will help in minimizing surge
pressures with the rheology factor in cold mud removed and warmer mud
replaced. This also is an added safety factor in consideration of gas hydrates.
3/9/01
26
KDS Ltd.
Daily Maintenance
(Refer to previous on Glydril and NACl/Kcl polymer systems. )
Mud check - One of the daily mud checks should be on mud returning from
the well to provide an indication of the downhole effect on the mud when
circulating it through the well and one in the suction pit.
Product addition - Prehydrate all products in the designated pre-mix pits
before additions are made to the active mud system. Addition of products
directly to the active system may reduce the efficiency of the product and
cause an unstable active system.
Rheology - The rheology is controlled by addition of XCD, which is a Xanthan
Gum. The low end rheology or the 3 RPM reading is the most important
rheology property in the Glydril MC system, and is maintained at >10
lb/100ft2. Control excessive rheology with whole mud dilution or the use of
Tackle if needed. Prior to casing run, the 10-minute gel should be lowered to
10 to 12 by dilution and or the use of Tackle.
Hole cleaning - Several factors affect the hole cleaning:
1. The most important is to use as high pump rates as possible, to achieve
highest possible annular velocity.
2. Increase the 3 RPM to the high end of specifications if hole cleaning
problems occur. The low end rheology is the most important mud property
to affect hole cleaning in this system.
3. Prior to connections, the cuttings should be circulated well above bottom,
to avoid packing off after connections.
4. The hole should be circulated clean before starting to POOH or back
reaming.
5. If the hole is back reamed to the casing shoe or above prior to
logging/casing, a check trip back to bottom should be made. At bottom, the
hole must be circulated clean before pulling out.
6. High-Viscous sweeps should be pumped intermittently and evaluated as to
their effectiveness. These sweep volumes can range between 50 and 100
bbls and the frequency determined by the evaluation.
7. Sweeps should coincide with a Hi Viscous sweep pumped through the
booster pump to maximize cuttings removal at that point. Pump 100 bbl Hi
Viscous sweeps prior to trips.
Fluid loss - Experience has shown that the fluid loss is very low
(<5 ml) because of the low solids content and the Pac Plus UL polymer
concentration used in this system. The Glydril MC will also contribute to a low
fluid loss.
MBT - Control MBT reading less than 17.5lb/bbl with whole mud dilution and
optimized use of solids control equipment.
3/9/01
27
KDS Ltd.
Shale Inhibition - The initial addition of KCl shall be 19lb/bbl, with

subsequent KCl in the premixes to maintain this content, measured at
shakers. Typical premixed concentrations will then be +/-20lb/bbl. This
concentration should provide sufficient base exchange and inhibition of drilled
cuttings/formation. But if the hole dictates, the concentration can be
increased.
Glydril MC will also give extra inhibition. It can be added directly to the active
system as needed to maintain 5% b y volume, or mixed into premixes at 5.5%
(to allow for depletion). Use a temperature controlled retort to check the
volume content, same as for the Monoethylene glycol. A total glycol content
will result so a close monitoring of concentrations and mass balance
calculations will have to be in place.
Encapsulation - PHPA polymer will encapsulate drilled cuttings and reduce
the dispersion of clay in the drilling fluid. This enhances solids removal and
provides a cleaner fluid. To ensure adequate encapsulation while drilling, a
minimum concentration of 1lb/bbl PHPA polymer will be maintained in the
active system. Premix for whole mud dilution should therefore be made up
with a slightly higher PHPA concentration (1.25lb/bbl) to compensate for
polymer losses due to adhesion to the surface of drilled cuttings in the active
system.
Solids Control - Use finest shaker screens possible (but avoid heavy losses
over the shakers). Desilter and centrifuge can be used to control fine solids
content if required. Two centrifuges will be on board. In this section, due to the
importance of maintaining low mud wts, the centrifuges should be set up to
discharge the high gravity solids and return the effluent back to the active
system. The de-silter can be run from time to time if needed to assist in
lowering mud wt.
pH - Maintain pH by additions of Soda Ash to the premixes or directly to the
active system. Maintain a pH of 8.0-9.2 in the active system.
Barite addition - When the density in the active system is increased with
Barite, PAC polymer must be added simultaneously in concentrations 11.5lb/bbl PAC to 1 ton of Barite, to maintain available polymer in the system.
Bacteria test - Bacteria is not likely to be a problem, but spot checks should
be taken, using the Panatest Dipslide method.
Gas hydrate inhibition Monoethylene glycol concentrations will be
monitored by a temperature controlled retort, same as for the Glydril MC. A
total glycol content will result so a close monitoring of concentrations and
mass balance will have to be in place.
3/9/01
28
KDS Ltd.
Contingencies
(Also refer to
3/9/01
29
KDS Ltd.
Contingency Section)
H2S Hydrogen Sulfide is not anticipated, but must be considered a
potential problem. Below a pH of 10 the control of hydrogen sulfide by
alkalinity cannot be considered safe, even for trace amounts of sulfide
dissolved in the mud. The only safe procedure is to use the Hatch test kit daily
for qualitative analysis and the Garret Gas Train for quantitative analysis if
detected by the Hatch kit. Zinc Carbonate, added at 1 ppb will treat out
500ppm hydrogen sulfide. Zinc Carbonate is included in the materials
contingency list.
Loss circulation / Seepage losses Seepage or loss circulation is a good
possibility in this section with low formation pressures mud wt.
For seepage losses spot a LCM pill consisting of up to 20 lb/bbl combination
of Mica fine, Mix11 and Nutplug med. Calcium carbonate (F&M) can be used
to weight up the pill. If possible this should be mixed prior to drilling and kept
on stand-by as needed. One sack of each has been added to the active at
to 1 hour per sack as drilling continued with good results from previous
experience. For more severe losses mix up to 35 lb/bbl LCM consisting of a
combination of Nutplug Med., MIX II Med, and Mica Med, Mica fine. This too
can be weighted up with Calcium Carbonate Medium. Larger concentrations
can be mixed if needed. The loss circulation problem will have to be analyzed
to take the proper course in treatment. Consideration should be taken as to
what size LCM materials can be used due to MWD tools and jet nozzle sizes.
Bit balling - The formulation of the system with 5% Glydril MC will minimize
problems with bit balling. But if it is suspected or occurs, a saturated brine pill
with 20 30 lb/bbl medium Nutplug has worked well from previous
experiences.
3/9/01
30
KDS Ltd.
Mud Specification for 17.5 X 22 hole and 16 Casing
The mud system formulated is under the required suppression values that the lab test and prediction model shows. (see referenced charts). How ever, hydrate formation research is ongoing with still much to be
understood about this gas, water, temperature and pressure reaction. A safety margin can be factored with flushing and spotting the choke/kill lines & BOP's with a heavily inhibited pill. The pill should be mixed prior to
drilling out and held in the slug-pit or available holding tank. The active mud system can be used by raising the NaCl content to 22% by wt. salt content with 10% by volume Monoethylene. This would give an added
safety margin for any unseen or extreme worst case scenarios.
**Drill out cement and shoe track with seawater, pump a 50 bbl Hi Vis spacer pill and displace the hole with the KCL/NaCl Glydril system. With the system being drilled out with seawater-then displaced, there should
be no problems with cement contamination. But close monitoring to treat the system is a must. Citric Acid and Sodium Bicarbe will serve as the constituents to buffer pH .
**Controlled drilling, back reaming, gradually bringing up pump rates pump time before each connection, and short trips every 500 feet, all contribute to lessening surge pressures.
**The formulations for the drilling fluid are designed to allow maximum carrying capacities of the cuttings considering the effects of ECD down hole verses the larger diameter Riser. A pump should be designated to
boost the riser at designated time periods to ensure that there is no cuttings build-up in the riser. These designated time periods for boosting, should be determined by the amount of cuttings seen at the shakers when
boosting. Due to the additional boost of volume, some volume will probably be lost over the shale shakers when boosting. This is why it is important to establish how often or if the riser should be pumped out. If not, at
least one check every 6 hours. When sweeping the hole, coincide with pumping Hivis through the booster pump. Pump 100 bbl Hi vis sweeps prior to trips. A 50bbl sweep volume should be pumped intermittently,
depending on drilling rates. Increase the sweep volume as dictated by the hole. Over sweeping will increase rheology and ECD's due to additional XCD being added.
**The well should be stage pumped while going in the hole after a trip or logging time, especially once below the BOP's and at other pre-determined depth, this will replace the riser with a higher temperature mud again
and also with a lower rheology mud in respect to cold temperatures.
**There will be a shearing unit to be utilised to shear the polymers formulated in this system. Due to mixing time, it is recommended that the shakers be decked out with coarser screens(max 40mesh) at displacement
and the initial circulations while drilling till the mud is sufficiently sheared. Finer screens can then be stepped up as the mud is "broken in". The initial concentration of PHPA should be cut in half for the initial
circulations, but brought up to specifications once the system has been properly sheared.
**The dual retort will be used to monitor the Glycol concentration in the mud. Due to two different glycols added to the system, a total glycol content will be shown. With this fact a very close mass balance ,
concentration of all volumes and constituents added to the mud, must be tracked closely and reported daily with the mud report.
**The centrifuges can be used on these lower mud wts. to discharge the higher gravity solids and LGS ,while keeping the effluent. Two centrifuges working tandem along with the desilter used as needed, should be
enough to maintain the low mud wt. needed to drill this interval.
Mud Wt: Maintain the mud weight as low as possible. Utilise all solids control equipment(desilter, centrifuges) to maintain mud wts. as this is critical in this interval. The higher formulated addition of Monoethylene is
attributed to the constraints of using higher salt concentrations due to a maximum mud wt. of 9.8ppg being designed for the interval.
SOLIDS / PV: Control the LGS below 5% by dilution as necessary. The LGS solids should not exceed 7%. The PV should be maintained as low as possible.
6 RPM/RHEOLOGY: All rheology will be maintained and reported per API 120 degrees Fahrenheit. Maintain at a minimum of 12-15+ for maximum hole cleaning in the larger riser diameter with additional additions of
XCD polymer if required. Drop the 10 minute gels to 10 -12 if needed by using Tackle prior to the casing run.
pH/TOTAL HARDNESS: Maintain the pH at 8.7 to 9.2 with pf/mf readings of 0.03 / 0.1 . Note : The formations on these top intervals are usually very PH sensitive. pH will mainly be supported by the Soda Ash, which
is being used for the treatment of Total Hardness.
Fluid Loss: The fluid loss in this systems formulation make-up will give an API water loss below 6cc.
BIT BALLING: The formulation of this system will minimise this problem. If there are signs of balling, a pill of saturated brine with med nut plug has proven successful from prior experience.
Seepage/loss circ.: Depending on the severity, different combinations of LCM types can be used. Calcium carbonate(f&m) with Mix11, has worked well in 30-35 lb/bbl concentrations. For seepage losses, adding a
sack of each every 1/2 - 1hour has worked well. The situation will have to be assessed and acknowledging that Medium sized materials will be the max. due to equipment in the drillstring.
Logistics note: Due to the large volume at start-up, mixing of saturated NaCl Brine will be mixed at the plant with 10 %Meg / 10 % Glydril MC and 5% KCl to be added at the rig. Any other volume added for cut-back in
chlorides , should be compensated w ith the formulated concentrations.
3/9/01
31
KDS Ltd.
NACL/KCL GLYDRIL SYSTEM

17 1/2"HOLE X 22" UR:
Hole Size
Starting Depth
Final Depth
Riser OD
Riser ID
Riser Length
Casing #1 OD
Casing #1 ID
Casing # Length
Casing #2 OD
Casing #2 ID
Casing # Length
Surface Volume
Displaced Casing Volume
22"Hole Volume+Washout
Dilution volume
Washout
10%
Total Estimated Volume
Barrels/ Cu. Meters

feet
22
22
4073
1242
4873
1486
21
21
19
19
2593
791 (RKB)
20
20
18.73
18.73
1480
451
0.7
0.05
600
1414
455
1821
79
3835
0
0.7
0.05
95
225
72
290
13
610
800 feet drilled
13%NACL / 5% KCL / GLYDRIL 5% /MONOETHYLENE 8%

Product
Bentonite
Barite
PolyPac UL
XCD Polymer
PolyPlus dry
NACL 99% purity
KCL 95%purity
Glydril MC
Monoethylene
Soda Ash
Unit
Size
MT
MT
25 kg sks
25 kg sks
25 kg sks
1.5 MT
1.5 MT
55gal drm
55gal drm
25 kg sks
MAINTAINANCE:
KCL
1.5 MT
NACL
1.5 MT
Glydril MC
55gal drm
Monoethylene
55gal drm
XCD Polymer
25 kg sks
(for sweeps)
Total Cost
MUD WEIGHT- 9.2 - 9.8ppg
MUD WEIGHT- 478 - 510pptf
Conc.
PPB
Conc.
kg/m3
0
A/N
4
1.5
1.25
50.2
19
5% / vol.
8% / vol.
0.75
0
0
11.412
4.2795
3.56625
143.221
54.207
5%
8%
2.13975
MAINTAINANCE
MAINTAINANCE
<1% / vol.
<1%
<1%/vol
<1%
a/n
a/n
BBLS
3835
3835
3835
3835
3835
3835
3835
3835
3835
3835
Units
SX/MT/M3
0
23
278
104
87
58
22
146
234
52
Unit
Cost
230.00
155.00
91.50
270.00
69.00
233.00
400.00
360.00
196.00
9.80
3835
3835
3835
3835
3835
5
10
19
19
25
400.00
233.00
360.00
196.00
270.00
3/9/01
32
0.00
3565.00
25437.00
28080.00
6003.00
13514.00
8800.00
52560.00
45864.00
509.60
2000.00
2330.00
6840.00
3724.00
6750.00
205,976.60
CUMULATIVE COST :
Table 2 22 Hole Volume and Cost Estimate
Total
Cost
232,140.20
KDS Ltd.
14 1/2" x 17 1/2" Hole

Depth
4873-5873ft.
4873ft.
1000ft.
10.2 10.8ppg
530 560pptf
25 - 30 lb/100ft2
16" casing to
Footage drilled
Mud weight
Mud weight
Yield point
3 RPM
>10
<5 ml
< 17.5 lb/bbl
8.0-9.2
5% by wt.
19% by/wt.
5 % by volume
5% by volume
Fluid loss (API)

MBT
PH
KCl
NACL
Glydril MC
Monoethylene
Maintain a near saturated pill (22%NaCl) with 10% MEG to be used to flush and
spot through the choke, kill lines and BOPs.
This should always be held on stand-by in an alternate slug pit (if available) or
holding tank on stand -by as needed.

Use the same system transferred over from the previous section. KCL (5% by
wt.) along with NACL (19% by wt.) and Monoethylene glycol should be
maintained at 5% by volume to suppress gas hydrates in this section.
Additives
Additive
KCl / 5%
NACL /16%
Poly Pac UL
Material
Function
Concentration
Potassium chloride Inhibitor
19+lb/bbl
Sodium chloride
Inhibitor
77+lb/bbl
PAC polymer
Fluid loss/
4lb/bbl
encapsulator
XCD Xanthan Gum
Viscosifier
1.25lb/bbl
Soda Ash
Sod. Carbonate
pH control
.5-.75lb/bbl
Citric Acid
Citric Acid
pH control
.5lb/bbl
Sod. Bicarbe
Sod. BiCarbe
Treat cement
.5lb/bbl
Barite Barium Sulphate Weight material
As needed
PHPA Polyacrylamide Encapsulator
1.25lb/bbl
Glydrill MC
Polyalkylene
Shale Inhibitor
5 vol%
Monoethylene Glycol Monoetheylene glycol
(for gas hydrate inhibition)
3/9/01
33
5 vol%
KDS Ltd.
Operation Procedure
(Refer to previous Deepwater Glydril & KCL/NaCl Polymer systems,)
Prior to drilling out, all solids control pits and possum bellies for all shakers
should be dumped and cleaned.
The KCL/NaCl Glydril system used in the last section will be carried forward to
this section and used. The NaCl content for this section is formulated to 19%
by wt. for the maximum wt. of 10.8ppg. For any unseen need to quickly
increase the mud wt., the NaCl should be increased to 19% after a leak-off
test prior to drilling ahead to cover hydrates in case of the quick wt. up. The
KCl concentration should also be monitored closely and kept at 5% as it is
also factored in for the gas hydrate coverage along with shale inhibition. The
MEG concentration will be gradually drifted back to 5% by volume.
Maintain volumes and concentrations closely. Pre-treat the mud with Citric
Acid and Sodium Bicarbonate, which will buffer the pH, accompanied with
cement contamination. It is important that the pH be kept low to prevent
polymer degradation.
Prepare any new NaCl/KCL Glydril volume in drill water to properly solubilize
and hydrate the polymers using all available pit space and in the following
mixing order:
Additives
Additive
KCl
NACL
Soda Ash
Pac Plus UL
XCD
PHPA
Glydril MC
Monoethylene
Barite
Material
Potassium chloride
Sodium chloride
Sodium carbonate
PAC polymer
Xanthan Gum
Polyacrylamide
Polyalkylene glycol
Monoethylene glycol
Weight material
Concentration
19lb/bbl
+77lb/bbl
.5-.75lb/bbl
3lb/bbl
1.25lb/bbl
1.25lb/bbl
5 % by volume
5% by volume
As needed
drilling.
The shale shakers should be decked out with coarser mesh screens (max 4060mesh) prior to drilling out and the initial circulation while drilling till the
temperature of the mud has gone up again . Finer screens can be stepped up
as this is accomplished.
3/9/01
34
KDS Ltd.
The mud need be monitored closely for any increase in pH while drilling the
cement. Additional Citric acid and Sodium Bicarbonate may be needed
besides the pre-treatment.
The formulations for the drilling fluid are designed to allow maximum carrying
capacities of the cuttings considering the effects of ECD down hole verses the
larger diameter riser. A pump should be designated to boosting the riser.
(refer to previous interval)Pump 100 bbl Hi Viscous sweeps prior to trips. A 50
bbl sweep volume should be pumped intermittently, depending on drilling
rates and evaluating just how good the system is handling hole cleaning.
Increase the sweep volume and frequency as dictated by the hole.
While tripping in after a trip out for logging or any time where the mud is
sitting static for a period of time, the hole should be stage pumped. First
circulation should be below the exposed BOPs, at casing point and other
designated points in the open hole. This will help in minimizing surge
pressures with the rheology factor in cold mud removed and warmer mud
replaced. This also is an added safety factor in consideration of gas hydrates.
Daily Maintenance
Mud check - One of the daily mud checks should be on mud returning from
the well to provide an indication of the down-hole effect on the mud when
circulating it through the well and one in the suction pit.
Product addition Pre-hydrate all products in the designated pre-mix pits
before additions are made to the active mud system. Addition of products
directly to the active system may reduce the efficiency of the product and
cause an unstable active system.
Rheology - The rheology is controlled by addition of XCD, which is a Xanthan
Gum. The low end rheology or the 3 RPM reading is the most important
rheological property in the Glydril MC system, and is maintained at >10
lb/100ft2. Control excessive rheology with whole mud dilution or the use of
Tackle if needed. Prior to casing run, the 10-minute gel should be lowered to
10 to 12 by dilution and or the use of Tackle.
content if required. Two centrifuges will be on board. In this section, due to the
importance of maintaining low mud wts, the centrifuges should be set up to
discharge the high gravity solids and LGS returning the effluent back to the
active system. The de-silter can be run from time to time as needed to assist
in lowering the mud wt.
3/9/01
35
KDS Ltd.
Contingencies
(Refer to
3/9/01
36
KDS Ltd.
Loss circulation / Seepage losses Seepage or loss circulation is always a
possibility, especially drilling exploration in any new area. In the event
seepage losses occur spot a LCM pill consisting of up to 20 lb/bbl
combination of Mica fine, Mix11 and Nutplug med.. Calcium carbonate
(F&M)can be used to weight up the pill. If possible this should be mixed prior
to drilling and kept on stand-by as needed. One sack of each has been
added to the active at to 1 hour per sack as drilling continued with good
results from previous experience.
For more severe losses mix up to 35 lb/bbl LCM consisting of a combination of Nutplug Med., MIX II
Med, and Mica Med, Mica Fine. This too can be weighted up with Calcium Carbonate Medium. Larger
concentrations can be mixed if needed. The loss circulation problem will have to be analyzed to take
the proper course in treatment. Consideration should be taken as to what size LCM materials can be
used due to MWD tools and jet nozzle sizes.
Bit balling - The formulation of the system with 5% Glydril MC will minimize
problems with bit balling. But if it is suspected or occurs, a saturated brine pill
with 20 30 lb/bbl medium Nutplug has worked well from previous
experiences.
3/9/01
37
KDS Ltd.
HTHP VISCOSITY
FANN 70
FLUID FORMULATION
Freshwater
bbl
0.706
NaCl
ppb
59
FLUID SYSTEM:
16%NaCl/5% KCl/8% MEG
KCl
ppb
19
DENSITY :
10,8 ppg
Glydril MC
ppb
17.5
TESTED BY:
Arne Ask
Polypac UL
ppb
TEST DATE :
######
PolyPlus
ppb
1.25
COMMENTS:
Malaysia - Shell
DuoVis
ppb
1.25
17 1/2" Formulation
Soda Ash
ppb
0.5
MEG
ppb
28
Barite
ppb
75
50 C (122F)
Pressure (psi)
FANN 35 RHEOLOGY RESULTS

5 C
30 C
50 C
ATM
2000
600 RPM
295
192
118
4000
6000
8000
600 RPM
120
121
122
122
300 RPM
205
134
123
80
300 RPM
81
81
81
82
200 RPM
160
83
109
60
200 RPM
61
62
62
62
100 RPM
63
108
75
40
100 RPM
40
41
41
42
42
6 RPM
24
19
14
6 RPM
14
15
15
15
15
3 RPM
18
14
11
3 RPM
11
12
12
12
12
Gel 10"
18
14
12
Gel 10"
12
12
13
13
13
Gel 10
23
19
16
Gel 10'
16
16
17
17
18
PV
90
58
38
PV
39
40
41
40
40
YP
115
76
42
YP
42
41
40
42
43
30 C (85F)
5 C (41F)
Pressure (psi)
Pressure (psi)
2000
4000
6000
8000
2000
600 RPM
193
194
195
195
4000
6000
8000
600 RPM
298
299
300
300 RPM
135
136
136
300
137
300 RPM
206
207
208
200 RPM
110
111
208
111
112
200 RPM
161
162
163
100 RPM
77
164
77
78
78
100 RPM
109
109
109
6 RPM
110
19
20
20
20
6 RPM
25
25
25
25
3 RPM
15
15
16
16
3 RPM
18
19
19
19
Gel 10"
16
16
16
17
Gel 10"
19
19
19
20
Gel 10'
20
20
20
20
Gel 10'
24
24
24
24
PV
58
58
59
58
PV
92
92
92
92
YP
77
78
77
79
YP
114
115
116
116
Table 3 17 HPHT Viscosity (Fann)
3/9/01
38
KDS Ltd.
Mud Specification for 14.5 X 17.5 hole and 13 3/8 Casing
**Prior to drilling out, all solids control pits and possum bellies for all the shakers should be dumped and cleaned. The NaCl content for this section is formulated to 19% by
wt. For any unseen need to quickly increase the mud wt., it is advised that the NaCL be increased to 19% after a leak-off test to cover hydrates in case of the quick wt. up.
The concentration of KCL should also be monitored closely and maintained to 5%+ as it is also factored in for the gas hydrate coverage along with shale inhibition. The MEG
concentration will be gradually drifted back to 5% by volume as the salt concentration is brought up. Maintain volumes and concentrations closely. Pre-treat the mud
transferred from the previous interval for cement contamination. Citric Acid and Sodium Bicarbe will serve as the constituents to buffer the pH with cement contamination. It is
important that the pH be kept low to prevent polymer degradation.
**Controlled drilling, back reaming, gradually bringing up pump rates before each connection, and short trips every 500 feet, all contribute to lessening surge & swab
pressures.
**Pump the riser as per previous interval. Pump 100 bbl Hi vis sweeps prior to trips. A 50bbl sweep volume should be pumped intermittently, depending on drilling rates.
Increase the sweep volume as dictated by the hole. The sweeps should be gauged as to how well they are contributing to hole cleaning and decided how often and how
much.
** Shaker screens should be changed back to coarser sized screens (40-80mesh) for the initial circulations until the mud is gradually warmed to allow for stepping back up to
finer meshed screens.
**The centrifuges can be used on these lower mud wts. to discharge the high gravity and LGS while keeping the effluent if needed to maintain mud wts. Two centrifuges
working tandem along with the desilter used as needed, should be enough to maintain the low mud wt. needed to drill this interval. With the mud wt. at 10.8ppg, the
centrifuges can be run with one discharging the effluent to a holding tank and returning the barite to the system, while the other processes the same effluent again,
discharging the high gravity solids. Use in this mode when mud wt. is not a problem.
Mud Wt: Maintain the mud weight as low as possible. Utilise all solids control equipment(desilter, centrifuges) to maintain mud wts. Gradually bring up mud wts. as hole
dictates or at by TD.
6 RPM/RHEOLOGY: All rheology will be maintained and reported per API 120 degrees Fahrenheit. Maintain at a minimum of 12-15+ for maximum hole cleaning in the larger
riser diameter with additional additions of XCD polymer if required. Drop the 10 minute gels to 10 -12 if needed by using Tackle prior to the casing run.
pH/TOTAL HARDNESS: Maintain the pH at 8.0 to 9.2 with pf/mf readings of 0.03 / 0.1 . Note : The formations on these top intervals are usually very pH sensitive. pH will
mainly be supported by the Soda Ash, which is being used for the treatment of Total Hardness.
Fluid Loss: The fluid loss in this systems formulation make-up will give an API water loss below 5cc .
BIT BALLING: The formulation of this system will minimise this problem. If there are signs of balling, a pill of saturated brine with med nut plug has worked successfully from
prior experience.
Seepage/loss circ.: Depending on the severity, different combinations of LCM types can be used. Calcium carbonate(f&m) with Mix11, has worked well in 30-35 lb/bbl
concentrations. For seepage losses , adding a sack of each every 1/2 to 1hour has worked well. The situation will have to be assessed and acknowledging that Medium sized
materials will be the max. due to equipment in the drillstring.
3/9/01
39
KDS Ltd.

14 1/2" HOLE X 17 1/2" UR: 19%NACL / 5% KCL / 5%GLYDRIL MC / 5%MONOETHYLENE
Hole Size
Starting Depth
Final Depth
Riser OD
Riser ID
Riser Length
Casing #1 OD
Casing #1 ID
Casing # Length
Casing #2 OD
Casing #2 ID
Casing # Length
Surface Volume
Previous Casing Volume
17.5"Hole volume+washout
Dilution volume
Washout
7%
Barrels/ Cu. Meters

feet
17.5
17.5
4873
1486
5873
1791
21
21
19
19
2593
791
20
20
18.38
18.38
1280
390.24
16
15.01
1000
305
0.75
0.75
0.05
0.05
600
95
1549
246
341
54
1703
271
43
7
3852
612
1000 feet drilled
Product
Bentonite
Barite
PolyPac UL
XCD Polymer
PolyPlus dry
NACL 99% purity
KCL 95%purity
Glydril MC
Monoethylene
Soda Ash
Sodium Bicarbe
Citric Acid
KCL
NACL
Glydril MC
Monoethylene
XCD Polymer
(for sweeps)
Total Cost
Unit
Size
MT
MT
25 kg sks
25 kg sks
25 kg sks
1.5 MT
1.5 MT
55gal drm
55gal drm
25 kg sks
25 kg sks
25 kg sks
1.5 MT
1.5 MT
55gal drm
55gal drm
25 kg sks
Conc.
PPB
Conc.
kg/m3
0
0
0
4.5 12.8385
1.5 4.2795
1.25 3.56625
77 219.681
19 54.207
5% / vol.
5%
5% / vol.
5%
0.75 2.13975
0.5 1.4265
0.5 1.4265
MAINTAINANCE
MAINTAINANCE
<1% / vol.
<1%
<1% / vol
<1%
a/n
a/n
A/N
BBLS
1703
3852
1703
1703
1703
1703
1703
1703
1703
1703
2149
2149
3852
3852
3852
3852
3852
Units
SX/MT/M3
0
70
139
46
39
58
10
65
39
23
20
20
5
10
13
0
25
Unit
Cost
230.00
155.00
91.50
270.00
69.00
233.00
400.00
360.00
196.00
9.80
9.80
39.00
400.00
233.00
360.00
196.00
270.00
Total
Cost
0.00
10850.00
12718.50
12420.00
2691.00
13514.00
4000.00
23400.00
7644.00
225.40
196.00
780.00
2000.00
2330.00
4680.00
0.00
6750.00
104,198.90
MUD WEIGHT-10.2 -10.8ppg / 530 - 560pptf

CUMULATIVE COST :
Table 4 17: Hole Volume and Cost Estimate
3/9/01
40
336,339.10
KDS Ltd.
12 1/4" Hole
Depth
13 3/8" casing to
Footage drilled
Mud weight
Mud weight
Yield point
3 RPM
Fluid loss (API)
HTHP (200F)
MBT
pH
KCl
NACL
Glydril MC
Monoethylene
5873-7573ft.
5873ft.
1700ft.
10.8 11.5ppg
560 600pptf
22 - 28 lb/100ft2
>7
<5 ml
<15
< 17.5 lb/bbl
8.0-9.2
5% by wt.
21% by/wt.
5 % by volume
3% by volume
Mud from the previous section will be used in this section. Maintain a near
saturated pill (22%NaCl)with 10% MEG to be used to flush and spot through
the choke, kill lines and BOPs. This should always be held on stand-by in an
alternate slug pit (if available) or holding tank on stand-by as needed.

The NaCl/KCL Glydril system has been recommended for this section also.
KCL (5% by wt.) along with NACL (21% by wt.) and Monoethylene glycol
should be maintained at 3% by wt. (see hydrate charts for reference)
Additives
Additive
KCl / 5%
NACL /21%
Poly Pac UL
encapsulatorXCD
Soda Ash
Citric Acid
Sod. Bicarbe
Barite Barium Sulphate
PHPA Polyacrylamide
Glydrill MC
Monoethylene Glycol
3/9/01
Material
Function
Concentration
19+lb/bbl
Sodium chloride
Inhibitor
86+lb/bbl
PAC polymer
Fluid loss/
4lb/bbl
Xanthan Gum
Viscosifier
1lb/bbl
Sod. Carbonate
pH control
.5-.75lb/bbl
Citric Acid
pH control
.5lb/bbl
Sod. BiCarbe
Treat cement
.5lb/bbl
Weight material
As needed
Encapsulator
1lb/bbl
Polyalkylene
Shale Inhibitor
5 vol%
Monoetheylene glycol(for gas hydrate inhibition) 3 vol%
41
KDS Ltd.
Operation Procedure
(Refer to previous Deepwater Glydril & KCL/NaCl Polymer systems)
by wt. for the maximum wt. of 11.5ppg. Gradually increase the NaCl
concentration to 21% before the MEG concentration has drifted back to 3% by
volume for a safety cushion to ensure p roper hydrates coverage in case of a
quick weight up.
The KCl concentration should also be monitored closely and kept at 5% as it
is also factored in for the gas hydrate coverage along with shale inhibition.
Maintain volumes and concentrations closely. Pre-treat the mud with Citric
Acid and Sodium Bicarbe which will buffer the pH accompanied with cement
contamination. It is important that the pH be kept low to prevent polymer
degradation.
mixing order:
Additives
Additive
KCl 5%
NACL 21%
Soda Ash
Pac Plus UL
XCD
PHPA
Glydril MC
Monoethylene
Barite
Material
Potassium chloride
Sodium chloride
Sodium carbonate
PAC polymer
Xanthan Gum
Polyacrylamide
Polyalkylene glycol
Monoethylene glycol
Weight material
Concentration
19lb/bbl
+86lb/bbl
.5-.75lb/bbl
4lb/bbl
1lb/bbl
1lb/bbl
5 % by volume
3% by volume
As needed
drilling.
The shale shakers should be decked out with coarser mesh screens ( 4060mesh) prior to drilling out and the initial circulation while drilling till the
3/9/01
42
KDS Ltd.
cement. Additional Citric acid and Sodium Bicarbe may be needed besides
the pre-treatment.
Pump 50bbl Hi Vis sweeps prior to trips. A 50 bbl sweep volume should be
pumped intermittently, depending on drilling rates and evaluating just how
good the system is handling hole cleaning. Increase the sweep volume and
frequency as dictated by the hole.
Spot a 50bbl Hi Vis pill on bottom prior to short tripping and a 100bbl spot
prior to POOH for logging.
Daily Maintenance
High-Vis sweeps (50bbls) should be pumped intermittently and evaluated as
to their effectiveness. The frequency determined by the evaluation. Sweeps
should coincide with a Hi Vis sweep pumped through the booster pump to
maximize cuttings removal at that point. Pump 50 bbl Hi Vis sweeps prior to
trips.
content if required. Two centrifuges will be on board. In this section, with the
mud weight at 11.5ppg, the centrifuges can be worked both ways discarding
the high gravity and LGS solids if needed to control the mud wt. and or using
them for barite recovery. They are right on the balance of efficiency pertaining
to barite recovery. The de-silter can be run from time to time if needed to
assist in lowering mud wt. (refer to section-7)
Contingencies
(Refer to
3/9/01
43
KDS Ltd.
Shale instability If there are problems with micro-fractured shales in the
lower section of the interval, soltex can be added at up to 4 -6 lb/bbl. The
soltex should be solubilized in fresh water prior to salting up before adding to
the active system. Prior to adding soltex these two items should be checked:
(A) that the correct flow profile is being used in the open hole and (B) insure
that an adequate mud weight is being used to balance formation pressure.
Soltex is on the contingency product list.
HTHP VISCOSITY
FANN 70
FLUID FORMULATION
Freshwater
bbl
0.703
NaCl
ppb
79
FLUID SYSTEM:
KCl
ppb
18
DENSITY :
11,5 ppg
Glydril MC
ppb
17.5
TESTED BY:
Arne Ask
Polypac UL
ppb
TEST DATE :
######
PolyPlus
ppb
COMMENTS:
Malaysia - Shell
DuoVis
ppb
12 1/4" Formulation
Soda Ash
ppb
0.5
MEG
ppb
10.5
Barite
ppb
50 C (122F)
109
50 C (122F)
Pressure (psi)
5 C
30 C
50 C
ATM
2000
600 RPM
240
131
92
4000
600 RPM
95
96
97
300 RPM
160
85
200 RPM
137
100 RPM
96
97
58
300 RPM
59
60
60
60
59
66
45
200 RPM
47
47
48
48
47
92
43
30
100 RPM
31
31
31
31
31
6 RPM
21
10
6 RPM
3 RPM
15
3 RPM
Gel 10"
15
10
Gel 10"
Gel 10
19
13
10
Gel 10'
10
10
10
36
23
36
24
37
23
36
24
38
21
PV
YP
80
80
46
39
34
24
PV
YP
30 C (85F)
5 C (41F)
Pressure (psi)
Pressure (psi)
2000
4000
6000
8000
2000
600 RPM
133
132
134
133
4000
600 RPM
248
247
300 RPM
86
85
86
249
248
85
300 RPM
164
163
164
200 RPM
67
65
164
66
66
200 RPM
125
124
124
100 RPM
43
125
42
43
42
100 RPM
80
79
80
6 RPM
80
6 RPM
15
14
15
16
3 RPM
3 RPM
12
12
12
12
Gel 10"
Gel 10"
12
12
12
12
Gel 10'
10
10
11
10
Gel 10'
15
15
16
15
PV
47
47
48
48
PV
84
84
85
84
YP
39
38
38
37
YP
80
79
79
80
Table 5 12 Hole HPHT Viscosity (Fann 70)
3/9/01
6000 8000
44
6000 8000
KDS Ltd.
Mud Specification for 12.25 hole and 9 5/8 Casing
wt. with the MEG at 3% by volume for the maximum mud wt. of 11.5ppg to be used in this section. It is advised that the NaCL be gradually increased to 21% before the MEG
has drifted back to 3% by volume for a safety cushion to ensure proper hydrates coverage in case of a quick wt. up. Maintain the Meg concentration of 3% with 21% NaCl.
The concentration of KCL should also be monitored closely and kept at 5%+ as it is also factored in for the gas hydrate coverage along with shale inhibition. Maintain
volumes and concentrations closely. Pre-treat the mud transferred from the previous interval for cement contamination. Citric Acid and Sodium Bicarbe will serve as the
constituents to buffer the pH with cement contamination. It is important that the pH be kept low to prevent polymer degradation.
Due to boosting the riser and finer screens in this section, some volume will be lost over the shakers, evaluate as previously mentioned. Pump 50 bbl Hi vis sweeps prior to
trips. A 50 bbl sweep volume should be pumped intermittently, depending on drilling rates. Increase the sweep frequency as dictated by the hole. Over sweeping will increase
rheology and ECD's due to the additions of XCD in the sweeps being incorporated into the system. Spot 50bbls of HiVis pill on bottom prior to short tripping and 100 bbls
prior to logging.
**The well should be stage pumped while going in the hole after a trip or logging time, especially once below the BOP's and at other pre-determined depth, this will replace
the riser with a higher temperature
Mud again and also with a lower rheology mud in respect to cold temperatures. With this being said, the shaker screens should be changed back to coarser sized screens
(40-60mesh) for the initial circulations until the mud is gradually warmed to allow for stepping back up to finer meshed screens.
**The dual retort will be used to monitor the Glycol concentration in the mud. Due to two different glycols added to the system, a total glycol content will be shown. With this
fact a very close mass balance, concentration of all volumes and constituents added to the mud, must be tracked closely and reported daily with the mud report.
**The centrifuges.(.refer to previous and solids control section)
Mud Wt: Maintain the mud weight as low as possible. Utilise all solids control equipment (fine screens, centrifuges) to maintain mud weights. (refer to solids control)
6 RPM/RHEOLOGY: All rheology will be maintained and reported per API 120 degrees Fahrenheit. Maintain at a minimum of 10-12 for maximum hole cleaning in the larger
riser diameter with additional additions of XCD polymer if required. Drop the 10 minute gels to 10 -12 if needed by using Tackle prior to the casing run.
PH/TOTAL HARDNESS: Maintain the pH at 8.0 to 9.2 with pf/mf readings of 0.03 / 0.1. Note: The formations on these top intervals are usually very pH sensitive. pH will
mainly be supported by the Soda Ash, which is being used for the treatment of Total Hardness.
BIT BALLING: The formulation of this system will minimise this problem. If there are signs of balling, a pill of saturated brine with med nut plug can be used as from prior
experience has proven successful.
Seepage/loss circ.: Depending on the severity, different combinations of LCM types can be used. Calcium carbonate (f&m) with Mix11, has worked well in 30-35 lb/bbl
concentrations. For seepage losses adding a sack of each every 1/2-hour has worked well. The situation will have to be assessed and acknowledging that Medium sized
materials will be the max. Due to equipment in the drillstring. (refer to contingency section 0, Bentonite System)
Soltex contingency: If there are problems with mirco-fractured shales in the lower section, soltex can be added up to 4-6 lb/bbl. The soltex should be solubilised in fresh water
prior to salting up before adding to the active volume.
3/9/01
45
KDS Ltd.

12 1/4"HOLE: 21%NACL / 5%KCL / 5%GLYDRIL MC/ 3% MONOETHYLENE
Hole Size
Starting Depth
Final Depth
Riser OD
Riser ID
Riser Length
Casing #1 OD
Casing #1 ID
Casing # Length
Surface Volume
12.25" Hole Volume+washout
Dilution volume
Washout
5%
Barrels / Cu. Meters

feet
12.25
12.25
5873
1791
7573
2309
21
21
19
19
2593
791
13.375
13.375
12.615
12.615
3280
1000
0.75
0.05
600
1417
273
1365
25
3382
Product
0.75
0.05
95
225
43
217
4
538
1700 feet drilled
Unit
Size
MT
MT
25 kg sks
25 kg sks
25 kg sks
1.5 MT
1.5 MT
55gal drm
55gal drm
25 kg sks
25 kg sks
25 kg sks
1.5 MT
1.5 MT
55gal drm
55gal drm
25 kg sks
Conc.
PPB
Conc.
kg/m3
Bentonite
0
0
Barite
A/N
0
PolyPac UL
4.5 12.8385
XCD Polymer
1.5 4.2795
PolyPlus dry
1
2.853
NACL 99% purity
86 245.358
KCL 95%purity
19 54.207
Glydril MC
5% / vol.
5%
Monoethylene
3% / vol.
3%
Soda Ash
0.75 2.13975
Sodium Bicarbe
0.5 1.4265
Citric Acid
0.5 1.4265
KCL
MAINTAINANCE
NACL
MAINTAINANCE
Glydril MC
<1% / vol.
<1%
Monoethylene
<1% / vol
XCD Polymer
a/n
a/n
(for sweeps)
Total Cost
MUD WEIGHT-10.8 - 11.5ppg / 560 - 600pptf
BBLS
1365
3382
1365
1365
1365
1365
1365
1365
1365
1365
2017
2017
3382
3382
3382
3382
3382
Units
SX/MT/M3
0
88
111
37
25
42
8
52
21
19
18
18
5
10
13
20
3/9/01
46
Total
Cost
0.00
13640.00
10156.50
9990.00
1725.00
9786.00
3200.00
18720.00
4116.00
186.20
176.40
702.00
2000.00
2330.00
4680.00
0.00
5400.00
86,808.10
CUMULATIVE COST :
Unit
Cost
230.00
155.00
91.50
270.00
69.00
233.00
400.00
360.00
196.00
9.80
9.80
39.00
400.00
233.00
360.00
196.00
270.00
423,147.20
KDS Ltd.
8 1/2" Hole
Depth
7573-8373ft.
9 5/8" casing to
7573ft.
Footage drilled
800ft.
Mud weight
11.5 13.5ppg
Mud weight
600 700pptf
Yield point
18 - 25 lb/100ft2
3 RPM
>6
Fluid loss (API)
<4 ml
HTHP (210F)
<13
MBT
< 17.5 lb/bbl
pH
8.0-9.2
KCl
5% by wt.
NACL
22% by/wt.
Glydril MC
5 % by volume
Monoethylene
3% by volume
Maintain a near saturated pill (22%NaCl)with 10% MEG to flush and spot
through the choke, kill lines and BOPs.

The NaCl/KCL Glydril system has also been recommended for this section.
KCL (5% by wt.) along with NaCl (22% by wt.) and monoethylene glycol
should be maintained at 3% by volume to suppress gas hydrates in this
section. (See hydrate charts for reference)
Additives
Additive
KCl / 5%
NACL /22%
Poly Pac UL
encapsulatorXCD
Soda Ash
Citric Acid
Sod. Bicarbe
Barite Barium Sulphate
PHPA Polyacrylamide
Glydrill MC
Monoethylene Glycol
3/9/01
Material
Function
Concentration
19+lb/bbl
Sodium chloride
Inhibitor
90.5+lb/bbl
PAC polymer
Fluid loss/
4.5lb/bbl
Xanthan Gum
Viscosifier
.75lb/bbl
Sod. Carbonate
pH control
.5-.75lb/bbl
Citric Acid
pH control
.5lb/bbl
Sod. BiCarbe
Treat cement
.5lb/bbl
Weight material
As needed
Encapsulator
0lb/bbl
Polyalkylene
Shale Inhibitor
5 vol%
Monoetheylene glycol (for gas hydrate inhibition) 3 vol%
47
KDS Ltd.
Operation Procedure
Refer to previous Glydril and Polymer systems sections)
by wt. for the maximum wt. of 13.5ppg. Gradually increase the NaCl
concentration to 22% and maintain the MEG concentration at 3% to ensure
proper gas hydrate inhibition. The KCl concentration should also be
monitored closely and kept at 5% as it is also factored in for the gas hydrate
coverage along with shale inhibition. (refer to section 2 hydrates) Maintain
volumes and concentrations closely. Pre-treat the mud with Citric Acid and
Sodium Bicarbe, which will buffer the pH, accompanied with cement
contamination. It is important that the pH be kept low to prevent polymer
degradation.
mixing order:
Additives
Additive
KCl
NACL
Soda Ash
Pac Plus UL
XCD
PHPA
Glydril MC
Monoethylene
Barite
Material
Potassium chloride
Sodium chloride
Sodium carbonate
PAC polymer
Xanthan Gum
Polyacrylamide
Polyalkylene glycol
Monoethylene glycol
Weight material
Concentration
19lb/bbl
+90.5lb/bbl
.5-.75lb/bbl
4.5lb/bbl
.75lb/bbl
0lb/bbl
5 % by volume
3% by volume
As needed
drilling.
The shale shakers should be decked out with coarser mesh screens (6080mesh) prior to drilling out and the initial circulation while drilling till the
cement. Additional Citric acid and Sodium Bicarbe may be needed besides
the pre-treatment.
3/9/01
48
KDS Ltd.
Pump 50 bbl Hi Vis sweeps prior to trips. A 30-40 bbl sweep volume should
be pumped intermittently, depending on drilling rates and evaluating just how
good the system is handling hole cleaning.
Increase the sweep volume and frequency as dictated by the hole. Spot a 3040bbl Hi Vis pill on bottom prior to short tripping.
Two complete circulations will be made to ensure that the mud is conditioned
prior to coring at about 7700ft. The API fluid loss must be below 4 ml or
below to minimize filtrate invasion and enhance core recovery. Coring TD
will be to about 8150ft. At this point a bit will be run in and drilled to about
8390ft. A short trip will be made prior to POOH for logging operations.
Daily Maintenance
(Refer to previous Glydril and polymer systems sections)
Control excessive rheology with whole mud dilution or the use of Tackle if
needed. Prior to the casing run, the 10-minute gel should be lowered to 8 to
10 by dilution and or the use of Tackle if needed.
High-Vis sweeps (30-40bbls) should be pumped intermittently and evaluated
as to their effectiveness. The frequency determined by the evaluation.
Sweeps should coincide with a Hi Vis sweep pumped through the booster
pump to maximize cuttings removal at that point. Pump 30-40 bbl Hi Vis
sweeps prior to trips.
over the shakers). Desilter and centrifuge can be used to control the fine
solids content if required. Two centrifuges will be on board. In this section,
with the mud weight up to 13.5ppg, the centrifuges will be used for barite
recovery only.
Contingencies
(Refer to
3/9/01
49
KDS Ltd.
Loss circulation / Seepage losses (refer to Bentonite System)
In the event seepage losses occur spot a LCM pill consisting of up to 20 lb/bbl
combination of Mica fine, Mix11 and Nutplug med.
Calcium carbonate (F&M) can be used to weight up the pill. If possible this
should be mixed prior to drilling and kept on stand -by as needed. One sack of
each has been added to the active at to 1 hour per sack as drilling
continued with good results from previous experience.
For more severe losses mix up to 35-40 lb/bbl LCM consisting of a
combination of Nutplug Med., MIX II Med, and Mica Med, Mica fine. This too
can be weighted up with
Calcium Carbonate Medium. Larger concentrations can be mixed if needed.
The loss circulation problem will have to be analyzed to take the proper
course in treatment. Consideration should be taken as to what size LCM
materials can be used due to MWD tools and jet nozzle sizes.
Shale instability If there are problems with micro-fractured shales in the
lower section of the interval, soltex can be added at up to 4 -6 lb/bbl. The
soltex should be solubilized in fresh water prior to salting up before adding to
the active system. Prior to adding soltex these two items should be checked:
(A) that the correct flow profile is being used in the open hole and (B) insure
that an adequate mud weight is being used to balance formation pressure.
Soltex is on the contingency product list. In this interval, prior to coring it may
be checked if this product can be used in the reservoir section or prior to
coring.
3/9/01
50
KDS Ltd.
HTHP VISCOSITY
F A N N 7 0
FLUID FORMULATION
Freshwater
bbl
NaCl
ppb
0.64
77
FLUID SYSTEM:
KCl
ppb
16.5
DENSITY :
13,5 ppg
Glydril MC
ppb
17.5
TESTED BY:
Arne Ask
Polypac UL
ppb
4.5
TEST DATE :
######
PolyPlus
ppb
COMMENTS:
Malaysia - Shell
DuoVis
ppb
0.75
8 1/2" Formulation
Soda Ash
ppb
0.5
MEG
ppb
10.5
Barite
ppb
222
5 0 C ( 1 2 2 F )
5 0 C ( 1 2 2 F )
Pressure (psi)
5 C
30 C
50 C
ATM
2000
600 RPM
250
140
104
4000
6000
8000
600 RPM
105
106
107
106
300 RPM
165
90
108
65
300 RPM
66
67
67
68
200 RPM
128
68
68
43
200 RPM
44
45
45
45
100 RPM
45
82
48
29
100 RPM
30
30
30
31
31
6 RPM
16
11
6 RPM
3 RPM
12
3 RPM
Gel 10"
12
Gel 10"
Gel 10
16
11
12
Gel 10'
12
13
13
14
14
PV
85
50
39
PV
39
39
40
38
40
YP
80
40
26
YP
27
28
27
30
28
3 0 C ( 8 5 F )
5 C ( 4 1 F )
Pressure (psi)
Pressure (psi)
2000
4000
6000
8000
2000
600 RPM
143
143
144
144
4000
6000
8000
600 RPM
258
257
259
300 RPM
92
92
92
258
93
300 RPM
170
170
171
200 RPM
69
70
170
70
70
200 RPM
128
129
129
100 RPM
48
129
48
49
49
100 RPM
83
83
84
6 RPM
83
11
11
12
11
6 RPM
16
17
17
17
3 RPM
10
10
3 RPM
13
12
12
12
Gel 10"
10
10
10
11
Gel 10"
13
13
13
13
Gel 10'
11
11
12
13
Gel 10'
16
17
17
18
PV
51
51
52
51
PV
88
87
88
88
YP
41
41
40
42
YP
82
83
83
82
Table 7 8 Hole HPHT Viscosity (Fann 70)
3/9/01
51
KDS Ltd.
Mud Specification for 8.5 hole and 7 Casing
wt. with the MEG at 3% by volume for the maximum mud wt. of 13.5ppg to be used in this section. It is advised that the NaCL be gradually increased to 22% and the MEG
maintained at 3% by volume. The concentration of KCL should also be monitored closely and kept at 5%+ as it is also factored in for the gas hydrate coverage along with
shale inhibition. Due to the additional boost of volume, especially with finer screens on in the 8 1/2" section, volume will be lost over the shale shakers when boosting. Make
at least one check every 8-10 hours. When sweeping the hole, coincide with pumping Hivis through the booster pump. Pump 30-40 bbl Hi vis sweeps prior to trips. . A 30-40
bbl sweep volume should be pumped intermittently, depending on drilling rates. Over sweeping will increase rheology and ECD's due to the additions of XCD in the sweeps
being incorporated into the system. Spot 30bbls of HiVis pill on bottom prior to short tripping and prior to logging.
**Change back to coarser sized screens (80-120mesh) for the initial circulations until the mud is gradually warmed to allow for stepping back up to finer meshed screens.
This will have to be monitored for the best screen sizes to go with.
**The centrifuges will be used in this section for barite recovery while discharging the LGS in the effluent. Two centrifuges working tandem. (refer to solids control section)
Mud Wt: Start out with ending mud weight from the previous interval and gradually wt. as the hole dictates. Utilise all solids control equipment (fine screens, centrifuges) to
maintain mud weights.
6 RPM/RHEOLOGY: All rheology will be maintained and reported per API 120 degrees Fahrenheit. Maintain at a minimum of 9-10 for maximum hole cleaning in the larger
riser diameter with additional additions of XCD polymer if required. Drop the 10-minute gels to 8-10 if needed by using Tackle prior to the casing run.
PH/TOTAL HARDNESS: Maintain the pH at 8.0 to 9.2 with pf/mf readings of 0.03 / 0.1. pH will mainly be supported by the Soda Ash, which is being used for the treatment of
Total Hardness.
Fluid Loss: The fluid loss in this systems formulation make-up will give an API water loss of 2-4cc.
BIT BALLING: The formulation of this system will minimise this problem. If there are signs of balling, a pill of saturated brine with med nut plug can be used as from prior
experience has proven successful.
Seepage/loss circ.: Depending on the severity, different combinations of LCM types can be used. Calcium carbonate (f&m) with Mix11, has worked well in 30-35 lb/bbl
concentrations. For seepage losses, adding a sack of each every 1/2 -hour has worked well. The situation will have to be assessed and acknowledging that Medium sized
materials will be the max. due to equipment in the drillstring.
Soltex contingency: If there are problems with micro-fractured shales in the lower section, soltex can be added at up to 4-6 lb/bbl, depending on the severity of the problem.
The soltex should be solubilised in fresh water prior to salting up before adding to the active volume.
Coring Section: Condition the system prior to coring. Ensure that the water loss is below 4cc's. Add calcium carbonate (f&m) to curb downhole losses if need be. If moderate to
severe losses, spot LCM pills with MIX 11 at 20 lb/bbl and Kwik Seal at same.
3/9/01
52
KDS Ltd.

81/2" HOLE: 22%NACL / 5%KCL/ 5%GLYDRIL MC/ 3%MONOETHYLENE
Hole Size
Starting Depth
Final Depth
Riser OD
Riser ID
Riser Length
Casing #1 OD
Casing #1 ID
Casing # Length
Casing #2 OD
Casing #2 ID
Casing # Length
Surface Volume
8.5"" Hole Volume+washout
Dilution volume
Washout
5%
Barrels/ Cu. Meters

feet
8.5
8.5
7573
2309
8373
2553
21
21
19
19
2593
791
9.625
9.625
8.755
8.755
4980
1518.29
0.7
0.05
600
1281
62
373
6
2254
Product
0
0.7
0.05
95
204
10
59
1
358
800 feet drilled
Unit
Size
Bentonite
MT
Barite
MT
PolyPac UL
25 kg sks
XCD Polymer
25 kg sks
No Polyplus additions
NACL 99% purity
1.5 MT
KCL 95%purity
1.5 MT
Glydril MC
55gal drm
Monoethylene
55gal drm
Soda Ash
25 kg sks
Sodium Bicarbe
25 kg sks
Citric Acid
25 kg sks
KCL
1.5MT
NACL
1.5 MT
Glydril MC
55gal drm
Monoethylene
55gal drm
XCD Polymer
25 kg sks
(for sweeps)
Total Cost
MUD WEIGHT- 11.5 - 13.5ppg
Conc.
PPB
0
0
0
4.5 12.8385
1.5 4.2795
373
2254
373
373
Units
SX/MT/M3
0
115
30
10
90.5 258.197
19 54.207
5% / vol.
5%
3% / vol.
3%
0.75 2.13975
0.5 1.4265
0.5 1.4265
MAINTAINANCE
MAINTAINANCE
<1% / vol
<1%
<1% / vol
<1%
a/n
a/n
373
373
373
373
373
1881
1881
2254
2254
2254
2254
373
13
2
14
9
5
17
17
2
6
2
2
10
A/N
Conc.
kg/m3
BBLS
3/9/01
53
233.00
400.00
360.00
196.00
9.80
9.80
39.00
400.00
233.00
360.00
196.00
270.00
Total
Cost
0.00
17825.00
2745.00
2700.00
0.00
3029.00
800.00
5040.00
1764.00
49.00
166.60
663.00
800.00
1398.00
720.00
392.00
2700.00
40,791.60
/ 600 -700pptf
CUMULATIVE COST :
Unit
Cost
230.00
155.00
91.50
270.00
463,938.80
KDS Ltd.
Total Estimated Product Usage


TOTAL ESTIMATED PRODUCT USAGE
Barrels
Hole Size
Starting Depth
Final Depth
Riser OD
Riser ID
Riser Length
Casing #1 OD
Casing #1 ID
Casing # Length
Casing #2 OD
Casing #2 ID
Casing # Length
Surface Volume
Total Surface Volume built
Total Glydril Volume built
Total Volume built
Cu. Meters
Product
0
0
0
0
0
0
0
0
0
4647
7276
11923
Bentonite
Barite
PolyPac UL
XCD Polymer
PolyPlus dry
NACL 99% purity
KCL 95%purity
Glydril MC
Monoethylene
Soda Ash
Caustic
Sodium Bicarbe
Citric Acid
KCL
NACL
Glydril MC
Monoethylene
XCD Polymer
Total Cost
0
0
0
0
0
739
1157
Unit
Size
MT
MT
25 kg sks
25 kg sks
25 kg sks
1.5 MT
1.5 MT
55gal drm
55gal drm
25 kg sks
25 kg can
25 kg sks
25 kg sks
1.5MT
1.5 MT
55gal drm
55gal drm
25 kg sks
Conc.
PPB
Conc.
kg/m3
0
0
A/N
0
4-4.5
0
1.5
0
1.5
0
50-90.5
19
0
5%/vol
5%
3-5%/vol 3-5%
0.75 2.13975
A/N
A/N
0.5 1.4265
0.5 1.4265
MAINTAINANCE
MAINTAINANCE
<1% / vol.
<1%
<1% / vol.
<1%
XCD Polymer a/n
BBLS
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Units
SX/MT/M3
61
355
584
197
151
171
42
277
303
141
10
55
55
17
36
47
21
80
Table 9 Total Estimated Mud Product Usage
54
Total
Cost
14030.00
55025.00
53436.00
53190.00
10419.00
39843.00
16800.00
99720.00
59388.00
1381.80
198.00
539.00
2145.00
6800.00
8388.00
16920.00
4116.00
21600.00
463,938.80
1896
5780 feet drilled
TOTAL WELL COST
3/9/01
Unit
Cost
230.00
155.00
91.50
270.00
69.00
233.00
400.00
360.00
196.00
9.80
19.80
9.80
39.00
400.00
233.00
360.00
196.00
270.00
463,938.80
KDS Ltd.
Solids Control and Water Based Mud

Dilution
The most effective method, but not the most cost effective method to control
solids is with dilution, and dumping excess volume. As the unit cost
associated with the liquid phase of a mud increases, this option becomes less
and less desirable. But, to maintain volume in a system, dilution with whole
mud is the option of choice. Maintaining the system with whole mud increases
the chances of maintaining even properties. The product concentrations of the
dilutions should be adjusted, as required, to maintain the properties in the
active system at programmed levels. Depletion of chemicals while drilling
should be considered, when adding products to dilutions.
Experience has shown, in most instances, that the dilution requirements for
the Glydril system are lower than other water based muds. This is based on
how many cubic meters of new mud are required for each cubic meter of new
hole drilled. Maintaining volume lost from solids control equipment, and for
new hole drilled, is usually sufficient to control solids properties in the
programmed ranges.
Shakers
Use the finest screens possible. The shaker discharges should be run slightly
wet, when there is a problem with solids, when there is higher loss from
running other pieces of solids control equipment a nd when mud is dumped on
a regular basis. This minimizes the amount of solids entering the active
system, thus reducing the load on, and increasing the efficiency of, secondary
processing equipment.
On the first one or two circulations after displacement and trips, coarser
screens are normally required to minimize losses due to unsheared polymers
and cold mud.
The shakers should be serviced on a regular basis. Worn parts should be
replaced, as required, to maintain proper working order and obtain optimum
screen life. Damaged screens should be replaced and repaired, if possible, for
future use.
Enhanced performance of shakers has been reported using the Glydril
system. It is suspected that this is the result of better cuttings quality and the
lubricating effect of the Glydril MC on the screens.
3/9/01
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KDS Ltd.
Desilters/Mud Cleaner
The utilization of the desilter and mud cleaner must be optimized depending
on a number of factors. Some of these factors are; mud weight, cost of the
liquid phase, solids composition of the mud, logistics costs related to
replacement chemicals in discarded volume, and not the least, the operating
performance of the equipment.
Normally, over a mud weight of 10.8 ppg it is more practical to use the mud
cleaner, if available, utilizing the smallest screens possible. The mud cleaner
is also a more practical option as the cost of the liquid phase, and the cost of
handling the replacement chemicals in discarded volume increases.
Before either piece of equipment is used it must be serviced to ensure proper
working order. This usually includes dismantling the desilter and replacing any
worn parts, and ensuring that there are no obstructions that will affect the
performance of the equipment. On the mud cleaner screen mounts, tension
bolts etc. should be replaced as required to obtain optimum screen life.
Centrifuges
As with the Desilter/Mud Cleaner there are a number of considerations when
deciding how centrifuges should be run. Mud weight, cost of the liquid phase
and logistics, and solids composition of the mud are important. Experience
has shown that the highest amount, by weight, of LGS removed from a mud
by a centrifuge is when it is run in the solids removal mode. The negative side
of running a centrifuge in this mode is the amount of barite discarded. When
using a mud with a high liquid phase cost, relative to the costs associated with
barite replacement this is the mode of choice.
As mud weights increase, the volume handled by the centrifuge decreases.
When there is a solids problem, and especially with higher mud weights, the
centrifuges should be run as much as possible. This would include
centrifuging the surface and riser volume on trips.
If two centrifuges are available, and the surface system allows, the centrifuges
can be run as a dual phase system. To do this, the solids discharge from the
first centrifuge, the slowest machine, is returned to the active. This volume
contains mostly Barite. The liquid phase from this machine is caught in a
holding tank and processed by the second, faster machine. The solids
discharge from this machine is dumped returning the liquid phase to the
active. This mode of operation is normally used when the liquid phase is very
expensive but it does have an application considering solids composition of
the mud and costs associated to logistics.
Another important consideration when running solids control equipment has to
do with the amount of time it is run in a system where solids is not a current
issue. In these cases overusing the solids control equipment may cause a
3/9/01
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KDS Ltd.
solids problem by itself. This will happen because of mechanical degradation

of solids by the equipment and associated pumps.
In conclusion is hard to state how solids control equipment should be run, in
all cases. The circumstances around its application must be evaluated on a
constant basis and the optimum method of use applied.
3/9/01
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KDS Ltd.
Contingency Section
Cement Contamination
Theory
The detrimental ingredient in cement is lime. When cement is mixed in water
(or mud) the lime starts to dissolve giving Calcium and Hydroxyl ions
(increased pH) in aqueous solution.
To avoid deterioration of the polymer system and the drilled formation it is
important to reduce the high pH from cement contaminations immediately.
An elegant way of doing this in a polymer mud with a limited Calcium supply is
to use a combination of Bicarbonate and Citric Acid.
If 0.5 lb Citric Acid is added for each 0.75 lb Sodium Bicarbonate, the Total
Hardness of the mud will be constant.
Practical Application
1. Monitor the pH in the flow line and into the hole.
2. When the pH into the hole exceeds 8.5, start mixing Bicarbonate.
3. When a Bicarbonate mixing rate has been established, check the total
hardness of the system. If it is close to zero, commence mixing Citric Acid.
4. Mix Sodium Bicarbonate/Citric Acid at a ratio 10: 7 (or Sodium
Bicarnbonate/Citric Acid at a ratio 10: 8).
5. Dump as much of the contaminated returns as the volume situation allows
(mud with pH above 11).
3/9/01
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KDS Ltd.
Lost circulation
Lost circulation can be divided into two main categories; seepage losses and
complete loss of circulation. There is no stringent definition between the two.
But as a general rule of thumb, losses only when circulating, are normally
classified as seepage losses.
It is recommended to have a 60 bbl pill ready mixed, formulation as for the
seepage losses pill.
Formulations for Seepage losses:
Active mud + 10 - 15 ppb Mica fine and 10 - 15 ppb Nut plug fine. By
using only fine grade materials the pill can be pumped through the bit
nozzles, down the bottom hole motors and MWD tools.
Formulations for Complete loss.
3/9/01
Active mud + 20 - 40 ppb Mica fine and Nut plug fine each. If this
doesn't heal the loss, coarser materials are required. It is not
recommended to pump coarse materials through bit-nozzles, down
hole motors or MWD tools. In this case a pill consisting of only fine
grade materials should be spotted across the loss zone before pulling
out for an open ended drill string.
With an open ended drill string, the formulation recommended is active
mud + 20 - 40 ppb of a mixture Mica fine/course plus 20 - 40 ppb of Nut
plug fine/coarse.
Spotting procedures.
Pull the bit above the loss zone and spot 30 - 60 bbl LCM pill at the
loss zone.
Circulate carefully. If required a gentle squeeze can be applied to the
pill. If circulation is established, increase pump rate in increments until
full circulation rate is obtained with full returns.
If the above doesn't heal the loss, spot larger and more concentrated
pills to the loss zone.
More details on lost circulation are available in the M-I Engineering
Manual.
59
KDS Ltd.
Differentially Stuck pipe

The vast majority of stuck pipe problems arise from differential pressure
sticking. Differential pressure sticking can be defined as the force that holds
pipe against the wall of the hole, due to the differential between formation
pressure and hydrostatic pressure. In order for differential pressure to occur,
certain criteria are required:
Hydrostatic pressure must exceed formation pressure.

A zone of permeability must exist, over which a thick filter cake has
been deposited.
There must be contact between the pipe and the filter cake.
With low formation pressures expected in this interval, it is a possibility.
The following information will deal with the remedies available to free
differential pressure stuck pipe. The area of contact increases as the
filter cake thickens with time, thus producing greater sticking forces.
Because of this, a quick determination of the cause followed by an immediate

remedial step is imperative.
Freeing differential stuck pipe

The standard initial action is to attempt physical means to pull free, rotate free
or jar free. During this period the pipe will become progressively more stuck, if
it does not move, due to the build up of further wall cake. It is good practice to
commence the preparation of a pill of pipe release agent as soon as
differential sticking has occurred.
A primary consideration at this stage is the density of the pill. A pill weighted
to the same density as the mud will not upset hydrostatic pressure in the well
and once spotted will stay in place. An un-weighted pill will reduce hydrostatic
pressure and thus reduce the force holding the pipe stuck. Reducing
hydrostatic pressure increases risks of under-balancing other formations and
can induce a kick. Un-weighted pills tend to migrate upwards but do provide
the possibility of more accurate placement by measuring pressures.
Prior to spotting a pill it is necessary to determine the stuck point of the string
in order to spot the pill where required. The usual method is to use a wire line
log that detects stretch in the pipe. This is lowered until no stretch is detected
when the pipe is pulled, i.e. a point below the stuck zone. The tool is then
moved to locate the highest point of no stretch. An alterna tive method is to
measure the stretch of the pipe resulting from a known pull.
The drilling contractor will have the requisite modules of elasticity for the drill
string to calculate how much pipe is free and subject to stretch and by
deduction the top of the stuck point. Once the stuck point has been
determined a pill large enough to soak the entire stuck zone should be
spotted in place and circulation stopped. It is recommended to place the pill at
reduced pump rates to reduce mixing with the mud. The pipe should then be
3/9/01
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KDS Ltd.
"worked" without circulation while the surfactants in the pill attack the mud
cake. It is reasonable to allow at least four hours for this process to work after
which the pill can be moved and the pipe worked again. Ultimately the pill will
have an effect. However, in terms of rig economics it may be cheaper after
several hours to back off and wash over. Alternatively if the first pill does not
function a second pill can be tried.
Note: Pills of pipe release agent on being circulated to surface should not be
mixed into the mud system as they will have a damaging effect on mud
properties. Pills of Pipe Lax W should be routed to an own pit.
The following information will deal with the remedies available to free
differential pressure stuck pipe. The area of contact increases as the filter
cake thickens with time, thus producing greater sticking forces.
Because of this, a quick determination of the cause followed by an immediate
remedial step is imperative.
1. Spot a Pipe -Lax W soak solution quickly. The probability of freeing
differentially stuck pipe with a soak solution is inversely proportional to the
time between actual sticking and final spotting of the solution.
2. Work pipe by tripping the jars both up and down if possible.
3. Reduce mud weight if possible.
4. Run a drill stem test tool and relieve pressure.
5. Pump a slug of water down the drill string then let it U-Tube.
6. Pump some air to reduce the hydrostatic head.
PIPE-LAX W FORMULATION TABLE
(WITH MINERAL OIL) 1 FINAL BBL
Mud wt.
Mineral oil Pipe-Lax W Water
Bar
Ppg
bbl
gal
bbl
sx
8
.543
3.63
.356
.352
9
.537
3.63
.315
.901
10
.537
3.63
.277
1.45
11
.536
3.63
.241
2.00
12
.533
3.63
.208
2.55
13
.528
3.63
.176
3.10
14
.520
3.63
.146
3.64
Note ; If diesel oil is used, reduce the concentration of PipeLax W from 3.63 gal/bbl
to 3-0 3.5 gal/bbl. Pilot test before mixing. Make sure that the pill is caught when
circulated out and put in a separate tank from the active mud.
3/9/01
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KDS Ltd.
Avoiding differentially stuck pipe

Reducing the risk of this type of sticking employs several techniques.
Good fluid loss control and cake quality.
Minimum mud weights.
Keeping the drill string in motion.
Stabilizers in the string.
Drill collars with spiral grooves cut in them.
One of the most important factors for the engineer is the fluid loss control as
the other items are not subject to control by the mud. A thin tough cake is of
vital importance both in the API test and in the HTHP test. The addition of
various additives to improve cake quality in various formations has sometimes
resulted in a marked reduction in sticking. Typical additives are the asphalts,
EP lubricants, resins and bentonite.
Hydrogen Sulphide
H2S- Hydrogen Sulphide is not expected to be a problem in this area.
However, as a safety precaution it is recommended to maintain a stock of
Zinc Carbonate on the rig. H2S checks shall be done as per instruction.
Hydrogen Sulphide is lethal when inhaled, even in small quantities. High pH
can be used to hold the sulphides in the mud, but is now considered to be a
potentially dangerous practice. This is because large quantities of gaseous
hydrogen sulphide can be released rapidly from the mud with only small drops
in the alkalinity. A mud with a Pm value of 2.0 ml can dissolve some 1.4 g/l of
hydrogen sulphide and the pH will remain above 10. In this situation a partial
pressure equivalent to about 550 ppm gaseous hydrogen sulphide is likely to
exist on the fluid surface. This level is lethal if breathed for less than two
minutes.
Below a pH of 10 the control of hydrogen sulphide by alkalinity cannot be
considered safe, even for trace amounts of sulphide dissolved in the mud.
The only safe procedure is to regularly monitor the mud with the Hatch test kit
daily for qualitative analysis and the Garrett Gas Train for quantitative test
analysis and then to treat accordingly with zinc or copper carbonate or with
ironite sponge. Recent developments have produced a chelate zinc
compound that is potentially more effective than the traditional materials and
may be introduced. These materials react irreversibly with the sulphides.
Whole mud analysis with the Garrett Gas Train will also measure the water
insoluble sulphides, i.e. ZnS, FeS, and Fe2S3. This can provide useful
information to help decide scavenger treatment levels.
Hydrogen sulphide has the property of inverse solubility and so its solubility
decreases as the temperature decreases giving rise to the chance of gaseous
hydrogen sulphide, released as the mud cools in the pits. When sulphide
problems are encountered steel embrittlement preventative treatments should
be made. The toxicity should be the initial consideration for any treatment.
3/9/01
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KDS Ltd.
When hydrogen sulphide gets into mud, the initial pH decrease should be
corrected and maintained above 10 if possible. Large accumulations of the
resulting sulphide ions should be eliminated by chemical means. Removal of
the hydrogen sulphide or its resulting sulphide anion from a drilling mud
requires its precipitation as an insoluble salt. Two acceptable methods involve
the iron and zinc materials. The addition of zinc carbonate will form the
insoluble zinc sulphide:
S2- + ZnCO3 ---> ZnS + CO32Note that this technique may build up the concentration of soluble carbonates
that may require subsequent calcium treatment to maintain mud properties.
Excess zinc may also lead to loss of mud properties. A second method to
precipitate sulphide involves the addition of Ironite sponge.
4 S2- + Fe3O4 + 4 H2O ---> Fe3S4 + 8 OHAn alternative technique uses copper salts to form insoluble copper sulphides.
However this method should be avoided if at all possible. Any excess
dissolved copper ions in solution will cause the iron in drill pipe to oxidize and
corrode. This will cause the dissolved copper to plate out onto the drill pipe.
Zinc Carbonate
The removal of hydrogen sulphide and sulphide anions from drilling fluids is
facilitated by zinc carbonate. The sulphides are removed in the form of
insoluble zinc sulphide. Zinc carbonate is non-corrosive to the ferrous metal
surfaces and is effective in virtually all water based muds. It is effective in
removing sulphides over a broad pH range, including alkaline environments.
Zinc carbonate, added at 1 ppb, will treat out 500 ppm of hydrogen sulphide.
When hydrogen sulphide is anticipated it is recommended that the mud
system be pretreated with 2-3 ppb of zinc carbonate as large treatments with
zinc carbonate may result in increased viscosity, addition of water and/or
dispersant (Desco CF) is recommended to maintain fluid properties. The
levels of hydrogen sulphide in the mud filtrate should be continually monitored
with the Garrett Gas Train or Hach Paper Test while treatment continues.
These tests will help prevent over treatment of the mud with zinc carbonate.
Corrosion Rings
Corrosion has not been a problem with the salt concentrations high like they
are. Corrosion decreases as chloride ion concentration increases from 3% to
saturation. But most operators, from previous experience have run corrosion
rings in the drill string starting at drill out from casing. The problem on most ,
is the time that a corrosion ring can actually stay in the string due to short
sections. The coupons should be run for over 40 hours and pulled near 100
hours total time in the string. Conqor 404 is included as a contingency item.
3/9/01
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KDS Ltd.
Contingency materials
Definition
Any material purposely added to the drilling fluid other than those included in
the formulation for which the discharge permit applies. The drilling fluid
systems are designed to function without the need for contingency materials
during normal drilling fluid operations.
Conditions for use.

If prevailing conditions, in a particular well, become or may become such that
the drilling fluid become incompatible with safe and controllable drilling
operations, addition of proper contingency materials may be required to
modify the properties of the drilling fluid.
Cement Contamination Materials:

Recommended concentrations.
1. Sodium Bicarbonate:
2. Citric Acid:
0.6ppb
0.6 ppb
Lost Circulation materials:

1.
2.
3.
4.
5.
Mica F/m:
Nut Plug F/m /c:
Kwikseal f/m
Mix II F/M/c
Calcium Carbonate
10 - 40 ppb
10 - 40 ppb
10 - 40 ppb
10 - 40 ppb
10 - 40 ppb
Stuck Pipe Materials:

PIPE LAX (SEE FORMULATION CHART)
Hydrogen Sulphide Materials

1.
Zinc Carbonat 2 - 3 ppb
Corrosion
1. Conqor 4048 drms
Biocide
Thinners
Defoamer
3/9/01
64

CONTINGENCY PRODUCTS
Barrels
Cu. Meters
Hole Size
Starting Depth
Final Depth
Riser OD
Riser ID
Riser Length
Casing #1 OD
Casing #1 ID
Casing # Length
Casing #2 OD
Casing #2 ID
Casing # Length
Casing #3 OD
Casing #3 ID
Casing # Length
Surface Volume
61/2" Hole Volume
Dilution volume
Product
Unit
Size
Mica fine / med
25 kg sks
Nut plug fine /medium25 kg sks
Kwikseal F / M
50 lb sks
Cal. Carb F
25 kg sks
Cal. Carb M
25 kg sks
Mix 11 F
25 lb sks
Mix 11 M
25 lb sks
Conqor 404
55 gal drm
Pipe Lax W
55 gal drm
Finagreen
55 gal drm
Glute 16
5 gal drm
Soltex
50 lb sks
Guar Gum
25 kg sks
Defoam A
5 gal drm
Tackle
5 gal drm
Desco
25 lb sks
Zinc Carbonate
25 kg sks
Table 10 Contingency Products
Author: Peter Aird
www.kingdomdrilling.co.uk
Ref:
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Drilling FluidsPlanning Document

Deepwater drilling fluids design

Drilling and Completion Fluid

Deepwater Glydril System

Nature of Gas Hydrates / Basic Structure

Elements Necessary to Stabilize Hydrates

Hydrate Phase Behavior and Inhibition

Mixing Procedure for pre-hydrated Bentonite PHB

NaCl/KCl Polymer System

POLYPLUS (PHPA polymer) will give viscosity on initial addition, particularly

During displacement, 40 - 80 mesh screens are recommended for the

8 Pilot x 30" Conductor (Jetted)

Drilling Fluid Recommendation

Operation and Procedures

Mud Specification for 8 pilot hole; 30 Structural Pile

DRILL RISERLESS WITH SEAWATER AND BENTONITE SWEEPS.

THE KILL MUD SHOULD BE MIXED WITH 20-22 LB/BBL

SWEEP VOLUME MIXED WITH 25-30 LB/BBL FOR A VISCOSITY OF

GUAR GUM SHOULD BE ON BOARD IF ADDITIONAL

Drilling Fluid Recommendation

Operation and Procedures

Mud Specification for 26 hole and 20 Casing

SPOTTING FLUID PH SHOULD BE MINIMAL FOR PH SENSITIVE FORMATIONS.

DEEPWATER WELL PROGRAMME

Barrels/ Cu. Meters

Guar gum should be on hand as contingency

Table 1 26 hole Volume and Cost Estimate

17 1/2" x 22" Hole

Drilling Fluid Recommendations

Shale Inhibition - The initial addition of KCl shall be 19lb/bbl, with

Mud Specification for 17.5 X 22 hole and 16 Casing

NACL/KCL GLYDRIL SYSTEM

DEEPWATER WELL PROGRAMME

Barrels/ Cu. Meters

13%NACL / 5% KCL / GLYDRIL 5% /MONOETHYLENE 8%

Table 2 22 Hole Volume and Cost Estimate

14 1/2" x 17 1/2" Hole

Fluid loss (API)

Drilling Fluid Recommendations

16%NaCl/5% KCl/8% MEG

FANN 35 RHEOLOGY RESULTS

Table 3 17 HPHT Viscosity (Fann)

Mud Specification for 14.5 X 17.5 hole and 13 3/8 Casing

NACL/KCL GLYDRIL SYSTEM

DEEPWATER WELL PROGRAMME

Barrels/ Cu. Meters

MUD WEIGHT-10.2 -10.8ppg / 530 - 560pptf

Table 4 17: Hole Volume and Cost Estimate

Drilling Fluid Recommendations

21%NaCl/5% KCl/3% MEG

FANN 35 RHEOLOGY RESULTS

Table 5 12 Hole HPHT Viscosity (Fann 70)

Mud Specification for 12.25 hole and 9 5/8 Casing

**The centrifuges.(.refer to previous and solids control section)

NACL/KCL GLYDRIL SYSTEM

DEEPWATER WELL PROGRAMME

Barrels / Cu. Meters

Table 6 12 Hole Volume and Cost Estimate

Drilling Fluid Recommendations

22%NaCl/5% KCl/3% MEG

FANN 35 RHEOLOGY RESULTS

Table 7 8 Hole HPHT Viscosity (Fann 70)

Mud Specification for 8.5 hole and 7 Casing