SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009

Minimizing Wellbore Damage in a Sandstone Reservoir

Using Effective Mud Management Practices



Authors: Dr. Ali S. Rabba, James E. Phillips, Saleh M. Al-Ammari and Monir Mohamed


ABSTRACT


Inducing formation damage in sandstone reservoirs
through poor drilling fluids management is a crucial
factor that can affect well productivity. An integrated
team assigned to manage drilling horizontal producers
for field development, developed a mud management
plan to monitor drilling fluid properties and maintain mud
system specifications to minimize formation damage in
the fields sensitive sandstone reservoir. This article
discusses the implementation of the engineered oil-
based drill-in fluid (DIF), particle size monitoring, and
drilling and completion methods designed to minimize
reservoir formation damage and help maximize well
productivity.
A particle size distribution (PSD) analyzer was used
in the field to monitor the PSD values of the particulates
in the drill-in fluid while drilling the sandstone reservoir.
Core samples were selected and analyzed using a
scanning electron microscope (SEM) to determine an
average pore size value.
A diesel-based DIF was specifically designed to
minimize formation damage. The DIF was formulated
with a 70/30 oil/water ratio (OWR) and was treated with
a sized calcium carbonate bridging agent to help
minimize spurt/total loss. The engineered bridging agent
was added to prevent formation damage that results
from the invasion of fines. Overbalance pressures were
also minimized to avoid the risk of differential sticking.
For better bridging results, the D90, D50 and D10
PSDs were instantaneously maintained in the
programmed range while drilling the entire sandstone
pay section with controlled rates of penetration (ROP).
The percentage of drill solids as a function of total solids
was also maintained at low levels with the use of
centrifuges and the addition of whole treated mud. Upon
reaching the total depth (TD), the bottom-hole assembly
(BHA) was changed to a reaming assembly and the
entire open hole section was reamed to TD.
After making a wiper trip, the operator tripped back
to bottom without pumping to simulate hole conditions
that would occur while running screens. Once the open
hole was deemed in good condition, the well was
displaced to a solids-free invert emulsion mud
maintained at the same density as the DIF. This fluid
was circulated over a 230-mesh screen prior to running
the screens to ensure that all fine sand and excess filter
cake were removed.
To date, more than 20 wells have been successfully
drilled and completed with sand screens using the
abovementioned methodology. Testing results of the first

three wells indicated minimum skin damage and good
and stable production rates.

INTRODUCTION

Compared to carbonate reservoirs, introducing formation
damage in sandstone reservoirs through poor drilling
fluids management is a crucial factor that can affect well
productivity. The subject sandstone formation is
composed of various facies of generally red-colored
poorly sorted conglomerate: sandstone, siltstone,
mudstone, caliche and modular anhydrite. Some high
angle cross-bedded weakly consolidated sandstones in
this section may be interpreted as sand dunes.
The Saudi Aramco integrated team has worked with
a drilling fluids service company to develop a mud
management plan to monitor drilling fluid properties and
maintain mud system specifications to minimize
formation damage in the fields sensitive sandstone
reservoir. The team has generated the following
guidelines to achieve minimum formation damage:

High quality products designed for reservoir
drilling.
Well site fluid management procedures.
Fluid modeling and management software.
Solids control recommendations and monitoring,
particle size distribution (PSD) maintenance.
Liquid mud plant for reconditioning fluid.
Specialized testing and mud processing
equipment.
Completion fluid design and management filter
cake breakers and filtration.
Improvement Process well-to-well application
of lessons learned.
High impact technology R&D support from
global experts.

The task was to chronicle the best-in-class mud
management practice used to drill and complete a Saudi
Arabian sandstone reservoir section (pre-Khuff). The
objectives included minimizing formation damage,
minimizing production drawdown pressures, and
enhancing well productivity and well life. Success is
demonstrated by avoidance of high post-rig stimulation
treatment costs or excessive workover operations.
It is well-known that water-free, oil-based drill-in and
completion fluids are the most non-damaging fluids for
use in a water-sensitive reservoir section
1
. The density
required to stabilize the wellbore called for the addition
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009
of 40 pounds per barrel (ppb) of sized calcium
carbonate. A variety of formulations were tested in an
effort to optimize the diesel-based fluid and calcium
carbonate additions. A diesel-based fluid with a 70/30
oil/water ratio (OWR) was determined to be the most
suitable system to drill the pre-Khuff sandstone reservoir
section.
More than 20 wells have been successfully drilled
and completed with sand screens using the mud
management methodology. Testing results of the first
three wells indicated minimum skin damage, improved
productivity indices and good stable production rates.

CAUSES OF FORMATION DAMAGE
RELATED TO DRILLING FLUID AND
ADDITIVES

When drilling the reservoir zone, the drilling fluid and
additives should be optimized according to the type of
formation to help minimize damage to the production
zone. Formation damage caused by drilling fluid can be
classified into two categories:

1. Damage caused by chemical incompatibility:
Formation of scale or precipitation of insoluble
salt due to reaction between formation fluids and
filtrate.
Invasion of excessive emulsifier into wellbore
which causes formation wettability changes, and
therefore, changes in rock permeability, which
may cause emulsion blockage.
Precipitation of asphaltic materials due to
contamination of the reservoir oil with filtrate.
2. Damage caused by blocking of pore space, Fig. 1:
Invasion of drilling fluid/drill solid particles into
formation. Drilling fluid particles going into
formation will be stopped inside pore space and
forming internal filter cake. Damage can be deep
with poor fluid in a permeable reservoir.
Ineffective external filter cake deposited by
drilling fluid.
Lack of efficient solid control equipment.


Fig. 1. How fine solids can plug pore throat.

Fig. 2. Good reservoir with oil in place, indicated by blue
coloring.

The addition of properly sized particles to the drilling
fluid will ensure good bridging of pore openings on the
surface of the reservoir rock. This facilitates the
formation of a thin impenetrable external filter cake that
will minimize the invasion of particles and filtrate, Fig. 2.
Thus the addition of properly sized acid soluble particles
will be positive with regards to reducing the formation
damage potential in any reservoir drilling fluid. Managing
the addition of properly sized soluble particles is
extremely important while drilling the reservoir section,
along with managing the total solids composition.

DATA COLLECTION AND ANALYSIS

Bulk Rock Mineralogy

Reservoir rock can be classified as mainly quartz (80% -
94%) with trace amounts of feldspars (6.1% - 0%), Table
1 and Fig. 3. The rock mineralogy changes significantly
with depth. Authegenic clays range from 0.5% to
approximately 3% (visual estimate). The main clay
element in the pore space is kaolinite (7.8% - 0.5%) with
a minor quantity of illite (2.6% - 2.1%) as pore filling
material.

Bulk Mineralogy Sample A
% by
Weight
Sample B
% by
Weight
Quartz 80% 94.4%
K Feldspar 6.1% 0%
Kaolinite 7.8% 0.5%
Illite+Mica 2.6% 2.1%
Chlorite 1.9% 0.7%
Illite/Smec 0.7% 1.4%
Dolomite 0.5% 0.6%
Calcite 0.4% 0.3%
Total 100.0% 100.0%

Table 1. XRD for bulk rock % by wt


SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009

Fig. 3. Whole rock XRD analysis.

Clay size fraction analysis <2 microns (m) clay
fraction, Table 2 and Fig. 4, represented 4% - 6.5% by
weight of the bulk rock analysis. Kaolinite (40.9% - 8.2%)
and chlorite (29% - 5.4%) were the dominant clay
minerals present. A significant amount of illite (12.5% -
40.3%) and illite/smectite (10.1% - 31.2%) were also
present, along with clay grade quartz (7.5% - 14.2%).
Illite was identified to be poorly crystallized while the
kaolinite and chlorite were identified to be moderately
crystallized. This suggested that kaolinite and chlorite
crystallization began quite early in the diagenesis of the
core sample, followed by illite.

Thin Section Petrography

Thin section analysis of a representative samples (A &
B) from offset wells showed the sample to be a well to

Clay Size
Mineralogy
Sample A
% by Weight
Sample B
% by Weight
wt% < 2 mic 6.5 % 4 %
Quartz 7.5% 14.9%
Illite 12.5% 40.3%
Kaolinite 40.9% 8.2%
Chlorite 29.0% 5.4%
Illite/Smec 10.1% 31.2%
Total 100.0% 100.0%

Table 2. XRD clay size fraction < 2 Mic


very well sorted, fine grained arkose sandstone, Fig. 5.
Grain diameters are up to 210 m, with a mode between
100 m to 200 m. Grains are subangular to rounded
with predominantly elongate (grain length > grain width)
to spherical (grain length = grain width) grain shape.
The sample showed dominantly concavo-convex
and some straight contacts, indicating that the sample
has undergone a moderate degree of compaction.
Detrital grains were dominantly composed of quartz
(70% - 80%), plagioclase feldspar (11.5% - 3.5%) with
less abundant potassium feldspar (3.5% - trace),
muscovite mica (1.0%) and tourmaline (trace). Illite was
observed to be replacing kaolinite and plagioclase
feldspar. Pyrite was observed to be scattered and in
places forming framboids (2.0%), less abundant was
hematite (1.0%), which was found to be pore filling.
Chlorite was also present but only in trace amounts and
forming as inclusion predominantly within quartz grains.
Analysis for the target reservoir section in the pre-
Khuff formation showed that kaolinite and illite/
montmorillonite mixed layer clay are the major clays
present. No other significant minerals were observed by
thin section analysis.
Authigenic constituents were composed
predominantly of locally abundant, grain rimming, pore
throat lining, pore filling fibrous illite clay (6.5% - 4.5%)
and pore filling and pore bridging platy kaolinite clay
(4.5% - 1.5%). Kaolinite did also take the form of
replacement of pre-existing feldspars. Dolomite (0% -
3%) was identified as well.

Whole rock XRD
0.1
1
10
100
Sample A Sample B
%

b
y

w
e
i
g
h
t

Quartz K Feldspar Kaolinite Illite+Mica Chlorite Illite/Smec Dolomite Calcite
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009

Fig. 4. XRD clay fraction wt% < 2 m.


Fig. 5. Thin section shows well to very well fine sand grains.

Pyrite (2%) was identified but was scattered
throughout the section. Less abundant and only present
within one area of the thin section was laths of gypsum
(0.5%) crystals of the order 400 m, which filled the
available pore space. No other significant minerals were
observed by thin section analysis. Hydrocarbon/bitumen
(3%) was identified only in one area of the sample where
it took the form of a pore filling and grain coating phase.
Porosity was restricted throughout the sample due to the
presence of authigenic constituents and the degree of
compaction. Pore-throat restricting occurrences of
authigenic clay minerals were observed.
Rare primary porosity (4.5% - 5.5%) consisted of
pore throats with diameters observed to be 5 m to 40
m (thin section analysis may have overestimated these




values due to the two-dimensional image.
Mercury injection analysis gives an accurate pore
size. Primary pores were generally elongate (pore length
> pore width). Secondary porosity (12% - 12.5%) was
observed within dissolved/removed unstable grains
(feldspars and clay). The apparent mode of secondary
pore openings was 55 m, with a maximum pore space
of 100 m. Interstitial clay and intercrystalline
microporosity (<2 m) may increase the porosity count,
but could not be visually determined by thin section
analysis. No other significant porosity was observed by
thin section analysis. Reservoir permeability was given
as a range between 60 millidarcies (md) - 600 md and
can reach 1,000 md in some cases. Based on these
findings, the D50 was determined to be in the range 25
mic to 35 mic. Using thin section results, Table 3, and
permeability data, a PSD modeling program designed to
match the formation and proposed fluid was used to
determine the optimum combination of bridging material
to fit the range of pore opening sizes.

DRILL-IN FLUID (DIF) BRIDGING AGENT
SELECTION

The selection of an appropriate bridging material is more
critical during reservoir drilling since the barrier should
be completely removed in preparation for placing the
well on production. Some bridging materials are solids
added to a drilling fluid to bridge across the pore throats
or fractures of an exposed rock, thereby building a filter
cake to help prevent the loss of whole mud or excessive

XRD clay fraction wt%< 2 mic
6.50%
4%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
Sample A % by wt < 2 mic Sample B % by wt < 2 mic
%

b
y

w
t

f
r
o
m

w
t
%


<
2

m
i
c

Wt % < 2 mic Quartz Illite Kaolinite Chlorite Illite/Smec

SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009
Sample A B
Well A A
Depth (ft)
XX13 ft XX68 ft
Detrital Grains
Quartz 70.5% 80.5%
Monocrystalline 69% 77%
Polycrystalline 1.5% 3.5%
Feldspar 15% 3.5%
P Feldspar 11.5% 3.5%
K Feldspar 3.5% Trace
Authigenic
Constituents
14.5% 16%
Illite 6.5% 4.5%
Kaolinite 4% 1.5%
Pyrite 2% 2%
Haematite 1% Trace
Quartz Overgrowths 1% 1.5%
Gypsum Trace 0.5%
Dolomite Trace 3%
Bitumen Trace 3%
Total 100% 100%
Porosity
Primary
4.5% 5.5%
Secondary 12% 12.5%
Total Porosity 16.5% 18%

Table 3. Thin section analysis

filtration. Bridging materials are commonly used in
reservoir drilling fluids and in lost circulation treatments.
For reservoir applications, the bridging agent should be
removable. Acid-soluble products include calcium
carbonate. Two mathematical methods, bridging agent
selection calculator and the drilling fluid graphics
software (DFG) hydraulics modeling program, were
used to calculate the proper bridging agent selection and
to design and select proper bridging material.
The following steps were used to complete the
mathematical method:

1. Estimate reservoir permeability (md) or use
known pore throat size of the reservoir.
2. Calculate the estimated pore-throat size from
permeability using the below formula:
Estimated pore-throat size m = C
( ty permeabili )
Where C is the coefficient of correction,
C = 0.95 for tight sand, and
C = 1.0 for permeable well sorted sand.
3. Select bridging agents and concentration.
4. Adjust the percentage of the bridging material to
get an overall Target D50 close to a calculated
estimated pore throat.

Using DFG software to select the proper
combination of bridging material, we have to enter the
D50 value then to let DFG select the materials. The
results will be an optimized combination of bridging
material. The highest modality represents the better
combination.
To ensure proper implementation of bridging in the
field, there are essential tools that have to be used on an
hourly basis while drilling. These tools are the PSD
analyzer and the permeability plugging apparatus (PPA)
test.

PARTICLE SIZE DISTRIBUTION (PSD)
ANALYZER AND CASE HISTORIES

DFG hydraulics modeling software was used to select
the proper combination of bridging material suitable to
achieve D50 within the proposed range. The PSD
analyzer, Fig. 6, uses laser diffraction technology to
ensure proper PSD in the drilling fluid. The main object
is to keep the D50 within range, and prevent it from
dropping dramatically. A significant decrease indicates
that a majority of bridging material has changed to fine
size, which may cause damage by invading the
reservoir. For this reason centrifuging mud to discard
fine solids is an essential way to maintain proper
bridging.
In fresh mud mixes, the calcium carbonate
concentrations are as follows: 5 m, 25 m and 50 m in
the ration of 1:3:1. When drilling commences, additions
of 5 m calcium carbonate are stopped completely and
substituted with 50 m calcium carbonate. Although
PSD had previously been used in different parts of the
world, this was the first use in the Middle East. PSD
modeling was used primarily to monitor PSD while
drilling the pre-Khuff reservoir formation.


Fig. 6. Malvern Mastersizer.
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009

Fig. 7. Permeability plugging apparatus (PPA).

PPA AND PPT TEST

The PPA
2
is a specialized apparatus used in the
permeability plugging test (PPT), Fig. 7. It is used to
determine the ability of particles in the drilling fluid to
effectively bridge the pores in the filter medium, and
therefore, the ability of the mud to reduce formation
damage in the reservoir. The particle plugging apparatus
is a static inverted high-pressure high temperature
(HPHT) filter press with a ceramic disk as a filter
medium. This static test measures the pore plugging
ability of a fluid.
The apparatus consists of an HPHT filtration cell that
has been designed to operate upside down (to remove
the effects of gravity) and to accept filter media of
different permeabilities. The medium is selected to
match the permeability of the reservoir to be drilled. The
filter medium is at the top so that sediment will not affect
the filter cake. Pressure is applied hydraulically from
below.
PPA is applied extensively during optimization of
pore throat bridging formulations using a bridging agent
(sized marble). PPA results are used to evaluate the
effects of varying bridging agent concentrations and
PSDs. The continued ability of field muds to provide
suitable bridging is typically evaluated using a
combination of PPA testing and particle size analysis.
The use of aloxite disks simulates the interaction of
the exposed face of the productive formation with the
drilling fluid, and, combined with the relevant variables of
the test, such as pressure and temperature, provides the
user with a very good representation of the filtration
process in the hole. The spurt loss and the total filtrate
should be corrected since the filter medium is usually
one-half the area size of the conventional API filter
paper. The method used to perform PPA is described
below.
Collect the fluid from the back pressure collector in a

measuring cylinder and record the amount. Ensure that
all the fluid has been expelled. This will be reported as
the spurt volume in milliliters (ml). Spurt loss is generally
defined as the filtrate or fluid loss that elutes through the
filter medium before a filter cake is established.
Record the total fluid collected over the 30 minute
period as Total Fluid Volume (ml).
Fluid Loss = Total Fluid Volume Spurt Volume.
PPA total = Spurt Volume + 2 *(Fluid Loss).
Check the pressure gauge during the test to ensure
you have constant pressure during the whole test. If the
pressure increases above the programmed value during
the test, then the whole test must be repeated.
Figure 8 shows an increase in the total filtrate
volume with increasing aloxite desk size, for the same
mud at the same pressure and temperature.

PPA APPLICATIONS

The PPA has been used successfully over the past few
years
2, 3
to resolve differential sticking issues. An
operator experienced several stuck pipe incidents
resulting from differential pressure sticking across
sandstone formations that were normally pressured. As
a result, the sandstone formations were drilled with an
overbalance pressure of 1,500 psi - 2,000 psi. Once the
problem was recognized, PPT tests were performed to
determine the optimum treatment of bridging material.
Initial tests of the base mud indicated a high spurt loss
and thick wall cake. Treatment with different sizes of lost
circulation material (LCM) material reduced the spurt
losses dramatically and enhanced the filter cake
quality/thickness. This in turn reduced the risk of
differential sticking significantly.

OIL BASED MUD (OBM) FORMATION

Fresh drill-in fluid (DIF) was mixed according to the
formulation, Table 4. Comparison between planned and
actual mud chemicals concentration showed that most of
the products were used within the programmed range.
The concentration of 5 m of calcium carbonate was
less than the proposed value. This is to support the
assumption in the design phase to stop adding 5 m of
calcium carbonate while drilling, and to keep the
centrifuge running all the times while adding 25 m and
50 m of calcium carbonate.
The reference values for D50

were chosen to be in
the range of 25 m - 35 m to cover a wide range of
pore throat sizes. Premium grade organophilic clay was
used to achieve proper fluid properties with minimal clay
content in the DIF. Figure 9 shows the PSD for fresh
mud with D10 = 11 m, D50 = 35 m and D90 = 75 m.

SOLIDS-FREE COMPLETION FLUID
FORMATION

The solids-free formulation was mixed with 55/45 OWR
to achieve the desired mud weight, Table 5. To minimize

SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009

Fig. 8. Total filtrate volume on different ceramic desk size.

Product Name Unit Size Planned
Concentration
Actual
Concentration
Diesel bbl 0.56 0.56
Primary Emulsifier lb 12 14
Secondary Emulsifier lb 4 6
Lime lb 4 6
Fluid Loss Reducer lb 6 5
Water bbl 0.23 0.23
CaCl
2
78% lb 66 55
Premium Organophilic Clay lb 2 - 3 2.3
Calcium Carbonate 5 m lb 8 5.8
Calcium Carbonate 25 m lb 24 25.1
Calcium Carbonate 50 m lb 8 5.3

Table 4. Formulation of 67 pcf DIF using sized calcium carbonate


Product Name Unit Size Planned
Concentration
Diesel bbl 0.43
Primary
Emulsifier
lb 12
Lime lb 6
Water bbl 0.35
CaCl
2
78% lb 92
Premium
Organophilic
Clay

lb

1 - 2
Secondary
Emulsifier
lb 12

Table 5. Formulation of 67 pcf solid free completion fluid

separation between the oil/water phases, the solids-free
fluid was sheared properly using a shearing device with
a 6 bit with jets connected to the rig pump.

FIELD IMPLEMENTATION

Prior to displacing to the DIF, the shakers were dressed
with 140-mesh - 180-mesh screens to prevent binding
from unsheared mud. After two full cycles and no losses
on surface, the shakers were progressively screened up
to 200-mesh and 230-mesh, and remained so
throughout the section. The PSD analyses on cuttings
and the shaker underflow showed that 200-mesh
screens were removing all solids above 75 m. The flow
was evenly distributed, although most of the time
shakers were running wet. It was preferred to lose a bit
Filtrate volume against different ceramic desk size for 67 pcf DIF
0
1
2
3
4
5
6
7
8
9
0 7.5 15 22.5 30
Time min
T
o
t
a
l

f
l
u
i
d

v
o
l
u
m
e

m
l
10 mic desk 20 mic desk 35 mic desk
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009

Fig. 9. Particle size distribution for 67 pcf fresh DIF.



Fig. 10. PSD and porosity vs. depth.
PSD trend while drilling
0
10
20
30
40
50
60
70
80
90
100
9
9
2
0
1
0
0
3
7
1
0
1
8
1
1
0
3
1
0
1
0
3
7
0
1
0
6
5
0
1
0
7
0
0
1
0
8
1
8
1
0
9
7
2
1
1
1
0
0
1
1
1
9
5
1
1
3
4
5
1
1
5
0
0
1
1
6
1
6
1
1
8
0
5
1
2
0
8
4
1
2
2
8
5
1
2
4
0
6
1
2
6
2
6
1
2
7
4
9
Depth ft
M
i
c
r
o
n

0
10
20
30
P
o
r
o
s
i
t
y

%
D10 D50 D90 Porosity
D
50 and trend
porosity
Porosity %
D
90
D
10
XX1100 XX1200 XX1300 XX1400
XX1500
XX1600 XX1700 XX1800 XX1900
PSD distribution for 67 pcf fresh mud
0
20
40
60
80
100
0.01 0.1 1 10 100 1000
Micron size
T
o
t
a
l

v
o
l
u
m
e

%
0
1
2
3
4
5
6
F
r
a
c
t
i
o
n

v
o
l
u
m
e

%

Total volume % Fraction volume %

SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009
with the finest screens rather than to incorporate solids
with coarse screens. A centrifuge with adjustable RPMs
was also run on the active system to remove solids as
much as possible. The initial DIF fluid presented D10 =
11 m, D50 = 35 m and D90 = 75 m.
The PSD was run several times a day while drilling
4

to help ensure that the active system remained within
the proposed specifications and to monitor particle size
to evaluate the condition of the DIF fluid and the
efficiency of the solids control equipment. After drilling
for a period of time, the mud system started to gain drill
solids and some of the calcium carbonate degraded to a
size less than 5 m. Therefore, the D50 was decreasing,
from initial 35 m to 27 m. The mud weight was
creeping toward 68 pounds per cubic ft (pcf) and the
equivalent circulating density (ECD) was consequently
affected.
To control this situation, an additional 25 m and 50
m of calcium carbonate were added to the system, and
the centrifuges were run continuously while drilling,
holding the mud weight and properties as desired. The
addition of 5 m of calcium carbonate had been
discontinued. PPT testing with suitable aloxite disk sizes
helped to simulate the average size of the pores in the
formation. The PSD and log porosity vs. depth was
tracked and plotted along the entire drilled section,
Fig. 10.
On reaching total depth (TD), the hole was
circulated, then a wiper trip was made to the shoe and
the drillstring was returned to bottom without pumping to
simulate hole conditions for running screens. Upon
reaching TD after the wiper trip, the hole was displaced
to a solids-free completion fluid, which was circulated
over 265-mesh screens. A pass screen test was
performed on the solids-free fluid before and after
displacement. A sample of this fluid was also tested for
PSD, and the results indicated D10 = 2 m, D50 = 7 m
and D90 = 21 m before running screens. These PSD
values remained steady until the end of the section.
Systematic visual checking was done every few hours as
an eventual increase in the diameter of the solids would
have required flushing shaker screens, but it was not
necessary.

RESULTS

1. More than 20 wells were drilled using the same
technique and the screen completion reached TD
efficiently.
2. Wells cleaned up in a few hours with stable wellhead
pressure.
3. Development was hailed as a huge success of best
in class DIFs and world-class mud management
services.
4. Cost of mud management services was only 20% of
the total cost of drilling fluid through the section.
5. Production data from three completed wells
indicates very low skin damage.
6. All wells established a vigorous and stable oil rate
after a short clean up, indicating minimum damage.

CONCLUSIONS

1. Engineered DIF design is essential and requires
adequate rock data to develop a hard filter cake.
2. The team has to ensure effective implementation of
the design criteria in the field under actual drilling
conditions.
3. A specific PSD is required to effectively bridge a
given pore throat distribution. PSD must include
particles that are smaller and larger than a third of
the pore throat diameter. Centrifuge equipment is
essential for discarding fine solids and promoting
proper bridging and reservoir protection.
4. For better bridging in OBM, the minimum
concentration of the bridging material should be
above 30 pounds per barrel (lb/bbl).
5. Addition of properly sized particles to the drilling fluid
will help ensure good external filter cake, which will
minimize the migration of fine solids into the
formation. The rate of penetration (ROP) has to be
controlled instantly while drilling for proper bridging.
6. Drilling was carried out with minimum overbalance to
minimize the tendency for fine solids to migrate into
pore throats causing irreversible formation damage.
7. Minimum fluid clay content was achieved through
the use of premium grade organophilic clay.
8. Low concentrations of emulsifiers were utilized to
minimize the risk of emulsion blockage.
9. Pore throat distributions have a wide range of
numbers that cannot be described with one
measurement

ACKNOWLEDGMENTS

The authors wish to thank Saudi Aramco management
for their support and permission to present the
information contained in this article.

REFERENCES

1. Al-Ammari, S.M., Phillips, J.E., Ogunsola, A., Al-
Mumen, A.A. and Ezzat, A.M.: Water-Free, Drill-In
Fluid Dramatically Improved the Producibility of
Sensitive Sandstone Reservoir, SPE paper 93702,
presented at the Middle East Oil & Gas Show and
Conference, Bahrain, March 12-15, 2005.

2. Davis, N., Mihalik, P., Lundie, P.R., et al.: New
Permeability Plugging Apparatus Procedure
Addresses Safety and Technology Issues,
SPE/IADC paper 52815, presented at the SPE/IADC
Drilling Conference, Amsterdam, The Netherlands,
March 9-11, 1999.

3. Ezzat, A.M., Rosser, H.R. and Al-Humam, A.A.:
Control of Microbiological Activity in Biopolymer-
Based Drilling Muds, SPE paper 39285, presented
at the Middle East Drilling Technology Conference,
Bahrain, November 1997.

SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009
4. Omland, T.H., Saasen, A., Taugbl, K., et al.:
Improved Drilling Process Control through
Continuous Particle and Cuttings Monitoring, SPE
paper 107547, presented at the Digital Energy
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11-12, 2007.
























































BIOGRAPHIES

Dr. Ali S. Rabaa is a Petroleum
Engineering Supervisor of the Nuayyim
and Central Arabia Units at Southern
Area Reservoir Management. He has
over 14 years of work experience with
Saudi Aramco, where he has worked in
reservoir management, drilling and
workover, Exploration and Petroleum
Engineering Center - Advanced Research Center
(EXPEC ARC) and gas production engineering. Alis
areas of interest include field development and reservoir
management, numerical simulation, reservoir
characterization, supplemental recovery, and
multidisciplinary integrated team projects.
In 1989 he received his B.S. degree in Applied
Chemistry from Umm al-Qura University, Makkah, Saudi
Arabia. In 1992 he received his M.S. degree in
Petroleum Engineering from Montana Tech, Butte, MT
and in 2000 he received his Ph.D. degree in Petroleum
Engineering from the Colorado School of Mines, Golden,
CO. Ali recently graduated from the PE Technologist
Development Program.
He is a member of the Society of Petroleum
Engineers (SPE) and American Association of
Petroleum Geologists (AAPG).


James E. Phillips is a PE Specialist in
Well Completions working in the
Technical Services Unit in the Abqaiq
Production Engineering Division. His
work has been centered on Central
Arabia completions, particularly in the
area of sand control. Jimmy has
designed and installed most of the
remedial vertical sand control completions in the Hawtah
Trend and was heavily involved in designing the NYYM
field horizontal sand control completions.
In 1979, Jimmy received a B.S. degree in Petroleum
Engineering from Mississippi State University,
Mississippi State, MS. He worked for Mobil Oil
Corporation as a Completions Engineer until he came to
Saudi Aramco in 1988 as a loanee from Mobil. Jimmy
began working directly for Saudi Aramco 1997. He has
been an active member of the Society of Petroleum
Engineers (SPE) since 1979. Jimmy is a past member of
the SPE Well Completions Committee and has served
as the Technical Paper session chairman in several
ATCE conventions.












SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009

Saleh M. Al-Ammari is the Supervisor
of the Drilling Fluids & Cement Unit of
the Exploration and Petroleum
Engineering Center - Advanced
Research Center (EXPEC ARC). He
completed the specialist development
program as a Drilling Fluids Specialist
in 2006. Saleh joined Saudi Aramco in
1992 after receiving his B.S. degree in Industrial
Chemistry from King Fahd University of Petroleum and
Minerals (KFUPM), Dhahran, Saudi Arabia. In 1997, he
received his M.S. degree in Petroleum Engineering from
the University of Tulsa, Tulsa, OK. Saleh is an API
voting member in subcommittee 13 (Drilling, Completion
and Fracturing Fluids). He is also a member in the
Society of Petroleum Engineers (SPE), and the
chairman of the Saudi chapter of the American Chemical
Society.


Monir Mohamed joined Baroid Fluid
Services in 2000 and works as a
Senior Technical Professional.
In 1986, he received a B.S. degree
with honors in Petroleum Engineering
from Cairo University, Giza, Egypt.
Upon his graduation, he taught as an
assistant instructor at Cairo University
for 6 months, then joined Amoco Egypt and worked as a
Drilling Engineer for 2 years. Monir received his M.S.
degree in Petroleum Engineering in 1992 from the same
university. During 1992 - 2000 he served in a various
fluid engineering positions, starting with Mud Engineer
then moving to Mud Plant Supervisor and promoted to
Field Supervisor in Syria. After a while, he was promoted
to the position of Country Operations Manager in Qatar
until the end of 2000.
Monir developed the quality assurance/quality
control for the first deep quest job in Saudi Arabia. He
also developed and published several solution profiles
regarding reservoir management services and filter cake
removal applications in sandstone reservoirs. During his
career, Monir has received numerous certificates of
appreciation for his work.