Lesson 6 Foam Drilling-1
Transcript of Lesson 6 Foam Drilling-1
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Harold Vance Department of Petroleum EngineeringHarold Vance Department of Petroleum Engineering
Lesson 6Foam Drilling
Read: UDMChapter 2.5-2.6, Pages 2.75-2.130
PETE 689 - UnderbalancedDrilling, UBD
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The Pattern Of Foam
Classic static
foam pattern onthe left.Foam in flowprobably looksmore like the oneon the right.
1 cm 1/2 inch
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Types of Flow Regimes(Lorenz, 1980)
MISTFOAMLIQUID GAS AERATED
LIQUID
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Fluid Phase Continuity
Mist
(97-100% Gas)Foam or Gaseated
(50-97% Gas)
Air/Gas
Water
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Mist Aerated Foam
50/1
1000/1500/1
100/1
30/1
10/1
99.8%
90%
Injection Ratio
Foam Quality
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Foam and Gaseation
FOAM “Emulsion”.
Hard to Separate. “NO” Pressure Surges. Huge lifting capacity.Plugs lost circulation
and reduces head.
GASEATIONMixture.
Separates easily.Heading and pressuresurges.Normal lifting capacity.
Reduces lost circulationby reducing head.
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Reasons for UB Drilling with Foam
1. Stops lost circulation.
2. Improve drilling rate.3. Protects the reservoir.
4. Avoid differential sticking.5. Hole cleaning with low
fluid volume.
Why Foam?
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Lifting Capacity
Powder
Regrinding AndMud Ring
Formation
LargeCuttings
Foam Air/Mist
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Lost Circulation with Foam
Reduced the mud densityno junk.Foam plugs lost zones.
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Lost Circulation with Foam
The Foam
bubbles arelost zoneplugging
agents!
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Improve Drilling Rate
Low bottom hole pressureincreases drilling rate.For hard rock, the new airhammer works with foam.
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-500 0 +500 +1000
p p
b p
DIFFERENTIAL PRESSURE (psi)
Effect of Differential Pressure
Bit Floundernot
uncommonwith foam
Perfect Cleaning
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Protect Reservoir
No formation damage withno influx into the well bore.Minimal pressure surges.
Controllable pressures.
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Protect ReservoirFoam is Perfect UB Fluid
In underbalancecondition, flow isinto the hole.Fluid does notruin the foam.
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Protect Reservoir
Foam is perfect UB FluidIn overbalancecondition, foambubbles block the matrix.Foam bubblesalso block fractures.
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Differential Pressure StickingDRILL PIPE
FILTER CAKE
DRILL COLLAR
, K P f
PH
PH > P f
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No Differential Pressure Sticking
DRILL PIPE
NoFILTER CAKE
DRILL COLLAR
, K P f
PH
PH > P f
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Foam Lifting CapacityNeeds Only Limited Fluid Volume
0.2
0.6
0.8
1.0
0
0.4
Dry
1.00 0.60.40.2 0.8
WetFoam
Relative Velocity 2
1
StableFoam
Foam Quality
Actually acts likethis
Theory
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Powder
Regrinding And
Mud RingFormation
LargeCuttings
Foam Air/Mist
Hole Cleaningwith Limited Fluid Volume
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Theoretical Foam Types
Stable Foam: 1-2% Surfactant.Stiff Foam: 1% Surfactant, 3-4% Gel,
Polymer. Use of viscosified waterinstead of fresh non-viscosified waterin the incompressible fluid component.
Viscosity additives: CMC, Xantan Gum,Polymers, etc..
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General Foam Agents
Foamer to reduce surface tensionof water.
Polymers to strengthen the filmaround the air bubbles.Soda Ash to soften water andraise the pH to 10.
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Fluids for Foam Drilling
Fresh water.Saline or brackish water.Oils not used to date.
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Small Foam Unit
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Large Foam Job
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Foam Theory
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Foam Structure
Required ElementsGasLiquidFoaming Agent• A surface active agent
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The Pattern Of Foam
Classic staticfoam pattern onthe left.Foam in flowprobably looksmore like theone on the right.
1 cm 1/2 inch
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Transfoam (Weatherford) All of the following may not applyto transfoam.Some of the methods of handlingTransfoam may vary. It is a slightly
different type of foamer.
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Foam Rules
Smaller bubbles are more stable.
Polymers make the skin aroundthe bubbles tougher.Bentonite makes the skin aroundthe bubbles more stable.
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Foam Rules
Soda ash in the watermakes the foamer work better.Soda ash in the waterbuffers the pH at about 10.
Different foamer may work best in certain areas.
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After Saintpere et.al.
Effect Of Pressure On Foam Stability,Correlation with Bubbles Man Diameter
B u b b l e s m e a n
d i a m e
t e r
(µ
m )
Pressure ( bar )0 5 10 15 20 25 30 35 40 45 50
1.000
900
800
700
600
500
400
300
200
100
0
0.700
0.600
0.500
0.400
0.300
0.200
0.100
0.000
D r a
i n a g e v e
l o c i t y
( m l / m
i n )
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Polyhedral Foam ContactTrue Foam
Plateau Border
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Bubble
Pressure RedistributionLesser Pressure Greater Pressure
R r
From high pressure to lower pressureDepends on film permeability
Gas diffusion.
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Foam StructureStabilization
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Stronger Bubbles
Smaller bubbles.More foamer.
Of the right kind. Add a surfactant.
Polymer.Other agent.
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Surface Active Materials
Retard DrainageIncrease surface viscosity.
Oxygen reactive additives.Migrating surfactants.
Ionically charged foamers.
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Migrating Surfactant
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Ionically Charged Foamer
Most foam system and
most foamers are anionicin nature.
If part of the outer wall of the bubble should becomecationically charged theinner and outer wallswould be attracted andthe wall would becomethinner at that point.
+
+++
++
-
- -
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Ionically Charged Foamer
Ionically charged foamerswill cause both walls of each bubble to carry the
same electrical charge.The walls will then repel,becoming thicker.
-
-
--
-
--
-
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Foamer Considerations
Concentration
Contaminants
Temperature
Solubility
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Foamer Concentration
H a
l f l i f e i n s e c o n
d s
% Foamer concentration
300
250
200
150
100
50
0
0 0.2 0.4 0.6 0.8 1 1.2
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FACTOR CHANGE EFFECT onDRAINAGE
EFFECT onSTABILITY
Foamer concentration Increase Decrease Increase
Solubility Increase Decrease Increase
Temperature Increase Increase DecreaseContamination Increase ----- Decrease
Major Factors of Foam Stability
All these factors are interdependent if T
goes up, instability increase, solubilityof the foamer increase. If solubilityincrease, stability increase.
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Causes of Bubble Disruption
Big Bubbles are weakerthan small bubbles.Salt water weakens thebubble surface.Oil weakens the bubblesurface.Some solids weaken thebubble.
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DEFOAM
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Bubble Disruption Defoamers
Most defoamers weaken the
bubble film - like an alcohol or oil.Some defoamers use fine silicatesolids to disrupt the bubble film.
Time and gravity drainage.
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Foaming AgentChemicals
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Straight Foamers
Anionic in NatureEthoxyl Alcohol Ether Sulfates
Alpha Olephin SulfonatesWidest applicability.Excellent solubility.
Good thermal stability.Hydrocarbon tolerance.High Costs.
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Amino-Propyl Betaines (Amphoteric)Will change properties with achange in pH from acid to basic.
Excellent stability.Good thermal stability.Good brine solubility.Fair yield.Relatively expensive.
Foam Boosters
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Alkanol Amides (Cationic)
Good thermal stability.Expensive.Incompatible with most foam
systems.
Foam Boosters
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Sodium Sulfosuccinates (Anionic)
Common.Good fresh-water solubility.Good thermal stability.
Extremely poor brinesolubility.
Foam Stabilizers
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Harold Vance Department of Petroleum Engineering
Alkyl-Phenol Ethoxylates (Nonionic)
Excellent surface activity.
Soluble in all waters.Good thermal stability.Compatible with other additives.
Provides poor foam quality.
Foam Stabilizers
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Harold Vance Department of Petroleum Engineering
PolymersFoam Stability Improvement
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Harold Vance Department of Petroleum Engineering
Polymer Uses
Drill solid flocculation.
Increased viscosity.Increased lubricity.Stabilize clays.Increase foam stability.
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Polymers
Organic or synthetic.Many monomers (repeating units).
Varied structures.
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Harold Vance Department of Petroleum Engineering
Polyacrylamides
Widely used.
MW = 8-10 million.
Varied ionic charge.
Synthetic
Polymers
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Harold Vance Department of Petroleum Engineering
Partially-Hydrolyzed Polyacrylamide
(PHPA)
Synthetic polymer.
Powder or liquid.
Synthetic
Polymers
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Harold Vance Department of Petroleum Engineering
Natural, OrganicCar boxy-methyl Cellulose
(CMC)Natural polymer from plants.
Cotton. Viscosity control.
Polymers
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Harold Vance Department of Petroleum Engineering
Hydroxy-Ethyl Cellulose (HEC)
Anionic.
Fluid loss control.
Viscosity control.
Natural, Organic
Polymers
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Harold Vance Department of Petroleum Engineering
Guar Gum
Natural polymer.Non-ionic, Branched chain.
MW = 200,000Low temperature.
Natural, Organic
Polymers
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Biopolymers Xanthan gum (XC)
Viscosity control. Fresh or salt water compatible.
Shear thinning.Increase foam stability, butwith poor lifting ability.
Polymers
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Harold Vance Department of Petroleum Engineering
Clay and Shale Stabilizers
Hole Stability
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Clay Swelling Mechanisms
Simple adsorption.
Osmotic swelling.
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Stabilizing Agents
KClExcludes water attraction.
Ammonium chlorides. Amine salts.
Cationic polymers.
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General Foam Types
Stable foamFoaming agentPolymer
Stiff foamFoaming agentPolymerBentonite
pH sensitive foam (amphoteric)Transfoam
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Foam Quality
Gas phase percent by volume
Expressed as: %Whole number
Decimal equivalente.g. 75, 75%, or 0.75
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Harold Vance Department of Petroleum Engineering
Foam Quality (In theory)
0-55% Aerated Fluid
55%-94% Foam94%-99.9% Mist
100% Gas/Air
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Powder
Regrinding And
Mud RingFormation
Large
Cuttings
Foam Air/Mist
Hole Cleaning
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FactorsEffecting Foam Quality
Pressure.Depth.Gas content.
Liquid content.
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Harold Vance Department of Petroleum Engineering
Maintaining Foam Quality
Gas and liquid injection rates.
Back-pressure on the system.Measurement.Calculation (computer models).
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Foam Texture
The “stability” of Foam
Not measured at present. Assumed in all the Math. A source of error, but we don’tknow how much.Best available guess is “half life”.
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Harold Vance Department of Petroleum Engineering
Foam Texture
The Foam Strength
Small bubbles -mixed at jet bit.Good foaming agent.
Polymer for film strength.
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Liquid Volumes
Begin with 1/10 of ConventionalMud Rate required to give a120 ’/min (40m/min) annularvelocity.
EXAMPLE: In an 8.75 ” hole, 400gpm is a normal mud rate. Forfoam start with 40gpm as aninitial try.
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Liquid Volume
This may have to be increased up to50-70% of normal mud volume tobuffer the steering tool or EM-MWD.Gas then likewise has to increase.
Be careful of friction dominatephase.
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Harold Vance Department of Petroleum Engineering
Rheological Models
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Bingham Plastic
The fluid will not flow until acertain minimum shear stress isexceeded. Once that minimumstress has been exceeded,additional shear stress isdirectly proportional to theshear rate.
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Shear Stress and Shear Rate for a BinghamPlastic Fluid (Bourgoyne et al., 1986)
g=
0
t
- t g
+ t g
g Shear Rate,
p
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Power Law
A Power-Law fluid withthe application of anyshear stress.Shear stress is a functionof shear rate for aPower-Law fluid, it is nota linear relationship.
Sh St Sh R t f P
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Shear Stress vs. Shear Rate for a Power-Law Fluid
(Bourgoyne et al., 1986)
t = k g
t
S h e a r
S t r e s s ,
. n
n < 1
Shear Rate, g
t = k g g. . n- 1
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The Published Experts Don’t Agree About Foam Fluid Behavior
Bingham Plastic Mitchell
KrugBeyer
Power Law OkpobiriIkoku
Sanghani
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ActuallyFoam sometimes flows as a plug.
And sometimes with a velocityprofile across the hole crosssection.
Viscosity changes with pressureand temperature as well aschemical content.
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Foam Flow
Foamsometimesflows as aplug.
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Foam Flow
Foamsometimesflows highviscosityprofile.
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Foam Testing
It is difficult to measure theviscosity of a foam.Instead a half-life test is used.
F T ti g
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Foam Testing
Half Life Procedure
Waring Blender Stop Watch 1000ml Cylinder
Foam Testing
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100mlwater
Foaming Agent0.5% (0.5ml)
Waring Blender Stop Watch 1000ml Cylinder
gHalf Life Procedure
Foam Testing
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Mix on high for 30 sec
Waring Blender Stop Watch 1000ml Cylinder
gHalf Life Procedure
Foam Testing
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Pour into cylinderand measure timefor 50ml of waterto appear
Water
FoamTime is half life
Waring Blender Stop Watch 1000ml Cylinder
Foam Testing Half Life Procedure
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Harold Vance Department of Petroleum Engineering
Foam DrillingEquipment
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Stable Foam Mixing System
(Hutchison)This is not a very good method
Detergent
Additives
Water
BlenderFor
DetergentSolution
Compressed Air or Gas
MeterFoamGenerator
Meter
20 Gpm PositiveDisplacementPump
Work string
Annulus
Blowdown
Foammanifold
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Harold Vance Department of Petroleum Engineering
Modern Foam Mixing System
Chemical
Chemical
MeteringPump
MeteringPump
ToMud Pump
F D illi g Eq i t
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Foam Drilling Equipment
Rotating Head
Foam Drilling Equipment
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Harold Vance Department of Petroleum Engineering
Gas Fluid Mixing System
Foam Drilling Equipment
Foam Drilling Equipment
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Harold Vance Department of Petroleum Engineering
Foam Mixing
The real key to
satisfactoryoperation is theuse of precision
injectionpumps.
Foam Drilling Equipment
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Foam Drilling Equipment
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Harold Vance Department of Petroleum Engineering
Weatherford Foam Unit
Foam Drilling Equipment
Foam Drilling Equipment
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Harold Vance Department of Petroleum Engineering
CompressorUsed in Foam Drilling
Foam Drilling Equipment
Foam Drilling Equipment
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Harold Vance Department of Petroleum Engineering
Rotary Primary Compressor in aUnitized Package
Foam Drilling Equipment
Foam Drilling Equipment
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Booster Compressor ina Unitized Package
Foam Drilling Equipment
Foam Drilling Equipment
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Harold Vance Department of Petroleum Engineering
Bakermodel Fbit float
Foam Drilling Equipment
Foam Drilling Equipment
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Bakermodel GBstring floatmaybe usedevery 500’
Foam Drilling Equipment
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Harold Vance Department of Petroleum Engineering
Recyclable FoamWeatherford TransFoam
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Harold Vance Department of Petroleum Engineering
Weatherford Transfoam
It is an amphoteric material -capable of reaction as either an
acid or base. A combination of two (or more)foaming agents that causefoam at a high pH and interfereand cause the foam to go flat ata low pH.
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Transfoam Applications
Environmental concern.
Space limitations.
Limited disposal options.
Transfoam
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Process DescriptionIntentional de-stabilization.
Decrease pH (10 to < 5)Foam immediately disappears.
Gas removal in separator.Liquid cleaning in shaker, cycloneand centrifuge.
Add make up foamer.Re-activation.
Increase pH
Si lifi d T f
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Simplified Transfoam
Foam/DeFoam/ReForm Cycle
Foam(100% Volume)
Liquidless than 5%
Foam
Activator
Foam(100% Volume)
+ Acid
Transfoam Recyclable Foam System
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Recovered SolutionReady for Reuse
Supplemental Defoamer Addition(if necessary)
Separator pH Signal to Control Acid Feed
Acid FeedCuttings
Blooie LineTo Air Pit
Separator
ShakerRecirculation
Line
P
pH Signal to Control Alkaline Feed
P AcidStorage
pH LimeHopper
Lime Feed
Mud Pits
Polymer Flocculant Addition if Necessary
Solids
Control
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Considerations
Limitless cycles.Make-up foamer requiredfor loss to formations andsolids.Water soluble, non-toxicadditions.
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Advantages
Cost EfficientLess Chemical UsedLess Make-up WaterLess Space
EnvironmentalOffshore
Less Disposal
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Advantages
Adaptable fluid. Any water base drilling mudcan be used.
Limitations
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Limitations
Acid environment.Corrosion ?
Good separator required.Defoamer possibly required. Availability.
Personnel.Equipment.
Canada
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Concord Unit-foam
A conventionalfoam used with
a defoamer.Foam is killedwith defoamer,
then rebuiltwith foamer.
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