section 6b

barite sag
section 6b Scomi Oiltools

introduction 2
barite sag fandamentals 2
key parameters 2
influencing factors 3
symptoms 3
awareness & planning 3
mud properties & testing 4
prevention 5
management of sag problems 5
monitoring 5
operational practices 6
Section

6b deviated drilling - hole cleaning

deviated drilling - barite sag

introduction
Barite sag is recognised as a significant hazard in deviated wells using both weighted oil and water
based drilling muds. Detailed research has been conducted into the underlying fundamentals
and key influencing factors causing barite sag. The following guidelines will detail how good planning
and job execution will ensure the drilling fluid does not allow barite sag.

barite sag fundamentals

Barite sag is the result of dynamic and / or static slumping of weight material in the annulus.
The majority of sag occurs under dynamic conditions in deviated wells.

Barite beds caused by dynamic sag tend to slump down the well during static periods, causing
density variations. Sag beds behave differently and have different characteristics to cuttings beds.
At low solids concentrations, settling occurs in a segregated way, whereas in dense concentrations
settling occurs block-wise at relatively low velocity. During sag, the denser, larger particles settle
first, causing the overlying fluid to be lighter and more buoyant. This reduces the settling velocity
of the smaller particles in the higher buoyed fluid over time.

Sag can occur in any well deviated by more than 30o. The effect is most pronounced in wells with
a deviation of between 60o and 75o. Sag beds formed at angles below 60o slump faster than those
at higher angles.

Sag can occur in any fluid type and at any density range where weight material is present. Generally,
the higher the density the greater the risk. Sag increases with time

Sag can occur dynamically where it is absent or minimal under static conditions.

Local settling at the top and low sides of the well during low-rate circulations and static periods
causes a pressure imbalance, forcing lighter mud upwards and accelerating the sag process, known as
the Boycott effect.

The 4 zones of barite sag beds are, from bottom to top, the slump bed, sediment bed, suspension
zone and clarified fluid zone.

Volume gains / losses can be induced by sag due to annular density variations.

key parameters
ƒ Hole Angle & Length
ƒ Annular Velocity
ƒ Drill Pipe Rotation
ƒ Flow Regime
ƒ Mud density
ƒ Mud Rheology
ƒ Weight Material
ƒ Particle Size & Shape
ƒ Particle Concentration
ƒ Time


influencing factors
ƒ Barite sag is principally controlled by dynamic flow.
ƒ Flow rate & drill pipe rotation are the most important drilling parameters which influence sag.
ƒ Low annular velocities induce sag, especially when the drill pipe is eccentric & not rotating.
ƒ Mud rheology is a key sag control mechanism.
ƒ Sag impacts upon critical wells with close pore pressure & fracture gradients.
ƒ High temperatures generally thin muds, increasing the sag potential of fluids.
ƒ Sag potential depends upon the mass of weight material.
ƒ Casing design impacts sag potential when small gauge holes coincide with large annular diameters
in the well, reducing the annular velocities in the broader zones.
ƒ The higher the O/W ratio of an oil mud, the greater the sag potential.
ƒ Over-treatment of wetting agents can thin fluids and increase sag potential.
ƒ Fluid loss reducers and other additives can reduce mud rheology and increase the sag potential.
ƒ In water base fluids, there is a greater potential for solids agglomeration of smaller particles.
ƒ Particle size distribution is a key determining factor.
ƒ Excessive solids control processing can increase sag potential by reducing particle size variations.

symptoms
Mud Weight Fluctuations
Any inexplicable variations in mud weights might indicate a sag problem. Heavy spots can often be
correlated with slugs pumped. Light spots are often the first indications of barite sag.

Stand Pipe Pressure Variations

Fluctuations can occur as light and heavy spots pass through the drill pipe and nozzles. Variations
can occur due to mud hydrostatic differentials and frictional pressure losses. These are often cyclic in
nature.

Increased torque & drag

Settled barite beds may increase torque and drag in a similar way to cuttings beds in deviated wells.

Mud losses and gains

Unexpected losses may occur when heavy spots reach the near-vertical section of the well, causing
increases in the fluid hydrostatic pressure. The opposite may occur, when light spots reduce the
hydrostatic, causing the well to flow.

awareness & planning

Awareness and planning are essential prerequisites to eliminating sag problems. Anticipate and
plan for potential barite sag in all deviated wells above 30o, especially for 60o - 75o wells.

Be aware that well planning, well type, well environment, well profile, casing design and hole size,
will directly influence the potential risk of sag.

Where necessary, conduct pre-well fluids testing to assess the potential for barite sag and
incorporate specific mud property and engineering guidelines in fluids programs. Program for, and
provide, the relevant additional fluids testing equipment and reporting guidelines for well site
engineers.

In ERD wells, recognise that constraining factors, such as the need to control ECD values and
SPP limitations, may restrict the ability to manipulate anti-sag mechanisms such as rheology
adjustments and flow rates.


Section

6b deviated drilling - hole cleaning

Recognise that barite sag beds are different from cuttings beds in their behaviour and that sag
beds may be readily dispersed by correct application of flow rates and rotary.

mud properties & testing

rheology
• Primary Mechanisms
The primary mud property control mechanism for barite sag is manipulation of the low shear rheology,
Fann 6 and 3 rpm values, for dynamic sag and the initial 10 sec gel strength for control of static sag.
Well-bore temperatures affect rheology and well-site measurements need to properly account for the
effects of bore hole temperatures on rheology.

• Low Shear Rheology

Elevating the low shear rheology and establishing the correct relationship between these two
variables is a proven mud control mechanism for eliminating dynamic sag. A rheology value known
as the Low Shear Rate Yield Point (LSRYP), obtained by the formula 2 x 3 rpm – 6 rpm, may be used
to measure the fluid sag-control condition. In general, LSRYP values in the range 7 - 15 lb/100ft2 have
been shown to eliminate sag but the optimum range of LSRYP values for a specific fluid should be
arrived at by experience.

• Gel Strengths
The 10 sec gel strength should be high enough to deter static sag. Values below 7 have been shown
to result in greatly increased static sag potential. Again, testing and field experience will indicate
the correct range of values for a specific fluid. The 10 min & 30 min gels do not form sag control
mechanisms.

• Temperature Effects
Higher temperatures thin muds and generally lower the rheology, especially oil base systems.
Rheology measurements need to account for temperature effects.

mud weight
Mud weight measurements are a key area for monitoring sag. To ensure accuracy, measurements
should be taken frequently, especially after trips, using a pressurised mud balance, which should be
regularly calibrated.

Plotting mud weights against other variables such as time and SPP can often reveal cyclic and other
trends in sag behaviour.

oil / water ratio

Increasing the O/W ratio tends to thin oil based muds and increase the sag potential or sag
rate. Increasing the low shear rate modifier concentration will help combat this problem.

particle size distribution

Particle size variations are beneficial in deterring sag. Conversely, uniformity of particle size
encourages sag. Measurement of the particle size distribution and other particle properties helps
to understand sag problems and provides information that may be used correctively.

sag testing
Various apparatus exist for sag measurement for use on high temperature ERD wells. It may be
prudent to provide well-site sag testing apparatus such as this for critical wells, where the results
can then be used as a guide to treatments.


prevention
ƒ Ensure that adequate pre-well fluid testing has been conducted and that the sag potential of the
fluid has been identified.
ƒ Avoid using old fluid that has been identified as problematical. If using an old fluid, ensure that it
has been properly re-conditioned and contains as broad a spectrum of particle sizes as practicable.
ƒ Ensure that the fluid has a sufficient LSRYP to deter sag and that the LSRYP is maintained within
the desired range.
ƒ Ensure that all organophilic clays are exposed to high temperature and pressure shear. This
is important for them to achieve full yield and therefore effectiveness. This type of shear is
usually accomplished either by a special HTHP surface shear system or by circulating through the
bit.
ƒ Maintain the 10 sec gel strength within the desired range and avoid low static barite sag.
ƒ Avoid excessive dilutions, which lower rheological values and encourage sag.
ƒ Avoid excessive solids control techniques, which degrade the solids and reduce the particle
size variation. Where protracted centrifuging is necessary to control LGS, replenish the fluid with
fresh weight material and suspension agents.
ƒ Maintain an adequate concentration of low shear rate (LSR) modifier, i.e. premium grade clay,
especially when diluting.
ƒ Avoid using low shear rate (LSR) liquid rheology modifiers, which have been shown to be less
effective sag control mechanisms than solids.
ƒ Levels of surfactant or oil wetting agent must be sufficient to prevent barite agglomeration into large
clusters.
ƒ Avoid increases in the O/W ratio unless specifically required to reduce or minimise pump
pressures.
ƒ Avoid over thinning fluids prior to running casing and preferably do not thin until casing has been
run.
ƒ Ensure that the fluid is in condition prior to any extended low-shear operations such as running
casing or logging.
ƒ Maintain strict QC testing of weight materials, LSR modifier, LSR liquid rheology modifiers and
suspension agents.
ƒ Avoid over-treating with additives and surfactants which are known to encourage sag.
ƒ Avoid prolonged periods of non-rotational slow circulation, especially where annular velocities
in critical deviated intervals fall below 50 ft/min.
ƒ Regularly calibrate mud testing equipment and use a pressure balance to measure the fluid
density.
ƒ Periodically conduct particle size analysis in order to provide a early warning of impending sag.
ƒ The use of sub API grade (325 mesh) barite has proven beneficial.

management of sag problems

Sometimes, it is not possible to prevent a sag problem. Therefore, it is necessary to manage it. Success or
failure will be governed by the well conditions and by well-site actions.

monitoring
It is important to monitor the variables appropriately in order to be able to determine if there is a
problem and to judge the effectiveness or otherwise of any remedial actions.

Mud Weights – Monitor mud weights closely and ensure that a pressure balance is used for accuracy.
Plot graphs of mud weight against other variables to determine any cyclic behaviour.

Stand Pipe Pressure – Monitor the SPP and record any unexplainable fluctuations. Fluctuations
could be caused by density variations inside the drill string, barite beds leading to slumping and
partial pack-off or density variations in the well resulting in U-tubing differentials.


Section

6b deviated drilling - hole cleaning

Torque & Drag – High torque and drag may indicate the presence of a barite sag bed. Remember
that, unlike cuttings beds, sag beds behave as liquids and flow down the well bore.

Volumes – Monitor volumes closely. Barite sag can become a well-control problem, caused by density
variations in the upper near-vertical annulus, leading to down-hole losses and gains.

operational practices

Circulating & Conditioning - If barite sag is observed, attempt to remedy by stopping operations
to circulate and condition the fluid for as long as necessary. Ensure sufficient circulating time to allow
for any rheology modifications to be effective and to balance out any density variations. Premium
grade clay viscosifiers, e.g. CONFI-GEL HT, require both shear and temperature to fully develop the
rheology. If there is no impediment, ensure maximum annular velocity and rotary during circulations.

Adjusting the LSRYP – Where possible, adjust the LSRYP to a higher value by additions of low shear
rate modifiers and allow time for treatments to be effective.

Rotary Vs Sliding – Sag is greater when the pipe is stationary and otationis a proven deterrent
mechanism. If slide drilling, especially on ERD wells with angles between 60˚ and 75˚, attempt to
compensate with high annular velocities. Supplement this technique where necessary by pulling back
one stand and rotating at high speed, especially after prolonged periods of slide drilling. Design the
BHA for this contingency.

Trips – Recognise that sag increases with time. Consider rotary wiper trips to stir up barite beds
and consider staging into the well following trips and static periods in order to minimise the effect
of reintroducing settled weight material into the system.

Additional Mud Testing - Determine if there are additional tests, site or shore-based, or mud
testing methods that may help to indicate the way to reduce or even eliminate the sag problem.

fine grind weight materials

Traditional weight materials used for high density fluids are primarily API barite and occasionally
haematite. Recently interest has been growing in the use of specialty materials including fine grind
barite (HyPR-BAR) and manganese tetraoxide (HYDRO-MAX). These fine grind materials do not readily
settle or sag but support the formulation of reduced viscosity high density fluids which allow lower ECD
values in critical wells.

HyPR-BAR is an economical non API sub-400 mesh barite which typically exceeds API quality
specifications for mineral quality. HyPR-BAR is specifically ground for formulation and maintenance
of drilling fluids in which ‘barite sag’ is virtually eliminated in all fluid types and densities. HyPR-BAR
with its inherently low contribution to viscosity provides a solution for wells with narrow mud density
windows.

HyPR-BAR is useful for the design of economical reservoir drill in fluids which readily flow back
through and are non-damaging to production screens. This characteristic also allows use of up to API
325 mesh screens on surface equipment. Drilled solids build up is greatly reduced, dilution may be
reduced by up to 75%, and reduction in overall mud cost can more than compensate for the modest
increase in cost of this material.


HyPR-BAR grind size is in the range of:
D10 1 - 3μ
D50 7 - 12μ
D90 27 – 32μ
Maximum 3% > 44μ
(as measured with Malvern PSA)

Compared with API barite:

D10 2 – 4μ
D50 18 – 25μ
D90 60 – 68μ
Maximum 3% > 74μ
(as measured with Malvern PSA)

HYDRO-MAX, average particle size of about 1 micron, is a high purity precipitated manganese
tetraoxide. The density of 4.8 SG is superior to that of the highest quality barite available. High density
fluids formulated with HYDRO-MAX have lower solids content than conventional barite systems. Lower
solids content generally allows improved (lower) rheological properties, with potential improvement in
filtration control, and typically higher penetration rate.

Note: As with all critical wells and applications, fluids using these products
should be formulated and tested before being used in the field.