Petroleum Development Oman

Total Drilling Fluid Management Program

for Tawf Dahm-3 (D) Deep Vertical Gas Exploration Well
Version 0.0 Draft
Location Tawf Dahm-3 (D)
Well No Tawf Dahm-3 (D)
Type of Well: Deep Vertical Gas Exploration Well
Rig No 92
UIK21-Anwar Date 18th-August-2015
CONTENTS
S.No SUBJECT Page No
A DRILLING FLUID,CEMENT AND COMPLETION
PROGRAMME

1.0 Well Design and Mud Properties

2.0 Mud System
2.1 23” Hole
2.2 16” Hole
2.3 12 1/4” Hole
2.4 8 3/8” Hole

3.0 Cementing
4.0 Packer Fluid & Completion Brine program
5.0 Reporting
6.0 Acknowledgement

B APPENDICES

1.0 Preparation of pre-hydrated bentonite gel (PHB)

2.0 Hole cleaning
3.0 Lost circulation
4.0 Solids control equipment
5.0 Contingency chemicals
6.0 Stuck pipe
7.0 Ground rules and self-appraisal for mud engineers
8.0 Bit balling
9.0 LTOBM waste disposal
10.0 Foaming problems

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 1. WELL DESIGN AND MUD PROPERTIES

A) OBJECTIVE:
The main objective of Tawf Dahm-3 (D) is to drill a Vertical Gas Exploration well to:
1. To appraise Tawf Dahm-1H1 gas discovery in Al Khlata and Lower Gharif base sands.
2. To test for hydrocarbon presence in deeper Barik and Miqrat reservoirs.
3. Primary target reservoirs are Lower Gharif Basal sands and Al khlata and secondary target
reservoirs are Barik and Miqrat
4. Complete the well and test the reservoir capability to produce with sustained commercially
attractive flow rates.
5. Keep the well to become a long-term producer.

This well will be drilled with Inhibitive WBM & OBM systems from the surface-hole section through
the reservoir section. The mud systems have been designed to overcome the key drilling problems
encountered in the field, listed as follows:
 Losses Management in the Surface Hole Fars, UeR - and in the Natih, Shuiba and Khuff
formation (12 1/4-inch open hole).
 Shale Stability Management in the Fiqa Shargi, Nahr Umr and Gharif shale formation
 Hole-Cleaning Efficiency to prevent bit balling in the Fiqa, induced losses in the Natih,Shuaiba
and Khuff formation and excessive reaming while drilling in the deeper reservoir-hole section.
B) CSG POLICY: Tawf Dahm-3 (D) is planned to be drilled as follows.
HOLE VETICAL/ CSG/LINER SHOE AT
DEPTH RANGE (M)
SIZE(INCH) DEVIATED DEPTH(M),Formation
23” Vertical Surface to ±612 (10-15 m inside Arada) 18 5/8” Csg inside Fiqa Arada

16 Vertical ± 612 to ±1,481 m (20 m inside shuaiba) 13 3/8 Csg at ± 20 into Shuaiba

12 1/4 Vertical ± 1,481 to ±3,296 m (20 m inside Upper Gharif) 9 5/8” Csg at ±20 into Upper Gharif
5 ½” X 4 ½” Tapered Cemented
8 3/8 Vertical ± 3,296 to ±5,150 m (50 m inside Amin)
Completion tbg into Amin

B) SUMMARY OF MUD PROPERTIES

Hole Size 23” 16” 12 ¼” 8 3/8”

Mud # Mud #1 Mud #2 Mud #3 Mud #4
Mud type PHB/ Muddy Versa Clean Simple Salt, Starch& XCD Versa Clean
Water OBM weighted up with CaCO3 OBM
Mud Weight kPa/m ALAP 11.5-11.8 11.4 - 11.6 11.6-12.0
API Fluid Loss ml N/C NA <5 NA
HPHT at BHST N/A <3 N/A <3
YP         Pa (Mud ) >20 9-14 12-15 9-13
YP Pa (Hi Vis) >35 (PHB) 23-28 21-25 18-22
6 RPM N/A 8-12 8-13 7-10
K+ g/l N/A N/A N/A N/A
KCl Kg/m3 N/A N/A N/A N/A
Cl- Kg/m3 N/A N/A As high as possible (80 < Cl-< N/A
160)
pH 9 - 9.5 N/A 8.5-9.0 N/A
% LGS ALAP <5 <5 <5
Deviation 00 00 00 00
Oil water ratio N/A 70/30 –75/25 N/A 70/30 –80/20
Cl- WPS Kg/m3 N/A >230 N/A >230
Electrical stability volts N/A >600 N/A >600
Excess Lime Kg/m3 N/A >10 N/A >10
Remarks Increase the Use Wellbore Strengthening
mud weight as materials in Appendix 3. Increase
per the hole the mud weight as per the hole
condition. condition.

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 2. General Instructions & Precautions to Mud Engineer

1) This TFM contains latest learnings from Al Bashair & Deep Gas Development and Exploration Wells.
2) Test the WSW for Chlorides, Calcium and Magnesium and report on the first mud report.
3) A sample of the WSW should also be tested for sulphate - contact UIK 21
4) Use RO water to prepare fresh mud rather than preparing with WSW which has high hardness. This
will help in better yield of the polymers.
5) Any WSW used in to displace well for inflow test, completion etc. must be treated to reduce the
Calcium to less than 100 ppm and also be treated with 200 mg/l KT-170 scale inhibitor.
6) Ensure availability of all chemicals including contingency chemicals (before Spud) especially Barites at
least 80 Sx.
7) Mud Balance to be Calibrated Every Day. Pressurised Mud Balance to be used for checking mud
weight.
8) See that all Solids control equipment are functional before spudding. Use Solids control equipment
effectively.
9) Change the shaker screens in time rather than leaving for somebody else.
10) Rig up centrifuge during spudding and call for the operator in time.
11) See that the degasser is in working condition always. Test every day for half an hour
12) Avoid unnecessary dumping of mud through sand trap, during cementing etc..
13) Decrease the dead volume in the tanks.
14) Send the Critical Mud properties graph every day.
15) Send updated Excel EOWR report to UIK 21 every week on Saturday evening.
16) Please do not go by general conventions like earlier it was done so we need to do rather think why you
should do it and avoid it if it is not required.
17) The mud properties given are only general guidelines and you need to use your intelligence and
experience to prepare and maintain the mud. Where ever it is possible you need to try to decrease the
unnecessary costs in the system.
18) Always prevention is better than cure, hence keep the mud in good condition always so that your mud
maintenance costs will come down.
19) Order chemicals judiciously as per plan.
20) Avoid damage of the chemicals by forklift or due to improper handling. Cover them properly. You know
damaged chemical cost is 5-10% in PDO which can be avoided.
21) Have good communication between Mud Engineers and mud tester’s relievers and other important rig
team like floor man, AD, Driller etc.
22) Have good communication with UIK Desk Engineer and discuss about the progress of lean time to
time.
23) Keep stocking OBM for the the 12 ¼” section (Will be drilled using Oil Based Mud) as
the first two sections are drilled very fast.
24) The 12 ¼” hole sections involves change out from WBM to OBM. Displace the 13 3/8” casing cement
jobs with 5 m3 fresh water and WSW to allow easy switch (easy rig down/ up between the OBM cutting
box gear to WBM shoot line gear) for the next section as well easy clean of mud tanks offline.

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 3. Mud Systems

3.1. 23” Vertical Hole Depth Surface to ± 612 m

A) Mud System

This section is to be drilled using Muddy Water / PHB Hi Vis Sweeps up to top of Fiqa Arada.

B) Basis of Design

As partial to total losses are expected in this section in Fars and UeR it is economical to drill with
WSW and use Prehydrated Hi Viscous Bentonite (PHB) gel sweeps for hole cleaning up to top of
Fiqa Arada. Also the bentonite gel will help in sealing the loss zones (so pump every connection of
6-8 m3 sweeps, as it was seen effective to prevent losses in some wells in North). As Fiqa Shargi is
problematic time dependent shale it is recommended to spot mud before POOH.

C) Mud Parameters for 23" Vertical Hole (Up to Shammar)

Mud Parameter Comments

Mud type PHB/ Muddy Good WSW management is very much essential for
Water successful drilling of this section.
Mud Weight kPa/m ALAP Keep diluting the mud with fresh WSW and dump Sand
trap frequently.
API Fluid Loss ml N/C Do not use any Fluid loss reducing additives.
YP Pa >35 YP of PHB Hi Vis pills to be pumped (>35-45 Pa). Use
XC polymer if required to get the Viscosity.
6 RPM N/A
pH 9 - 9.5 p H of the PHB
% LGS ALAP Run all Solids control equipment
Deviation 0 Vertical

D) Section formations:
Surface Sediments (Taqa), Dammam, Rus, UeR (U,M), UeR Shammar, Fiqa Arada

S. Formation Dept Main Characteristics MW (kPa/m) YP(Pa) Remarks

No h
1 Surface 0-36 ALAP >35 (PHB)
Sediments
2 Dammam ±36 ALAP >35 (PHB)
3 Rus ±81 ALAP >35 (PHB)
4 UER ±413 Lime Stone ALAP >35 (PHB) Seepage to total losses
5 UeR Shammar ±586 ALAP >35 (PHB)
6 Fiqa Arada ±597 Shale / Limestone ALAP >35 (PHB) Fiqa collapse

E) Approx. Concentration, Consumption and Cost of Chemicals

S. No Chemical Conc. (Kg/m3 ) Remarks

1 Bentonite 80-120 Use Fresh water or WSW with less salinity (NaCl < 3.0 kg/m3)
2 Caustic Soda 1.0-2.5 kg/m3 Conc. depends on pH

F) Potential Problems and Solutions:

 Hole-cleaning – Pump Hi Viscous PHB pills at regular intervals. See Appendix for further details.
 Partial to total losses– the casing will be set in Arada.: drill and / or use LCM.

G) Salient Points of the Mud program.

1) OBM for 16” section

Keep stocking OBM for the next section as this section is drilled very fast (the 12 ¼” will
be drilled using Oil Based Mud).

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2) Preparation of Bentonite gel
See Appendix

3) Well Site Water (WSW)

Good Well Site Water Management is very much essential for successful drilling of this section
as partial to total losses may occur.

4) Spudding
Spud the well with Bentonite gel. As drilling further continues add WSW to the system to
maintain Mud Weight as low as possible to avoid losses. As drilling progresses further due to the
Hi Viscous pills pumped and clay coming from formation, the system becomes muddy water,
Viscosity & weight increases. Try to maintain the mud weight as low as possible by adding water
to the system (but maintain an overall Bentonite concentration of 21-28 kg/m3)
Keep the Cellar pumps in good condition to pump the return fluid from cellar. Keep one additional
cellar pump standby.

5) Mud Weight
Maintain mud weight as low as possible.
Try to maintain mud weight as low as possible keeping in view having enough margin between
the cement slurry weight and mud weight. This will help in achieving good CBL.

6) Dump and Dilute

Always dump the sand trap frequently and add fresh WSW to the system while drilling with
WSW/PHB so that the MW can be maintained as low as possible which will help in avoiding
losses and increase in ROP. Bit balling can also be avoided as the clay streaks being drilled will
disperse easily in to fresh WSW. Fairly high dilution rates of 2-4 m3/hr is recommended.

7) Partial to total losses

There is every possibility of seepage to total losses in Fars ( Approx 60-80 m). Sometimes these
losses can be cured by the drilled cuttings. If the losses are above 10 m3/hr, LCM Pill may be
pumped to cure losses. These LCM pills can be pumped as a spot, on fly as drilling progress, or
ahead of cement if cement plug or during the 18 5/8” cementation ahead of cement slurry to
have some bridging. If total losses occur it is better to cure with cement plugs rather than trying
with LCM Pills.

LCM Pill for curing Losses @ Top Hole.

Other SAP # Moderate loss Severe Losses
Chemical Unit
name (5-10 m3/hr) (>10m3/hr)
70-90 kg/m3 70-90 kg/m3
PHB
(YP=22-28) (YP=22-28)
CaCO3 - 10 micron   1001129965 500 kg 50 kg/m3 25 kg/m3
CaCO3 - 25 micron   1001129964 500 kg 50 kg/m3 25 kg/m3
CaCO3 Fine 1001129879 500 kg 50 kg/m3 25 kg/m3
CaCO3 Medium 1001129962 500 kg 50 kg/m3 75 kg/m3
CaCO3 Coarse 1001129963 500 kg 50 kg/m3 100 kg/m3
Mica Fine 1000064969 25 kg 50 kg/m3 40 kg/m3
Mica Coarse 1000064970 25 kg 30 kg/m3 40 kg/m3
Resilient Graphitic Rebound
40 kg/m3
Carbon (Rebound) 1000755925 25 kg 30 kg/m3
Cellulose LCM Dynared/
30 kg/m3 40 kg/m3
(Dynared/Barofibre) Barofibre 1000755926 25 kg

8) Yield Point
Up to inside UeR pump Hi Viscous prehydrated bentonite gel pills (YP > 35 Pa) at regular
intervals to keep hole clean.

9) Hi Vis Pills
Use Pre Hydrated Bentonite pills as Hi Vis pills(YP>35 Pa) at regular intervals to keep hole
clean. So pump every connection of 4-8 m3 Hi Vis sweeps, as it was seen effective to
prevent/minimize losses in some wells in North.

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 They should be pumped depending on the Hole Condition, ROP, and the cuttings recovered with
the previous Hi Vis pill pumped.

While @ Bottom pump 10 m3 of Hi Vis pill (YP>35 Pa) so that the hole will be clean by the time
TD is reached.

10) ROP
Controlled drilling will help in avoiding losses. Up to UeR it is better to control ROP at 10-15 m/hr.

11) Solids Control Equipment

Run Desander, Desilter and Centrifuge continuously so that Mud Weight can be maintained as
low as possible. Ensure that Shale Shakers are not bypassed.
Use coarser screens (40 API) to start with and once the mud is sheared increase up to 120 API.
See Appendix for further details.

12) ECD Values

Always monitor the ECD value and adjust the Mud Weight accordingly. If any losses are
observed you may decrease the MW accordingly.

13) Bit Balling

Good bit hydraulics are necessary to minimize bit balling , experience from the past wells
showed a HSI of at least 3.0 is recommended, No freshwater pills are to be pumped - brine with
starch only(350 kg/m3 NaCl with 12 kg/m3 Starch). Dump the pill when it reaches surface

14) Section TD

After reaching TD sweep hole with two Bentonite Hi Vis pill of 7-9 m3 each of YP of 35 Pa
to help clean the wellbore of any accumulated cuttings and or cavings. Spot a weighted
Saline XC Polymer Hi Viscous pill of 13.8 kPa/m at bottom covering up to top of the loss
zone ( if any) or 150-200 meter from the Bottom of the section (if no losses) before POOH
to assist with casing running:

Inhibitive Saline XC Polymer Hi Viscous pill at bottom

Required Fresh Water and WSW

Soda Ash 1.0-2.0 kg/m³
Caustic 1.0-2.0 kg/m³
KCl 70 kg/m³
NaCl 250 kg/m³
Starch 16-20 kg/m³ to get fluid loss of less than 3.5 cc/30 min.
XCD Polymer 3-4 kg/m³ to get YP of 14-16 Pa.
CaCO3 To get the required weight of 13.8 kPa/m.
XCD Polymer 3-4 kg/m³ to get YP of 35-40 Pa.

During the cement job it is better to displace with few m3 of fresh water followed
by WSW.

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 3.2. 16” Vertical Hole Depth ± 612 to ± 1,481 m

A) Basis of Design

As this section will be drilled through lengthy reactive Fiqa shale, it is recommended to have the
use Oil Base Mud (Versa Clean LT OBM) contingency mud ready for deployment in this section to
improve the rate of penetration, performance and shale inhibition.

B) General Precautions

1. Ensure that sufficient notice is given to MI Swaco at the start of the previous section for calling
out the OBM of required weight. Make sure MI Swaco sends a plan detailing tank and OBM
delivery Contact the Well engineer and UIK for support if required. Initially minimum of 200-250
m3 of OBM and 30 m3 of Base Oil is required.

2. The mineral oil being used is EDC 95-11 (SHOC card S123). It has the following advantages:
A) It contains less than 1% (average 0.1%) aromatics compared to diesel at 30-50%.
B) It is the aromatic compounds, which are most dangerous in diesel.
C) It is less volatile than diesel so there should be less vapour emissions. It also has a low
odour.

C) Mud Parameters for 16” Deviated Hole

Mud Parameter Specification Comments

Mud type Versaclean LTOBM

Mud weight kPa/m 11.5 – 11.8 Increase the mud weight as per the hole
condition.
HP-HT Fluid Loss ml <3 Filtrate must be all oil
at 121°C
PV < 30 ALAP, Use thermo cup at 500C
YP Pa 9 -14 Use thermo cup at 500C
YP Pa 23-28 ( for HiVis) For Hi Vis for hole cleaning, & weighted
some time if required.
Oil water ratio 70/30
6 RPM 8-12 Use thermo cup at 500C
30 minute gel Pa < 18 Use thermo cup at 500C
Cl- WPS Kg/m3 >230-240 (mainly all the Use Calcium Chloride
time)
Electrical stability volts > 600 Minimum ES to start drilling with is of ES 300
to 350 volts (with HPHT fluid loss of no
water-only oil of less than 3 cc/30 min @
121°C), but to treat & maintain better ES
while drilling to > 600 volts.
Excess Lime Kg/m3 > 10
% LGS ALAP< 5 % Optimise SCE to minimise LGS < 5 %
Deviation 0 0
NOTE: The properties specified above are to be maintained during drilling operations.

Call Out Mud Properties:

The below mud properties will be used for the OBM call out, mud will be treated and the
above properties will be achieved during drilling operations.

Mud Weight = 11.3 – 11.6 kPa/m

Oil /Water ratio = 70/30
Electrical Stability = 300 – 350 volts
 MI LLC will endeavour to deliver OBM with mud weight close to that specified in
the callout. In case that the mud weight of the OBM delivered is lower than the callout,
PDO will supply the weighting material (barite) to achieve the mud weight. In an event if

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 the delivered MW is higher than the call out, mud dilution and stripping of solids & weight
material by centrifuging will be done prior to displacement.
 The 300 – 350 volts electrical stability value is for the fresh and partially sheared
mud. This value will slowly increase to ~500 volts once the mud is circulated into the hole
during the initial stages of drilling with normal treatment of chemicals.

D) Sections formations:
Fiqa Arada, Fiqa Shargi, Natih (A/B, C, D, E, F & G), NahrUmr & Shuaiba.

S. No Formation Main Characteristics (SHALE, Remarks

LIMESTONE, SILT ETC)
1 Fiqa Arada Shale/Limestone Lime stone with streaks of shale
Figa Sharji Shale
Natih Limestone/Shale Lime stone with streaks of shale
Nahr Umr Shale
Shuaiba

E) Potential Problems/Hazards
 Unstable Fiqa Shale
 Differential sticking
 Washing down while CSG Running in hole
 Losses in the Natih and/or Shuaiba

F) Salient Points Of The Mud Programme

1. Displacement of WBM with OBM

Plan to drill out the shoe and cement with the OBM which will give some time to get the
properties into specification. Otherwise there could be excessive invisible loss time
associated with circulating and conditioning the mud. Drill out any ratty cement above the
float collar with WSW and pump a 8 m 3 viscous WBM sweep to clean the hole of debris.
After the sweep has returned at surface pump a 10 m 3 CaCl2 brine spacer followed by the
OBM mud.

Prior to displacement, it is imperative that the checklist for rig modifications is complete.
Particularly important is that the dump valves are properly sealed & secured & that ALL
water sources to the tanks are locked off. Have toolbox meeting with crew prior to
displacement.

 The tank set needs to be reasonably clean before VCM is put in it - reasonably
clean means no solids build up in e.g. pit corners & sufficiently clean to prevent
contamination of the VCM - it does not need to be spotless. Call out a Vacuum tanker to
remove WBM left in the tanks.

 Pump at maximum flow rate and DO NOT stop until displacement is complete:
 Pump 10 m³ Saturated Ca Cl2 brine.
 Follow with OBM.

 Incorporate initial, uncontaminated, brine spacer into WBM & dump.

 Incorporate oil contaminated water into OBM.
 Use coarse (approx 50 API) screens on shakers to prevent blinding with water wet
solids. Depending upon how good the hole-cleaning has been and how effective the
displacement, there will probably be a lot of solids and highly viscous WBM returned. Be
prepared to slow down the pumps at this stage to prevent overflow. 140*70*70/140*80*70
 Change screens after OBM is displaced & rheology is acceptable for running fine
screens.

2. MUD WEIGHT
Start this section with 11.5 kPa/m mud weight and increase gradually to 11.8 kPa/m at TD.
Use Barite for increasing weight. Use Weighted Hi-Vis pills for good hole cleaning.
If the Mud Weight need to be increased more than 11.8 kPa/m due to some reason or
the other contact the base (Operation Engineer) or UIK21 ( Anwar).

3. OIL WATER RATIO

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 Maintain oil water ratio, in the range of 70/30, preferably closer to 70/30 to minimize base
oil consumption.
Check the Oil Water ratio after taking the OBM in to Active tank and check the Oil
Water Ratio and if it is not within specifications inform MI, DS and UIK. Treat it to
the specifications.

4. Hole-Cleaning : See Appendix

Pump hivis pills with YP > 23 Pa as and when required. If still hole cleaning is not good,
pump weighted hi-vis pill of 15-16 kPa/m.

5. RHEOLOGY
Yield Point: Maintain Yield Point between 9-14 Pa. If the hole cleaning is not good YP may
be increased. Higher the YP circulating pressure will be high. Hence check the circulating
pressures while increasing YP.

Low End Rheology: Low end rheology is very much important in build up section as the
cuttings tend to settle at lower side. Maintain Low End rheology as per specification.

Plastic Viscosity : Run centrifuge to maximum capacity, use maximum possible fine
screens on shale shakers to maintain the PV as low as possible (30 CP). Use 200-240
API screens.

6. Cuttings Volume
As the cuttings are dumped into skips it should be possible to estimate whether correct
amount of cuttings are being removed or not. For 16" hole calculate the theoretical amount
of cuttings to be produced per metre drilled. Measure the cuttings volume, monitor the
recovery percentage, and take appropriate action of pumping tandem pills and report in the
daily report.

7. HPHT Fluid Loss

Maintain the HPHT <3 ml. Use Versatrol to control fluid loss if required. The natural tight
emulsion should provide sufficient fluid loss control on its own. The HPHT filtrate should
be all oil. If there is slightest indication of water or emulsion in the filtrate there is a lack of
emulsion stability. This must be treated at once with VersaSurf.

8. Excess Lime

Maintain Excess Lime at >10 kg/m3.

9. Emulsion Stability

Maintain Emulsion stability >600 Volts.

10. Water Phase Salinity

Maintain WPS around >230-240g/l by using Calcium Chloride.

N.B. Oil Base Mud take some time to shear fully to get maximum yield.

11. Formation Losses

There is a chance to get losses. Hence extra care should be taken as OBM is costly.
Pre-treat the mud with 25-40 kg/m 3 each of CaCO3 (10 mic) and CaCO 3 (25 mic) &
CaCO3 fine to avoid losses (while drilling). Still if losses occur the concentration may be
increased. See Appendix 3 for curing losses.
If losses persist at 10m³/hr. or greater or total losses reach 100 m³ then the well
should be displaced to an inhibited XC Polymer WBM after consulting the
base.

12. Surface Losses

Potential sources of surface mud losses, additional to the mud adsorbed on cuttings, are:

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  improperly operated shale shakers;
 losses over the shakers during initial circulation of cold mud;
 dumping of sand traps
 dumping of contaminated spacers;
 Accidental opening of valves, overflowing of pits and inadequate equipment to
handle oil based mud.
 Unaccountable losses may be reduced by proper house-keeping procedures.

13. Solids control:

 Initially run API 50 screens on all shakers as the VCM will be cold and fairly
viscous. Afterwards, the shakers should be dressed with the finest screens
possible, min API 100-170 screens. For trips, ensure one shaker has API 50
screens on to compensate for cold/viscous mud, to prevent overflow. Depending
on the shakers and if possible the top or rear screens should be pyramid &
the front 2 screens, flat panel. The flat panel screens will provide better
cuttings drying.

 The centrifuge should be run to minimise LGS build up as required. RPM's should
be run as high as possible (>2800) to minimise OOC and wet, expensive
discharges.

 Until and unless it is very much required do not run Desander and desilter as there
is a chance of OBM to leak through gland packing’s cones etc.

14. Daily oil-on-cuttings measurements are required.

Use the spreadsheet provided by PDO & report OOC for both the shakers & the
centrifuges. The OOC should be reported in gm/kg. The expected average oil-on-cuttings
should not exceed 100 gm/kg if the Accuracy check % is > 5 it means that the data used is
not correct, the Accuracy check must be < 5 % to be accurate. With a 70/30 ratio instead of
a 80/20 ratio the OOC (oil on cuttings) value should be less than normally seen while
drilling.

15. Mud before cementing:

After reaching TD Prior to POOH drilling assembly increase the mud weight in consultation
with base to around 11.8 kPa/m ( To counter ECD) and after RIH casing to bottom during
circulation lower the YP (for better displacement while cementing). Use Versathin and
Base oil for this purpose.

16. Other Precautions

 When starting to circulate, kick in the pumps very slowly and gently increase the pump
rate to avoid inducing losses after the mud has been stationary for some time. Gels
quickly build up once the mud has been left stationary for some time and high ECDs
can induce downhole losses.
 Have good communication with rig team, If you are in doubt call UIK 21 (Anwar) Or
Operation Well Engineer.

17. Other Precautions

 When starting to circulate, kick in the pumps very slowly and gently increase the
pump rate to avoid inducing losses after the mud has been stationary for some
time. Gels quickly build up once the mud has been left stationary for some time
and high ECDs can induce downhole losses.
 Have good communication with rig team, If you are in doubt call UIK 21 (Anwar) Or
Operation Well Engineer.
 While RIH casing break circulation or gels every 300-400 meters for 10-15
minutes.

During the cement job it is better to displace with 5- 7 m3 fresh water followed by
WSW. To allow better OBM displacement out of the well and clean up mud tanks
to receive the WBM for next section.

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 3.3. 12 1/4” Vertical Hole Depth ± 1,481 to +3,296 m

This section is to be drilled using Simple Salt, Starch& XCD and weighted up with CaCO3.

A) Basis of Design:

In this section and as per seen in Hole #1 of Jerian-2 with OBM in Jubaila formation that losses were
encountered in many different formation. Wellbore strengthening is required (as per Appendix-3) right after from
the beginning of drilling through this section. Losses management is essential to continue drilling this section.
Therefore the section will be drilled initially with Simple Salt, Starch& XCD and weighted up with CaCO3.

Sodium Chloride is to be used as much as possible to maintain low solids mud and inhibition and with mind to
control the losses some CaCO3 should be in the system. Starch/HT Starch and PAC used as fluid loss reducing
additives.

Inhibition is not required while drilling until losses is managed (once in lower khuff losses should be managed).
Once in lower Khuff Inhibition can be increased using Soltex, PHPA and KCl (only if sever hole condition). At
the TD spot a Weighted Hi Vis (at 25 Pa) Pill (at 2.0 kPa/m more than the mud weight) at the bottom to
cover to top of lower Khuff (use 3% Polyamine(if available and based on hole condition of the wiper trip)
+ 10% KCl + 25 kg/m3 Soltex +3-6 kg/m3 PHPA) .

Sulphonated Asphalt (Soltex, CORTSAS etc) for Shale stabilization, KCl for Shale inhibition and PHPA for Shale
encapsulation.

B) Mud Parameters for 12 1/4” Hole

Mud Parameter Specification Comments

Mud type Simple Salt, Starch& XCD and IF required Soltex & PHPA will be
weighted up with CaCO3 added after controlling the losses.
KCl also can be added if sever hole
stability problems were encountered.
Mud Weight kPa/m 11.4-11.6 Keep the mud weight as low as
possible.
Adjust according to hole condition.
Observe for cavings while drilling.
API Fluid Loss ml <5 Use Drilling Starch
YP Pa 12-15 If hole cleaning is not adequate
increase YP.
6 RPM 7-10 Attempt to maintain Z value above 4
K+ g/l N/A Not required. Only if sever hole
problems might be added. K+
required at that time is 40-45 kg/m3
or 9% KCl.
Cl- Kg/m3 80-160 Chlorides due to NaCl.
pH 8.5-9.0 Use Caustic Soda
LGS % <5 Run all SCE effectively to maintain
LGS<5 %
Deviation 00 Vertical

11
 C) Section formations:

Shuaiba, Kharaib, Lekhwair, Habshan, Jubalia, Hanifa, Tuwaiq, Dhruma, Mafraq, Sudair, Khuff, and Upper
Ghariff.

S.No Formation Main Characteristics MW YP Remarks

kPa/m Pa
1 Lekhwair Lime Stone/Dlomite 11.4 12-13 Minor losses
2 Habshan Lime Stone 11.4 12-13 Minor losses
3 Jubaila 11.4 12-13 Modrate to Total Losses
4 Hanifa 11.4 12-13
5 Tuwaiq Mountain 11.4 12-13
6 Dhruma Lime Stone/Shale 11.4 13-14 Minor losses
7 Mafraq Sand Stone/Silt stone 11.4 13-14 Minor losses
8 Sudair Dolomite/Anhydrite 11.4 13-14 Minor losses
9 Khuff (U,M& L) Lime Stone with hard 11.4-11.6 13-14 Modrate to Total Losses
Dolomitic streaks Tight hole while POOH
Ghariff Shale/Sand stone 11.6-11.8 14-15 Bit balling, cavings
and other shale problems

D) Potential Problems/Hazards:

1) Seepage, Minor to total losses – To avoid seepage losses incorporate 25 kg/m3 each of 25 M and 10 M
Calcium Carbonate in the system.
Detailed discussion will be given in losses section.
2) Wellbore instability (not a problem in this section) Use Shale Inhibitors, Shale Stabilizers and Shale
encapsulators and maintain tight fluid loss control.
3)Bit balling – Normally bit balling is a not problem in this section, if it happens 10 % Drilling
Detergent pills may be pumped.
4) Differential sticking tendency –See Appendix.

E) Salient points:
1) Build as much as possible of mud at 11.4 kPa/m , YP- 12 Pa and adjust all other parameters as per the
section requirement. Treat the mud with Sodium Bicarbonate to avoid any contamination while drilling
cement.

2) Mud Weight:
Maintain the same mud weight of 11.4 kPa/m till Khuff lower , increase to 11.8 kPa/m before entering Ghariff.
Depending drilling hole and wiper trips mud weight might be f increased up to 12.5 kPa/m.

Use minimum 50 kg/m3 CaCO3 (25 M and 10 M) to have better filter cake. Remaining all use as
much as possible NaCl. This will help in maintaining a low solids system. Use KCl (80-90
kg/m3)before entering in to Ghariff.
While increasing mud weight keep an eye on losses, differential sticking tendency, ECD Values
etc. As this is a slim hole design the ECD Values will be higher in comparison to conventional
wells.

It is better to drill this section as much low mud weight as possible as there is every chance of losses
in Khuff. In the nearby offset well losses were observed. Hence MW should be maintained as low as
possible without geopardizing the well control situation.

3) Well Bore Strengthening : As partial to total losses are expected in Habshan, Jubaila and
Khuff

Refer to APPENDIX 3

4) Losses :

Refer to APPENDIX 3

5) K+ Ion: (not required only if hole condition, discuss with UIK21). The K+ ion concentration must
be maintained at 40-45 g/l (of K+), which is equivalent to 80-90 kg/m3 of KCl before entering in to

12
 Ghariff. Do not add any KCl while drilling Nahr Umr. Test K+ ion concentration as per standard
API Potassium test procedure (Precipitation with Sodium Perchlorate).

Observe the integrity of cuttings coming out of hole. If good ion exchange occurs the cuttings will
be independent rather than sticking to each other.

Do NOT estimate K+ ion conc. from mass balance.

After testing in the centrifuge method if you find any decrease in the K + ion concentration it
shows that there is ion exchange occurred with K+ ion. Then to maintain the K+ ion concentration
add some more KCl and maintain the required concentration level of 80-90 kg/m3.If the K+ ion
concentration depletes too fast you may increase the total amount KCl concentration.

6) Sulphonated Asphalt (Soltex, CORTSAS etc): (not required, if there is indication of hole stability
signs add initially 10-15 kg/m3).

In the mud prepared initially add only 15 kg/m3 of Soltex and mix thoroughly. Otherwise some
soltex will overflow from the shaker if complete concentration of 25 kg/m3 is added. As soon
as drilling proceeds, start adding Soltex to the system. This should reach a concentration of
20-25 kg/m3 before opening Nahr Umr. Premix the Soltex with mud first in reserve pit and
bleed slowly into the active system. If you observe any hole instability issues you may
increase the Soltex concentration in consultation with base.

N.B. Do NOT use mass balance to calculate the active concentration of Soltex, as
Soltex will be absorbed by shale’s and gets depleted from the system. Therefore, add 2-
3 kg/m3 Soltex, daily while drilling. Check the nature of cuttings.

7) PHPA (LV): (not required) Add 3-6 kg/m3 PHPA to the system depending on the severity of
shale and condition of the shakers. Incorporate PHPA slowly in to the system otherwise shakers
will get blinded with PHPA. Before mixing PHPA to the system shear it thoroughly in the reserve
pits and add as premix. Never add PHPA directly to the active system.

8) RHEOLOGY
Yield Point: Use 4-6 kg/m3 XC Polymer to maintain YP at 12-15 Pa. Increase the YP if you find
any fill at bottom or other hole cleaning problems. Check the circulating pressures while increasing
YP.
Plastic Viscosity: Try to maintain Plastic Viscosity as low as possible by effectively running of all
solids control equipment including centrifuge.
Low End Rheology : Maintain low end rheology as per specification by using XC Polymer.

9) Hi Vis Pills: Maintain rheology as planned. If the rheology is maintained as recommended hivis
pills may not be required to be pumped. However intermittently pump hivis pills and see for
cuttings recovery. If there is any increase in cuttings recovery then only pumping of hivis pills need
to be continued or increase the YP of the system if there is no problem with circulating pressure.
Observe the cuttings surfaced with hivis pills and report. Do not pump hivis pills on regular basis
after one or two stands as a policy, always pumping of Hivis pills should be guided by the cuttings
came out with the previous hivis pill, fill at bottom after connections, Drag etc. See Appendix on
hole cleaning for further details.

10) API Fluid Loss

The API fluid loss needs to be @ less than 5.0 cc/30min with Drilling Starch 15-20 Kg/m3 and 5-
10 kg/m3 of HT Starch & 5 kg/m3 PAC LV (use PAC Lv if required only). Maintain fluid loss with
combination of Starch, Carboxymethyl starch (CMS), Soltex, and PAC (LV) & HT Starch if
required. Observe cake properties. Maintaining a thin and tough filter cake is very much essential.

11) pH: Maintain pH in the range 8.5-9.0.

12) Methylene Blue Test (MBT): Perform MBT tests regularly and report in multiples of 3.5 kg/m3 if
you are using 2 ml sample. MBT is an indication of Clay content in the mud. Especially while
drilling shale’s and clay formation it gives good indication of amount of dispersion of clay in to the
system. Try to maintain MBT Values as low as possible. If you observe high MBT Value >21
kg/m3, dilute the system and reduce the clay content as low as possible(around 21 kg/m3).

13
 13) Hardness: The hardness of WSW is very high in North area. Better to use as much as possible
RO water. Still if the hardness levels are high treat with Soda ash.

14) Stuck Pipe: Evaluate fully whether the stuck pipe incident is Differential or Mechanical and take
necessary precautions. See Appendix for further details.

15) Lubricant (Radiagreen): It is advisable to use 0.5-1 % Lubricant for avoiding any chance of bit
balling and to have better filter cake.
16) Losses: Please see the losses prevention document in Appendix.

17) Wiper trips: It is better to have wiper trip after drilling Mafraq formation and one more wiper trip
in Khuff before drilling Ghariff. This will help in wiping out any ledges left and swelled shale.
After drilling to TD while pulling out if severe problems are faced in Gharif, it is better to do a wiper
trip up to top of Ghariff and increase the mud weight if required.
18) RIH CSG: RIH csg as per the predetermined rate of RIH csg. Calculate this rate basing on Swab
and Surge pressure calculation.
Wash down last three joints even if the csg goes freely to bottom. This I to avoid any surge
pressure due to gelled up mud.

During the cement job it is better to displace with 4-6 m3 fresh water followed by
WSW. To allow better WBM displacement out of the well and clean up mud tanks
to receive the OBM for next section. To drill the shoe track it should be fine to use
the OBM to drill directly after proper displacing of WSW to OBM.

G) Learning’s from the previous wells:

Wiper trips at regular intervals as mentioned in Point no 17 will help to
drill this section successfully without any problems.
As per the experience from previous well in Burhan, Good losses mitigation
Plan is very much essential and all concerned services should be planned.

================================================================================

3.4. 8 3/8” Vertical Hole Depth ± 3,296 to +5,150 m

A) Mud System

This section is to be drilled using Oil Base Mud (Versa Clean LT OBM).

B) Basis of Design
It is better to drill this section with OBM due:
 Long section to be drilled going through and Ghariff (long exposure time)
 Some of the hole problems can be eliminated,
 As high torque and stick slip are observed in this section,
 Log quality will improve

C) Potential Problems/Hazards
 H2S in formation (also a reservoir containing gas) up to x,xxx ppm on offset wells.
 May have Reactive Shales – Maintain required mud weight and other OBM properties.
 Problems during trips: It is recommended to have frequent wiper trips as this is a long
section to drill. The wiper trips should be approximately after drilling 500-700m or few days
of drilling.
 Hi Temperature - Use Mud Cooler
 Differential Sticking tendency - Use proper mud weight as per the hole condition.

D) General Precautions :
 Ensure that sufficient notice is given to MI Swaco at the start of the previous section for
calling out the OBM of required weight. Make sure MI Swaco sends a plan detailing tank
and OBM delivery Contact the Well engineer and UIK for support if required. Initially
minimum of 200-2250 m3 of OBM and 30 m3 of Base Oil is required.

14
  The mineral oil being used is EDC 95-11 (SHOC card S123). It has the following
advantages:
o It contains less than 1% (average 0.1%) aromatics compared to diesel at 30-50%.
It is the aromatic compounds, which are most dangerous in diesel. It is less volatile
than diesel so there should be less vapour emissions. It also has a low odour.

E) Call Out Mud Properties:

 The below mud properties will be used for the OBM call out, mud will be treated and the
above properties will be achieved during drilling operations.
 Mud Weight = 11.6 kPa/m
 Oil /Water ratio = 70/30
 Electrical Stability = 300 – 400 volts
 MI LLC will endeavour to deliver OBM with mud weight close to that specified in the callout.
In case that the mud weight of the OBM delivered is lower than the callout, PDO will supply
the weighting material (barite) to achieve the mud weight. In an event if the delivered MW is
higher than the call out, mud dilution and stripping of solids & weight material by
centrifuging will be done prior to displacement.
 The 300 – 400 volts electrical stability value is for the fresh and partially sheared mud. This
value will slowly increase to ~600 volts once the mud is circulated into the hole during the
initial stages of drilling with normal treatment of chemicals.

F) Section formations

Upper Gharif, Middle Gharif, Haushi Lst., Basal Sands, Al Khalta, Saih Niyahada, Ghudun,
Barakat, Mabrouk, Barik, Al Bashair, Miqrat, Amin.

G) Mud Parameters for 8 3/8 ” Hole

Mud Parameter Specification Comments

Mud type Versaclean LTOBM

Mud weight kPa/m 11.6-12.0 Adjust according to hole condition. Planned Final Mud
weight is 12.0 kPa/m unless otherwise required.
Observe for cavings and hole stability problems while
drilling and Adjust MW accordingly.
HP-HT Fluid Loss ml at <3 Filtrate must be all oil
121°C
PV < 30 ALAP, Use thermo cup at 500C
YP Pa 9 -13 Use thermo cup at 500C, Use VG 69
YP Pa 18-22 ( for HiVis) For Hi Vis for hole cleaning, & weighted some time if
required.
Oil water ratio 70/30
6 RPM 7-11 Use thermo cup at 500C
30 minute gel Pa < 18 Use thermo cup at 500C
Cl- WPS Kg/m3 >230 (mainly all the Use Calcium Chloride
time) to 250 (with time
of drilling for more than
three weeks)
Electrical stability volts > 600 Minimum ES to start drilling with is of ES 300 to 350 volts
(with HPHT fluid loss of no water-only oil of less than 3
cc/30 min @ 121°C), but to treat & maintain better ES
while drilling of > 600 volts during drilling the first 8-12
hrs.
Excess Lime Kg/m3 > 10
% LGS ALAP< 5 % Optimise SCE to minimise LGS < 5 %
Deviation 0 ±0o Use Low & Hi Vis for Hole cleaning when section have
more than 20o.
Remarks Increase the mud weight as per the hole condition.
Consult WE/UIK21.
NOTE: The properties specified above are to be maintained.

15
H) Salient Points Of The Mud Programme

1) Displacement of WBM with OBM

Plan to drill out the shoe and cement with the OBM which will give some time to get the
properties into specification. Otherwise there could be excessive invisible loss time associated
with circulating and conditioning the mud. Drill out any ratty cement above the float collar with
WSW and pump around 8 m3 viscous WBM sweep to clean the hole of debris. After the sweep
has returned at surface pump a 7-10 m3 CaCl2 brine spacer followed by the OBM mud.

Prior to displacement, it is imperative that the checklist for rig modifications is complete.
Particularly important is that the dump valves are properly sealed & secured & that ALL water
sources to the tanks are locked off. Have toolbox meeting with crew prior to displacement.

The tank set needs to be reasonably clean before VCM is put in it - reasonably clean means no
solids build up in e.g. pit corners & sufficiently clean to prevent contamination of the VCM - it
does not need to be spotless. Call out a Vacuum tanker to remove WBM left in the tanks.
Pump at maximum flow rate and DO NOT stop until displacement is complete:
Pump 7-10 m³ Saturated Ca Cl2 brine.
Follow with OBM.
Incorporate initial, uncontaminated, brine spacer into WBM & dump.
Incorporate oil contaminated water into OBM.
Use coarse (approx 50 API) screens on shakers to prevent blinding with water wet solids.
Depending upon how good the hole-cleaning has been and how effective the displacement,
there will probably be a lot of solids and highly viscous WBM returned. Be prepared to slow
down the pumps at this stage to prevent overflow. 140*70*70/140*80*70

Change screens after OBM is displaced & rheology is acceptable for running fine screens.

Once the initial VCM has been made up, virtually no Versa Emul treatment is usually required.
Treatment with Versa Emul tends to increase the viscosity. Avoid treatment with Versa Emul
unless mixing new mud. Preferentially, VersaSurf should be used at a normal treatment level
of approx 0.25-0.5 litres/m³ of VCM per 100 metres drilled.

2) MUD WEIGHT
Knock out all the solids using centrifuge and adjust the mud weight to 11.4 kPa/m and slowly
increase. Keep an eye on losses. Use Barites 4.1 S.G. for weighting up the mud as this will
help in controlling the plastic viscosity. Hold the same mud weight until final POOH. Weighted Hi-
Vis pills for good hole cleaning.
If the Mud Weight need to be increased more than 12.0 kPa/m due to some reason or the
other contact the base (Operation Engineer) or UIK21 ( Anwar).

3) OIL WATER RATIO

Maintain oil water ratio, in the range of 70/30, preferably closer to 70/30 to minimize base oil
consumption.
Check the Oil Water ratio after taking the OBM in to Active tank and check the Oil Water
Ratio and if it is not within specifications inform MI, DS and UIK. Treat it to the
specifications.

4) RHEOLOGY
Yield Point: Maintain Yield Point between 9-13 Pa. If the hole cleaning is not good YP may be
increased. Higher the YP circulating pressure will be high. Hence check the circulating pressures
while increasing YP.

Low End Rheology: Low end rheology is very much important in build-up section as the cuttings
tend to settle at lower side. Maintain Low End rheology as per specification.

Plastic Viscosity: Run centrifuge to maximum capacity, use maximum possible fine screens on
shale shakers to maintain the PV as low as possible (30 CP). Use 160-200 API screens.

16
5) Hole-Cleaning with Hi Vis PILLS
Pump hivis pills with YP > 18-22 Pa as and when required. If still hole cleaning is not good, pump
weighted hi-vis pill of 14-17 kPa/m. See Appendix for extra Information.

6) Daily oil-on-cuttings measurements are required.

Use the spreadsheet provided by PDO & report OOC for both the shakers & the centrifuges. The
OOC should be reported in gm/kg. The expected average oil-on-cuttings should not exceed 100
gm/kg if the Accuracy check % is > 5 it means that the data used is not correct, the Accuracy
check must be < 5 % to be accurate. With a 70/30 ratio instead of an 80/20 ratio the OOC (oil on
cuttings) value should be less than normally seen while drilling.

7) Cuttings Volume
As the cuttings are dumped into skips it should be possible to estimate whether correct amount
of cuttings are being removed or not. For 12 1/4” hole calculate the theoretical amount of cuttings
to be produced per metre drilled. Measure the cuttings volume, monitor the recovery
percentage, and take appropriate action of pumping tandem pills and report in the daily report.

8) HPHT Fluid Loss

Maintain the HPHT <3 ml. Use Versatrol to control fluid loss if required. The natural tight
emulsion should provide sufficient fluid loss control on its own. The HPHT filtrate should be all
oil. If there is slightest indication of water or emulsion in the filtrate there is a lack of emulsion
stability. This must be treated at once with VersaSurf.

9) Excess Lime
Maintain Excess Lime at >10 kg/m3.

10) Emulsion Stability

Maintain Emulsion stability > 600 Volts.
N.B. Oil Base Mud take some time to shear fully to get maximum yield.

11) Water Phase Salinity

Maintain WPS around 230 g/l by using Calcium Chloride.

12) Solids control

 Initially run API 50 screens on all shakers as the VCM will be cold and fairly viscous. Afterwards,
the shakers should be dressed with the finest screens possible, min API 17--230 screens. For
trips, ensure one shaker has API 50 screens on to compensate for cold/viscous mud, to prevent
overflow. Depending on the shakers and if possible the top or rear screens should be
pyramid & the front 2 screens, flat panel. The flat panel screens will provide better cuttings
drying.

 The centrifuge should be run to minimise LGS build up as required. RPM should be run as high as
possible (>2800) to minimise OOC and wet, expensive discharges.

 Until and unless it is very much required do not run Desander and desilter as there is a chance of
OBM to leak through gland packings cones etc.

13) Formation Losses

There is a chance to get losses. Hence extra care should be taken as OBM is costly ($1,000-
1,400/m3). Pre-treat the mud as per Appendix 3 if required. Still if losses occur the
concentration may be increased and spot pills can be used. See Appendix 3 for curing losses.

If losses persist at 7m³/hr or greater or total losses reach 100 m³ then the well should be
displaced to an inhibited XC Polymer WBM after consulting the base.

14) Surface Losses

Potential sources of surface mud losses, additional to the mud adsorbed on cuttings, are:
 improperly operated shale shakers;

17
  losses over the shakers during initial circulation of cold mud;
 dumping of sand traps
 dumping of contaminated spacers;
 Accidental opening of valves, overflowing of pits and inadequate equipment to handle oil
based mud.
 Unaccountable losses may be reduced by proper house-keeping procedures.

15) Mud before cementing

After reaching TD Prior to POOH drilling assembly increase the mud weight in consultation with
base (To counter ECD). Decrease the YP as low as possible before POOH and after RIH liner to
bottom (for better displacement while cementing). Use Versathin and Base oil for this purpose.

16) Other Precautions

 When starting to circulate, kick in the pumps very slowly and gently increase the pump rate to
avoid inducing losses after the mud has been stationary for some time. Gels quickly build up once
the mud has been left stationary for some time and high ECDs can induce downhole losses.
 A mud cooler may be required at the end as this is a high temperature well to reduce the vapors.
 Have good communication with rig team, If you are in doubt call UIK 21 (Anwar) Or Well Engineer

I) Learnings from previous wells

1) Problems were noticed in the previous wells even with OBM, hence maintaining mud
properties as per specification is very much essential.

================================================================================

3.0) CEMENTING
Cement Recipes: Confirmed cement recipes and programmes will be given nearer the
time of cementing by Anwar Al Salti (UIK21).

Spacers: Spacers need to be designed with better rheology to have good displacement of the mud.
All the precautions to be taken will be given in detail in the cementing programme.

Mud before Cementing:

Thinner mud will help in better displacement with cement slurry. Keeping this in view follow the following
guidelines.

While drilling the last 50 m decrease the YP of the mud as low as possible without geopardising the hole
cleaning efficiency. This can be done by using Drillthin and Sodium Chloride solution which helps in
thinning the mud. During final circulation after reaching bottom with casing, circulate enough time to
condition the mud.

Prepare about 50 m3 of mud with low YP (6-7 Pa) and all other properties remaining same as the mud
used in drilling. Use as much as possible Sodium Chloride to have thinner solids free mud. Do a pilot test
to check for any settling.

Better to change over to this low YP mud in open hole, if enough low YP mud can be prepared, if not pump
the low YP mud before the spacer is pumped. This is required to have better displacement efficiency of the
mud by cement.

Properties to measure during Cement Job:

During cementing measure the slurry density and it should be constantly equal to the recommended slurry
density.

Also measure the time taken for spacer to reach surface and record the amount of excess cement/spacer
surfaced where ever it is applicable. This is very much required in top hole and intermediate section.
Remarks: Follow the cement programme and recipes issued by UIK 21 (Anwar Al Salti)
Discuss the cement programme with UIK 21 before performing the job to avoid
any confusion

18
 4.0) Packer Fluid & Completion brine (to be Confirmed)

This well will be completed using 4 ½” tbg cemented Completion.

otherwise please contact UIK/21 for an alternative fluid design.

1) Packer Fluid:  +/- 70-80 m³ pumpable of  R.O. Water  + of 4% KCl + xx Kg/m³ (280-330
kg/m3) NaCl Sodium Chloride NaCl up to (11.8 kPa/m) +  1.0-2.0 kg/m3 Caustic soda (to get a
pH of 9.0-9.5) + 0.5 lts/m3 Bioquat RP20 (Biocide) + Oxygen scavenger (use liquid sodium
bisulphite in 20 litre cans (SAP no. 1001005690)  at 1.5 ltrs/m3).

2) Completion Brine: The well will be completed with 10.2 kPa/m KCl (4%)  (from fresh water &/or
R.O water in clean mud tanks)  treated with 0.5 lts/m3 Bioquat RP20 (Biocide) and add Caustic
soda to achieve a pH of +/- 9.0. Add Oxygen scavenger –(use liquid sodium bisulphite in 20 litre
cans (SAP no. 1001005690)  at 1.5 ltrs/m3).

3) Spacer: we need to add (Biocide) and Oxygen scavenger to the spacer also to prevent seen
problems with packer fluid in some cemented completion at surface (parted cemented completion
specifically naming SR wells). Concentration of these materials as below…

+ 0.5 lts/m3 TK 3408 or Bioquat RP20 (Biocide(SAP No. 1001207341)) plus

Oxygen scavenger – (use liquid sodium bisulphite in 20 lts cans (SAP no.
1001005690))  at 1.5 lts/m3 to be added to the Spacer  Fluid just before pumping
down hole.

Measure all possible parameters of both the brines(Especially p H and Salinity and density) brines and
report in the DMR & EDM.

5) Reporting

In addition to a complete mud report, the mud engineer is to provide the following information in the Daily
Mud Report (DMR)

1. Concentration of all Polymers,Soltex K+ ion concentration and CaCO 3 in the mud.

2. Hole cleaning pills information chart to be filled.
3. Solids control equipment information like Screen sizes, Cone sizes, pressure, working
condition etc.
4 Hydraulics information should be completely filled.
5 Need to plot the important Daily Mud Parameters in Graph to understand the trends.
A model graph will be sent nearer the time.

6) ACKNOWLEDGEMENT

After receiving the mud programme the mud engineer at site should go through the programme and acknowledge the
concerned UIK Department incharge that he has gone through the programme and understood all aspects of the
programme. If he has any reservations he may discuss with the concerned UIK department incharge. Any
suggestions for improvement are always appreciated.

Any communication regarding the mud programme should be conveyed to the reliever in writing. Any mails received
regarding TFM should be handed over to the reliever.

19
 APPENDIX 1
Preparation of Pre-Hydrated Bentonite Gel (PHB)

Utilize a free tank as the pre-hydration tank. Do not use the fire tank for fresh water storage since this tank
should be maintained full at all times.

1. Use RO water for preparation of Bentonite gel and if required treat with Soda ash to decrease the hardness to <
200 ppm. Do not over treat.

2. Add Caustic to raise the pH to 9.0-9.5. Do not over treat.

3. Add Bentonite to the pre-hydration tank (90-100 kg/m 3). Shear the bentonite by circulating in the tank and passing
the PHB slurry through the mud guns. Shear the bentonite for at least 8 hours prior to use. Continue to shear at all
times.

4. After some pre-hydrated bentonite has been used in the active system, refill the tank with WSW and add the
appropriate concentrations of Soda Ash, Caustic and bentonite. Again, do not over treat. If over treatment with Soda
Ash or Caustic occurs, the bentonite in the pre-hydration tank will begin to flocculate and although the bentonite will
appear thick, the concentration will be too low for use in the active system.

Check the salinity of the WSW. If it is more use fresh water to prehydrate the Bentonite gel.

APPENDIX 2
HOLE CLEANING

Maximum possible circulation rates should always be maintained for having good hole cleaning. Sometimes it may be
difficult to achieve good hole cleaning with viscosity alone. To enhance hole cleaning, Hi vis pills need to be pumped
at regular intervals. These should be prepared with mud in use in a particular sections. Pills should have a YP of >
25Pa.

If still the hole cleaning problem persists the hi vis pills may be weighted to provide buoyancy for extra lifting capacity.
Weighting up such a pill is not the same as preparing a trip slug. The MW of a weighted hole cleaning pill should be
20-30% higher than the MW in use to work effectively.

The results of pumping hole-cleaning pills must be monitored & reported on the daily mud report as a percentage e.g.
“Pill returned increase in cuttings of approx 50%, on the shakers.” Pills must be of a volume to cover a minimum of
150 m of hole.

Do not pump brine only pills. The low viscosity of the brine enhances pore penetration of the fluid & may
lead to hole destabilization.

General recommendations

1) Do circulate the hole clean before trips till the shakers are clean. Minimum 2 cycle times is recommended
2) Do circulate the hole clean using hivis pills or tandem pills as per the hole profile before trips.
3) While circulating clean, always rotate & reciprocate the string.
4) Do run a torque & drag chart through the well. Pay full attention to increasing trends & take remedial action
5) Maintain low end rheology no lower than recommended parameters.
6) Over pulls or high torque indicate hole cleaning problems. Pump/rotate through area affected and pump hivis
pills if required.

The recommended hole cleaning measure of rheology is yield stress:

(Yz) = (2 x 3rpm) - 6 rpm readings.

Attempt to maintain this above 4. This must be reported on the daily mud report.

Low End Rheology

Not only YP , Low end rheology is another factor which is responsible for hole cleaning as when the fluid in
hole against drill pipe will have almost same shearing values. Hence give more emphasis on low end
rheology, especially while drilling deviated and Horizontal holes.

20
 APPENDIX 3
LOST CIRCULATION

A) 23” Hole:
There is every possibility of seepage to total losses in Fars. If the losses are above 10 m3/hr can
be with Cement plugs. In UeR partial losses are expected. These can be cured with drilled
cuttings. If it is not cured by drilling few meters further it is better to cure losses with Cement plugs.
Losses need to be cured completely as inhibited polymer mud will be used to drill Fiqa.

B) 12 1/4” Hole:
1) Mud Weight: Keep the mud weight @11.4 kPa/m till Khuff lower is reached.
2) ROP : Drill this section at moderate ROP without loading the annulus, especially in Jubaila
& Khuff.

3) Wellbore Strengthening :
As partial to total losses are expected in Habshan, Jubaila, Mafraq and Khuff formations
prepare every day 18-22 m3 LCM pill (use same mud  used for drilling this section
with same properties and same YP, increase visci only if required to keep the
materials in suspension) and add the additives in column #1. Keep bleeding this
solution in to Active system slowly while drilling right from start up of drilling the section as
losses seen in Habshan and Jubaila in hole #1 of this well.    Bleeding rate can be @ 1-2
m3/hr. This will help in strengthening the well bore. Always fresh LCM is available to seal
of the newly opened pore throats. Bleed Off in such a way mud weight is maintained
within ±0.1 kPa/m.

SAP # Unit Well Bore strengthening

Moderate loss(5-10 Severe
Chemical (bleeding LCM into the
m3/hr) Losses(>10m3/hr)
system,
column #1 column #2 column #3
XC Polymer (viscofier in 5-6 kg/m3 (YP=22- 6-8 kg/m3  (YP=25-
5-6 kg/m3 (YP=22-28)
WBM) 28) 30)
PHB** (viscofier in WBM) N/A N/A 70-90 kg/m3
VG-69 (OBM)!! To get (YP=22-28) To get (YP=22-28) To get (YP=22-28)
CaCO3 Grade (10) 1001129965 500 kg 50 kg/m3 50 kg/m3 25 kg/m3
CaCO3 Grade (25) 1001129964 500 kg 50 kg/m3 50 kg/m3 25 kg/m3
CaCO3 Fine     1001129879 500 kg 50 kg/m3 50 kg/m3 25 kg/m3
CaCO3  Medium  1001129962 500 kg 50 kg/m3 50 kg/m3 75 kg/m3
CaCO3  Coarse 1001129963 500 kg N/A 50 kg/m3 100 kg/m3
Mica Fine 1000064969 25 kg 40 kg/m3 50 kg/m3 40 kg/m3
Mica Coarse 1000064970 25 kg N/A 30 kg/m3 40 kg/m3
Resilient Graphitic
30 kg/m3 30 kg/m3 40 kg/m3
Carbon (Rebound) 1000755925 25 kg
Cellulose LCM 
30 kg/m3 30 kg/m3 40 kg/m3
(Dynared/Barofibre) 1000755926 25 kg

Sealing Latex 3% 3% 5%
1000996945 200 lt

** If during using water based mud and an aggressive curing LCM material needs to be used use PHB as a
viscofier with concentration of column #3 provided that there is no shale formation is open (discuss with
UIk21 if required).
!! In case of OBM use VG-69 as viscofier using the same other materials. Use same mud and add the materials and
viscofieres as required

21
 i. Tackling Losses after losses occur

1 If the losses occur drill about 30-50 m or till you can supply good quality mud.
2 If the losses are 5-10 m3/hr (able to mix required mud) keep drilling and prepare good
quality mud as per specification. Keep adding the LCM Pill as mentioned above in Step
No3 but at higher bleeding rate 2-5 m3/hr.

3 If the losses are seen first time and/or between 5-10 m3/hr use the LCM Pill as given
below. Open PBL sub to pump as per below advised (12-15 m 3). POOH to 30-50 above
the losses zone and hesitate squeeze(Gentle squeeze) two to three time the same pill
to establish good seal around the losses zone (while leaving it to soak, every 5-10
minutes hesitate and check for losses and pressure profile, very low squeeze
pressure of <200 kPa).
ii. Other precautions
1) Tank Capacity : Keep enough tanks to store as much mud as possible.
b) Chemicals: Keep enough drilling and LCM chemicals.
c) PBL Sub: Keep PBL sub in the string so that coarser materials can be pumped and the
nozzles will not plug.If it is not possible to keep PBL sub use bigger nozzles and adjust the
Hydraulics accordingly.
d) Do not commit mistakes which were committed in the previous wells. Hence always check what
was done in the previous wells of this area.

iii. Loss Seal pill (Fibers from Schlumbergr) can be used. Procedure will be given based on
losses rate.

C) 16 & 8 3/8” Hole (OBM) (Use above Table for materials with VG-69)

Because of the high cost of the OBM every effort should be made to prevent downhole and surface
losses.

There are many drilling practices that can cause losses by the hydraulic fracturing of a weak
formation amongst them are:

 Pressure Surges caused by the pumps being started quickly or stopped suddenly. Often
this may be exacerbated by a high gel structure of the stationary drilling fluid, which needs
to be broken before it starts to flow. Rotation of the pipe, prior to kicking-in the pumps, can
reduce the surge pressure, as can a reduction of the gel strength of the mud prior to any
trips.

 Pressure Surges when tripping. There are software programmes to indicate the critical
speeds for running pipe and casing and these should be used to avoid losses.

 Rapid pipe movement while circulating or reaming can also cause surges that can result in
losses.
 High ROP can cause annulus loading by the cuttings, which will increase the ECD and
cause losses. Software can be used to monitor the situation and maintain annular
pressures within the required parameters for loss free drilling. Parameters which may be
needed to accompany high ROP are mainly hole cleaning issues but can also be
rheological (increase in viscosity to carry the cuttings or a decrease to increase
turbulence), hydraulic (increase in pump rate) or a combination. Resultant changes to
increase ROP can however cause losses.

 The incorrect use of pills to clear cuttings from the annulus can also cause losses

 The same criteria apply to the placement of Hi Vis pills on bottom, prior to running casing.
When the casing is circulated prior to the cement operation, losses can be induced through
the extra pressure required to break the gel and move the pill up the annulus. In all cases
the pills should be tailored to the annular clearance. Casing should be washed down, from
above any pill left on bottom, to avoid moving a large pill or part of a pill and increasing the
hydrostatic column to where losses may be induced.

22
  Losses induced when casing or liner is on bottom by circulating at too high a rate, or when
circulating out a Hi Vis or weighted pill, can be alleviated by running computerized
cementing programmes in critical wells.

 The build-up of fines in the mud system will gradually increase the mud weight and cause
losses. The must be removed by the efficient use of solids control equipment, especially
centrifuges, or managed by dilution or whole mud replacement.

Incorporating large concentrations of lost-circulation materials into the whole system is not
recommended since these materials increase the equivalent circulating density. This often
compounds the lost-circulation problem instead of solving it. However there are some cases in
which seepage losses can be temporarily stopped or minimized by carrying small concentrations of
lost-circulation materials in the system.

Note that prior to pumping any LCM pills, it is essential to determine if they can be pumped through
the MWD and bit, The rule of thumb is that material of 1/3rd the diameter of an opening will plug
that opening. 1/7th the diameter of the opening will pass through. Between 1/3rd & 1/7th is thus,
the particle diameter that may plug a bit nozzle.

The maximum recommended concentration of LCM material for pumping through the MWD is 140
kg/m3 Fine and Medium material. When the pill is being pumped through the MWD reduce the
flow rate to less than 1.7 m3/min as this will reduce the chance of the tool blocking – check with
MWD engineer the flow rate at which the tool turns on

Note that the 10, 25 micron CaCO3 are not considered in the maximum LCM concentration of 140
kg/m3 due to their very small particle sizes.

D) Using Cement Slurries

If all available methods of curing losses with LCM do not work, cure the losses with Cement plugs. Before
performing cement job discuss in detail with UIK 21 to decide the nature of cement and the procedure to be
pumped depending on the nature of losses.

18.6 kPa/m fast set cement slurry should be pumped only on the fly depending on the nature of the losses.
Displacement should be limited to the pipe volume so only displace the LCM pills and the cement slurry
until it is exiting the pipe. Let the cement fall by its own into the loss zone if the losses are severe.
If the losses are moderate it is better to place the cement slurry and if you do no observe any decrease in
the fluid level, squeeze the slurry slightly without fracturing the formation.
Basic Recommendations
1. Always pump a LCM pill (300 – 350 kg/m³ CaCO 3), ahead of the cement to try and create a bridge for the
cement. The pill should be correctly formulated with additional XCD polymer to stop the LCM falling out of
the pill in the rig’s tanks and/or dead volumes.
2. Always try and squeeze the cement slurry into the fracture as this starts the hydration of the cement and
ensures that fractures or vugs are filled near to the wellbore and the cement is not removed, when drilling
recommences, causing losses to reoccur.
3. Contact Production Chemistry Department – UIK21 (Anwar), or UIK26 (Salim) before pumping cement
slurry.
4 During pumping these slurries it is advisable to use GRE pipe as the cement may set fast.

E) Drilling Practices:

There are many drilling practices that can cause losses by the hydraulic fracturing of a weak
formation amongst them are:

- Pressure Surges caused by the pumps being started quickly or stopped suddenly. Often this may be
exacerbated by a high gel structure of the stationary drilling fluid, which needs to be broken before it starts
to flow. Rotation of the pipe, prior to kicking-in the pumps, can reduce the surge pressure, as can a
reduction of the gel strength of the mud prior to any trips.

23
- Pressure Surges when tripping. There are software programs to indicate the critical speeds for running pipe
and casing and these should be used to avoid losses.

- Rapid pipe movement while circulating or reaming can also cause surges that can result in losses.

- High ROP can cause annulus loading by the cuttings, which will increase the ECD and cause losses.
Software can be used to monitor the situation and maintain annular pressures within the required
parameters for loss free drilling. Parameters which may be needed to accompany high ROP are mainly
hole cleaning issues but can also be rheological (increase in viscosity to carry the cuttings or a decrease to
increase turbulence), hydraulic (increase in pump rate) or a combination. Resultant changes to increase
ROP can however cause losses.

- The incorrect use of pills to clear cuttings from the annulus can also cause losses
-
- The same criteria apply to the placement of Hi Vis pills on bottom, prior to running casing. When the casing
is circulated prior to the cement operation, losses can be induced through the extra pressure required to
break the gel and move the pill up the annulus. In all cases the pills should be tailored to the annular
clearance. Casing should be washed down, from above any pill left on bottom, to avoid moving a large pill
or part of a pill and increasing the hydrostatic column to where losses may be induced.

- Losses induced when casing or liner is on bottom by circulating at too high a rate, or when circulating out a
Hi Vis or weighted pill, can be alleviated by running computerized cementing programs in critical wells.

APPENDIX 4
Solids Control Equipment

Maintain all solids control equipment most effectively to maintain the LGS as low as possible. If the solids
control equipment is working good maintenance of mud properties is easy, hence put all your efforts to
maintain the solids control equipment for best performance.

4.1) Shakers: Use finest possible screens on shakers. Keep sufficient screens in stock
14 1/2 “Hole - 40-100 API Screens
9 1/2” Hole – 120-180 API Screens
6 1/8” Hole - 200 - 240 API Screens

Do not bypass the shakers any time and allow the solids to get incorporated in to mud system. Any
damaged shaker screen change immediately otherwise solids will pass in to active system. Keep
changing the mounting rubbers time to time.

4.2) Desander: Minimum 2*12” Cones should be in running condition. This should be run continuously
during the top hole as clay coming formation will disperse in the WSW being used. This will help in
maintaining the mud weight as low as possible. In 9½” Hole this should be run as and when required. See
that there is always spray type discharge instead of rope type. Keep sufficient spares for Desander.

See that the pressure guage is always installed and in working condition. Normally the working pressure is
around 35-40 psi, however it need to be calculated depending on the mud weight used and feed head
height.

4.3) Desilter: Minimum 16*4” Cones should be in running condition. This should be run continuously in top
hole. In 9 ½” and 6 ½” Hole this should be run as and when required. See that there is always spray type
discharge instead of rope type. Keep sufficient spares for Desilter.

See that the pressure guage is always installed and in working condition. Normally the working pressure is
around 40-50 psi, however it need to be calculated depending on the mud weight used and feed head
height.

4.4) Centrifuge:

Be careful while installing the centrifuge as many safety aspects like power requirement etc need to be
taken in to care. Also take all necessary precautions given in the installation manual.

24
Use maximum possible rpm for better separation of solids. Adjust the parameters in such a way that
always dry solids come out of centrifuge. Once the centrifuge is stopped immediately clean it completely
otherwise the solids will accumulate inside the bowl and other equipment. Maintain the greasing schedule
for the pumps.

Monitor the Mud Weight of ingoing mud and out coming mud. Always there should be some difference
between the mud going inside centrifuge and the mud coming out of centrifuge. If both are same either the
centrifuge is not working or drilled solids are not there in the mud.

While performing Casing While Drilling and in 6 1/8” hole fine solids are generated. Efficient continuous
working of centrifuge is very much essential to keep the solids as low as possible.
Higher capacity centrifuge is recommended for this well.

APPENDIX 5
CONTINGENCY CHEMICALS

S.NO CHEMICAL UNIT AMOUNT REMARKS

TO BE STORED
1 PIPE FREE Drums 8 Used to free the stuck Pipe.

2 Zinc Carbonate Sx 80 Used as H2 S Scavenger. If the area

Is a Level 3 area keep more Zinc
Carbonate.

3 Citric Acid Sx 40 Used to decrease p H if the

mud is contaminated with cement
4 Sodium Bicarbonate Sx 40 Used to avoid cement contamination

5 LCM Material
CaCO3 (C,M,F) Bag Minimum quantity to pump at least
4 pills of 10 m3 each.
CaCO3 (10 M,25 M) Bag Minimum quantity to pump at least
4 pills of 10 m3 each.
6 Resilient Graphite Sx 80
6 Lime Sx 40 For treating Carbon Dioxide
7 Barite Sx 50 To use in case of Kick situation

Note:
1) Try to keep the contingency chemicals in LCM skid as these chemicals get damaged during rig moves. Time to
time open the LCM skid and check the condition of the chemicals. Especially after rig move check the condition
whether any damage during rig move etc.

2) As some of the contingency chemicals are used very rarely it is better to check the expiry date of each chemical. If
a particular chemical is expired write off the chemical and replenish with new stock.

25
 APENDIX 6
STUCK PIPE

Based on recent experience on many wells, the preferred pill for the stuck pipe is unweighted 1 drum in two m3 of
diesel. Volumes required for the 8 3/8 is 6-8 m 3 and for the 5 7/8 is 6 m3.

Final program on any selected contingency fluid will be advised prior to field application.
Option-1 – Pipelax Pill
Recommended Pipelax pill (1 m3 with density ~11.8 kPa/m) mixing procedure is also given as follows:
=> Diesel - 0.6 m3
=> *Pipelax - 70 lts/m3
=> Water - 0.3 m3
=> Baryte - 300 kg/m3 (or as required)
*Use 5 drums for 15m3 of pill
See recipe below for MB Pipe Free for different pill densities.
MB PIPEFREE spotting fluid formulation for 1m3.
Mud Mud Mud MB Pipe
Weight Weight Weight Diesel/Oil free (200 lt Water Barite
(ppg) (SG) (kPa/m) (m3) dr) (m3) (kg)
9 1.08 10.6 0.527 1/2 0.309 249
10 1.20 11.8 0.526 1/2 0.272 407
11 1.32 13.0 0.525 1/2 0.236 562
12 1.44 14.1 0.521 1/2 0.203 715
13 1.56 15.3 0.515 1/2 0.172 871
14 1.68 16.5 0.507 1/2 0.142 1023
15 1.80 17.7 0.496 1/2 0.117 1179
16 1.92 18.8 0.484 1/2 0.092 1331
17 2.04 20.0 0.469 1/2 0.071 1481
18 2.16 21.2 0.453 1/2 0.050 1634

Prior to use, roll the drums of MB PIPEFREE to completely remix any settled fraction.
7.2.2 Option-2: Crude Oil for Annular Hydrostatic Pressure Reduction
In the event that the second Pipelax pill does not work, it is recommended to pump 10-15m3 of crude oil
and displace same into the annulus. This is expected to result in a reduced hydrostatic pressure of 2000+
kPa (i.e. assuming an annulus of 8-3/8" OH and 5-1/2" drill string).
MDT run might be required to confirm the required maximum reduction in hydrostatic pressure.
7.2.3 Option-3: 15% HCl Acid*
The last option to be considered if the pills above do not work is the use of 15% HCl acid to be formulated
as follows:
(0.442m3 of 32%HCl + 0.556m3 of Water = 1m3 15% HCl) + 0.2% HAI-OS (Inhibitor) + 6kg/m3 Fe-2 (Iron
Control Agent). For this application **15 m3 of acid will be ordered from Halliburton (no acid expected to be
returned to base).
 
It is suggested to use water as spacer between the mud and acid not withstanding the potential dilution at
the fluid interface. A viscous XC polymer pill ahead and behind the water spacer is also recommended to
secure the acid at the desired interval. Recommended fluid sequence is therefore given as follows: viscous
pill, water, acid, water, viscous pill, displacement mud i.e.
Viscous pill - 2m3
Water - 1m3
15%HCl Acid - 3-5m3
Water - 1m3
Viscous pill - 2m3 (changed over to rig pump to pump viscous pill).
Displacement mud (11.8 kPa/m mud?).

*Soak acid in +/-3-5m3 stages and work pipe to free string.

**15m3 volume will be required to allow for excess/dead volume.
Note: THE ABOVE IS A GENERAL DISCUSSION TO GUIDE THE MUD ENGINEER ABOUT STUCK
PIPE INCIDENTS. DURING ACTUAL STUCK PIPE TIME, IT NEED TO BE DISCUSSED FURTHER
WITH THE BASE TEAM AND TAKE A DECISION FOR FUTURE COURSE OF ACTION.

26
 APPENDIX 7
Ground rules and Self-Appraisal for Mud Engineers

Twelve ground rules for effective rig-site WBM management

 Never start using any mud system for drilling operation without reviewing both the drilling
operations and mud programme together with emphasis on the drilling fluid-related mitigation
plans for anticipated HSE risks in the well.
 Never use any chemical or fluids in the well without an appropriate SHOC card and a proper
recording of the consumption in terms of chemical concentration, mud volume pumped,
returned to surface and lost in hole/formation for ease of future environmental impact
assessment.
 Never use incompatible/contaminated mix water for any mud system required i.e. hard/saline
water for PHB/Gel in surface-hole drilling, cement-contaminated water for mud mixing without
pre-treatment.
 Never use any new mud recipe or chemical without carrying out pilot test with actual chemicals
or newly introduced chemical on site.
 Never mix chemicals in a hurry (maximum yield is time-dependent - usually 10-15 mins per
25kg/sx of powdered chemicals).
 Never mix surfactants/lubricants or related liquid products inside the hopper in order to avoid
foam generation.
 Never bypass the solids control equipment.
 Never appraise hole cleaning performance without integration of both drilling parameters (i.e.
PWD, T&D, O/pulls, ECD) and surface observation of mud/cuttings returns at the shale shaker.
 Never appraise circulating mud quality during drilling without comparing test data for both the
active tank mud and mud returns downstream the shale shaker.
 Never leave circulating mud system untreated during drilling operation without dilution/re-
hydration using mud pre-mix and or water at the shale shaker.
 Never allow accumulation of solids in the mud system - always dump sand traps and ensure
clean active tank system during every major drilling interlude (e.g. after each hole section
drilling or during wiper trips/logging).
 Never maintain the same rheological properties for both the drilling fluid and the cementing
fluid during cementing operation (ensure a proper interface between the two different fluids) in
order to facilitate mud displacement in the open hole annulus.
4.2 Mud Engineers Pre-Job Self Appraisal*
No Appraisal Question YES NO
1 Do you have a copy of the final TFM program and understand its contents?
2 Do you have a copy of the final well drilling program and understand the
potential impact of drilling fluid quality on each phase of the drilling
operation?
3 Do you have knowledge of the relevant monograms or guidelines on plug-
setting, hole cleaning, wellbore stability management, loss circulation and
foam mitigation etc.
4 Do you have the relevant drilling-fluid-related HSE risk management skills
e.g. H2S detection/treatment, hazardous chemicals and kill fluids handling?
*If the answer to any of the questions above is no, contact the UIK/2 focal point before proceeding
with the operations.

27
 APPENDIX 8
BIT BALLING

In some areas of PDO operations there is a tendency of bit balling. If Bit or Stabilizer balling occurs it is
to be diagnosed properly the root cause for the balling to occur.

Reasons for bit balling:

1) Soft sticky clay or shale formations.

2) Improper bit hydraulics.
3) Inadequate flow rate
4) Improper nozzle sizes.
5) Use of higher weight on bits
6) Improper hole cleaning practices.
7) Improper design of the BHA
8) Improper bit selection
9) Improper inhibition, shale stabilization and encapsulation.
10) If the bit life is over and all teeth are warned out.

Avoiding Bit balling:

Bit balling can be avoided by properly diagnosing and taking care of that particular area due to which bit balling is
occuring.

1) Before starting of the section a thorough review of the formations to be drilled is very much essential for
selection of proper bit, designing the hydraulics, nozzle sizes, flow rates, Nature of BHA components etc.
2) Hole cleaning, Shale Inhibition, Stabilization and Encapsulation need to be improved.
3) If the bit balling is occurring in top hole where normally this section is drilled with WSW, it is better to dilute
the muddy water by dump and dilution method and use fresh WSW as far as practicable
4) Use of Surfactants: If in a particular area bit balling is prevalent it is better to incorporate Surfactants like
Condet in the system. If the bit balling happens while drilling, pump about 5-10% Condet pill. This will help to
dissolve the sticky material.Still if the bit balling prevails 2% Condet can be used in the entire system.
If the surfactants are used please be careful there is a chance for foaming in the mud system which
may cause erratic pressures stand pipe.

5) Use of Soap sticks: Procedure for use of soap sticks is given below.

6) Use of PHPA mud’s: Proper use of PHPA also helps in preventing bit balling by encapsulation.

7) If the bit balling occurs while drilling, stop drilling, pick up the string to off bottom and rotate the string at high
rpm as much as possible.

8) Pumping of Brine solution also may help but it should be used considering all other factors like hole stability,
well control issues etc. It is better to avoid pumping brine only pills.

9) Sometimes pumping Caustic pill also may help in avoiding bit balling but this should be the last option as
some of the polymers may get affected by the high concentration of Caustic Soda.

28
29
 Appendix 9
LTOBM WASTE DISPOSAL

During drilling operations, there will be 4 types of oil contaminated waste, which will require disposal:

 Drilled cuttings
 Centrifuged Solids
 Liquid spillage on site
 Liquid waste e.g. spacers from cement jobs

NB Cement spacers, cement contaminated mud and cement must be neutralized by adding a retardant to
the liquid. Options are sugar, citric acid or HR-25 (25 kg or 1 bag per m³ supplied by Halliburton).

The waste handling & disposal routes will be as follows:

Overview:
 Cuttings & solids go into Al Katheery tipper trucks and are sent to the Qarn Alam Oily Waste concrete
holding pits. Subsequent clean-up will be made by thermal desorption.
 Liquids go into a crude oil tank & are sent by vacuum truck to the Qarn Alam Oily Waste concrete
holding pits.

Procedures:
1. On location there should be a tank or skip of a capacity of approximately 20-25 m³. This will be placed
below the shakers' and centrifuge discharges to collect the cuttings & solids produced. Fluids
adsorbed onto these cuttings (of approx 10-20% w/w) will slowly separate. Prior to removal by
backhoe into the tipper truck, use the Mud Vacuum to remove the available fluid & discharge this back
into the shaker header box. It is important that during transportation there is no spillage. Any OBM
spillage on site should be mixed with sand & discharged into the tank or skip tank.

For disposal, call Al Katheery (385156) for a rock body tipper truck. This is to take the oily waste to the
Qarn Alam Oily Waste concrete holding pits. Estimated charges are as follows:

Rock Body Tipper R.O. 100 per day, or $260

Excavator JCB R.O. 60 per day, or $156
Trailer for Mobilization R.O. 150 per day. or $390

Action - Mud engineer/DSV

2. The cuttings/solids are to be transported to the Qarn Alam Concrete Oily Waste pits. The rig must
complete an FCN (field consignment note) & fax to ONO/1Q the Production Coordinator (tel -
24385551).

Action - DSV

3. For liquid disposal a crude oil tank will be positioned beside the mud tanks at the shaker end. A hose
will be connected to the side outlet valve of the shaker header box. During circulating operations
requiring disposal of oil contaminated liquids (as on dumping oil contaminated spacers during
cementing operations), when the liquids are to be dumped, the shaker gates (onto the shaker) will be
closed & the side outlet valve opened to permit discharge into the crude oil tank.

Action - Mud engineer

4. These liquids will be disposed of by vacuum truck at Qarn Alam. For vacuum truck call-out, tel -
384292. This is for OFSAT trucks. "Hotshot" terms apply for any callout within 48 hours, therefore, it is
likely that all callouts will be deemed "hotshot". Charges are expected to be as follows:
$1.1 per driven kilometre
+ $33 per hour @ site

A FCN will require to be completed as before.

30
 Action - DSV

N.B. No oil contaminated materials may be disposed outside of these procedures

Procedures for disposal of Oil Based Mud, Underbalanced Drilling mud and other non-drilling
related oily waste at the Oily Waste compound in Qarn Alam near the scrap yard.

1. General principles
 In general, Waste Management specification SP-1009 applies. The specifications below are in
addition to SP-1009.

 The oily waste yard is normally unmanned, the supervision being carried out by the Waste Yard
Supervisor, who is responsible for safe operation of the installation, for correct segregation of the
waste streams and for correct administration of the Waste Consignment Notes.

 Overall responsible and custodian of the oily waste storage facility is ONO/8Q.

 The oily waste yard has strict access controls and is locked to prevent unauthorized entrance of
personnel or animals. During the absence of the Supervisor the gates are locked at all times, any
entry of persons or vehicles is only allowed upon approval of the Supervisor.

 The segregation principle is that Oil Based Mud (OBM) waste is kept segregated from other waste
streams to allow recovery of the mineral oil. The other expected waste streams are tank sludge,
contaminated soil from spills and Underbalanced Drilling cuttings. Any other waste stream is not to be
disposed of in this compound.

 The waste is temporarily accumulated in the pits with the sumps permitting regular removal of the
mineral/crude oil collected at the bottom. The sludgy residue will subsequently be processed by a
Thermal Desorption Unit.

2. Transport of oily waste to the waste yard

 Before loading the waste at the source site, a waste consignment note must be correctly completed.
The note should specify very clearly if the load refers to OBM, to allow for segregation.

 Oily waste is collected from the source by a suitable lorry which has a tipping facility which will not leak
on the way from the source for 2 reasons:
a. Oily waste on roads could cause accidents.
b. Expensive oil could drip out and be lost instead of being recovered.

 Before leaving the source site a telephone call should be made to the Supervisor of the Scrap Area at
Qarn Alam informing him of an imminent delivery.

 On arrival the Waste Yard Supervisor should receive the Waste Consignment form and verify it for
correctness. He will then direct the driver to which pit the waste should be disposed and will supervise
the whole operation.

 The truck should drive into the compound, reverse up the slope to the appropriate pit, to the correct
section of the pit edge (demarked by two steel poles) and stop at the pit edge. Note that the truck
should not back into the pit as the flat unloading area should be 150mm below the edge of the
concrete pit. The wheels of the truck should stop at the pit.

 The lorry should drop the load ensuring that the entire load is dumped on the internal concrete ramp of
the pit.

 The Oil Based Mud waste generally has the consistency of very wet concrete and should be self
leveling inside the pit.

 After the unloading operations, the Supervisor will return the copy of the waste consignment note to the
truck driver. The truck driver should return the white copy of the waste consignment note to the DSV.

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 When the load has been dumped, the truck should leave the compound. There are gates at both ends
of the compound one of which will be used as the entrance and the other as the exit. In the event of an
emergency or major spillage any gate can be used. After the truck’s departure the Supervisor will lock
the gate of the facility.

Processing of the oily waste

The oil in the OBM should drain out through the material and collect in the sump. There is a slope from
both ends of the pit to the middle and, in the middle, from one side to the other where the sump is
constructed.

 The oil to be recovered can be sucked out of the sump pit using a submersible pump dropped in to the
sump or by using a truck mounted pump. The oil will be removed and processed at regular intervals,
the actual time period to be checked during the first few weeks. The crude oil will be removed by a
vacuum truck to the open drain pit in MPS station while the mineral oil from the OBM pit will go to the
MPS station for now. Later it will be recycled. At all times proper earthing arrangements shall be
made when emptying the sump pit.

HSE ISSUES:

The solubility of gas in oil is a safety issue when using OBM.

Kick detection, using conventional methods is more difficult in OBM than in water-based mud types
because of gas solubility. Since gas dissolves in OBM, the surface observable parameters (annular flow
rate, pit gain) do not change as rapidly as they would in a water-based mud. Stopping the pump briefly to
check for flow after a drilling break is not a reliable method of kick detection, when using OBM. Thermal
expansion may give a false indication of well flow, but has to be treated with caution. Other points to be
considered are:

 Design, build and institute the use of a pit level measure system so that it will reliably detect flow
volumes of <1 m3 (6 bbls);

 Educate field personnel to understand the difference between OBM and WBM response for kick
detection based on pit gain;

 Flow checks should be at least between 10-15 min., while carefully monitoring flow indications.

Other items which require attention are:

Electric earthing must be connected to all tank and pipe components when using OBM.

Personal Safety

Anyone handling chemicals should be aware of the properties of OBM, in order to ensure his own safety
and the safety of anyone else in the area. The above not only applies to personnel who are actually adding

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 Appendix 10
FOAMING PROBLEMS

If you are experiencing foaming problems a proper diagnosis for the cause of the foam in the mud is very much
essential.

Causes for foam in the mud:

1) High p H muds create foaming.
2) If you are using a salt saturated system there is every chance for foaming.
3) Potassium Chloride (KCl) also contributes for foam to develop.
4) Certain chemicals like Soltex contribute for foam to develop.
5) If you are using any surfactant like Condet, etc there is every chance for foaming.
6) If you are shearing the mud for longer period using centrifugal pumps there is every chance of foaming. Also
if some air is getting entrapped in the mud through pumps it may contribute for foam to develop.
7) Some gases like Carbon dioxide coming from formation may also create foaming.
8) If the well is flowing the first indication will be foamy mud.
9) If some chemicals are degrading they may create foam depending on the nature of the chemical.

Effect of Foam in the mud

1) Decrease in Mud weight and improper mud weight.

2) Erratic pump pressures.

Arresting of Foam

After properly identifying the problem foaming need to be tackled accordingly.

1) Decrease the p H by addition of fresh mud or Citric acid.

2) Check the pf, mf values
3) A good defoamer is very much essential for tackling the foam. Check the efficiency of the defoamer by
doing some pilot experiment.
4) If the foam is due to some chemicals it is better to mix them in the reserve pit, use defoamer and then
slowly bleed in to active system.
5) Check the pumps and all associated connections if any air is getting entrapped through some source and
repair the same.
6) Surfactants like Condet etc need to be incorporated in the system slowly instead of adding large quantity at
a time.
7) If some gases are coming from formation run degasser continuously and degass it. Check the efficiency of
degasser every day at least for half an hour.
8) Use Pressurized balance for checking the Mud Weight. Before checking the mud weight add little defoamer
if foam is there in the mud. Keep the mud stationary for some time stir it slowly with a small stick and then
check the mud weight.
9) If the foaming is due to chemical degradation if possible avoid using that particular chemical.
10) Avoid using any old chemicals with expired date of use.

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