Barite Sag Self Study Guide

Self Study Guide

 Self Study Guide

Credits and Copyright

Credits:
Subject Matter Expert.................................................. Dennis Clapper
Subject Matter Expert........................................................ Brian A. Daft
Subject Matter Expert................................................ Taran K. Endsley
Subject Matter Expert....................................................... Floyd Harvey
Subject Matter Expert..................................................... Dave Marshall
Subject Matter Expert............................................................. Pat Tabet
Subject Matter Expert.................................................. Steven G. Willis
Subject Matter Expert.......................................................... Wade Wise
QA Reviewer............................................................. Deepa Nair Gupta
QA Reviewer....................................................................... Marv Payne
Instructional Design Project Manager....................... Maria Alekseenko

Copyright notices:
© 2013 Baker Hughes Incorporated
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Table of Contents
Page
Course Overview......................................................................................................vii
Welcome................................................................................................................vii
Course Goals and Audience..................................................................................vii
Course Modules.................................................................................................... vii
Course Objectives................................................................................................ viii
Overview....................................................................................................................9
HSE in Wells......................................................................................................... 10
General Precautions.......................................................................................... 10
Well Site.............................................................................................................11
Responding to Emergencies..............................................................................12
Introduction to Barite Sag..................................................................................... 14
Definition of Barite Sag...................................................................................... 14
Dynamic Barite Sag........................................................................................... 15
Static Barite Sag................................................................................................ 16
Other Causes of Density Fluctuation................................................................. 16
Scientific Aspects of Sag...................................................................................... 21
Boycott Effect.....................................................................................................21
Stokes' Law........................................................................................................23
Consequences...................................................................................................... 27
Lost Circulation.................................................................................................. 27
Well Control....................................................................................................... 27
Stuck Pipe..........................................................................................................28
Wellbore Instability.............................................................................................29
Module Review Questions.................................................................................... 33
Variables for Barite Sag...........................................................................................34
Fluids Design........................................................................................................ 35
Fluid type........................................................................................................... 35
Mud Related Variables.......................................................................................35
Mud Treatments Which can Affect Barite Sag................................................... 36
Sag of Other Weighting Materials...................................................................... 38
 Operational Parameters........................................................................................42
Density............................................................................................................... 42
Hole Angle and Hole Size.................................................................................. 42
Module Review Questions.................................................................................... 46
Testing and Recommendations............................................................................... 47
Testing.................................................................................................................. 48
Barite Sag Window Test.................................................................................... 48
Static Sag Measurement....................................................................................50
Static Shear Strength Test.................................................................................51
Viscometer Sag Shoe Test (VSST)................................................................... 51
Recommendations................................................................................................ 55
Philosophy for Non-Aqueous Fluid (NAF) Design..............................................55
Sag Reduction................................................................................................... 56
Rig Site Monitoring.............................................................................................57
Module Review Questions.................................................................................... 61
Appendices.............................................................................................................. 62
Course Summary.................................................................................................. 62
Appendix............................................................................................................... 64
Module Review Answer Keys............................................................................... 65

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Course Overview

Welcome
Welcome to the Barite Sag Self-Study Guide! At BHI, learning is identified as one
of our core values. We believe a learning environment is the way to achieve the full
potential of each individual and the company. On behalf of BHI, we would like to
express our gratitude for your commitment to continued learning that both
increases your own individual potential and enables BHI to continue "Advancing
Reservoir Performance". We applaud your participation in this learning event and
hope that it results in future success in your current role.

Course Goals and Audience

Purpose
To explain the problems caused by barite sag
To recognize the factors that can contribute to barite sag
To recommend processes to mitigate barite sag
Audience
Field Engineers, Field Specialists, Coordinators, Application Engineers,
and Technical Sales

Course Modules
This course consists of the following modules:
Overview
Variables for Barite Sag
Testing and Recommendations

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Course Objectives
At the completion of this course, participants will be able to:

Outline safety considerations, scientific knowledge, and issues relevant to barite

sag

Identify different variables that influence the likelihood of barite sag

Outline testing procedures and recommendations for barite sag mitigation

Course Pre-Assessment

Step 1
Review each objective for the training you are about to receive. Consider your
pre-existing skill level for each objective.

Step 2
Rate your level of comfort with each of the objectives using the rating scale.

1 2 3 4
Unsure Somewhat Informed Reasonably Skilled Expert
I'm not quite I know something about I feel confident in my ability I consider myself to be
sure what this this topic but would to perform this specific an expert/master in
means/what prefer not to be objective and would feel this particular skill and
this would look evaluated on my comfortable being evaluated would feel very
like. performance without first on it without receiving much comfortable training
receiving more training. in the way of further training. my peers and being
responsible for the
results of their
resulting evaluations.

Step 3
Record your rating for each objective in a place that will be easy to refer to later
in the training.

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Module 1
Overview

Upon completion of this module, participants will be able to:

Identify the proper safety procedures that must be followed while working on the
well

Define barite sag and outline the other causes of density fluctuation

Define the Boycott Effect and Stokes' Law and the impacts they have on barite
sag

Outline problems that may occur due to barite sag

Lessons
1. HSE in Wells
2. Introduction to Barite Sag
3. Scientific Aspects of Sag
4. Consequences

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Lesson 1
HSE in Wells

Lesson Overview
This lesson consists of the following topics:
General Precautions
Well Site
Responding to Emergencies

General Precautions

Key Health, Safety, and Environment points to

remember
Tasks/activities may only be performed by
trained/qualified/authorized personnel, e.g.
personnel competent in mud design,
monitoring, and well control procedures.
Verify data, equipment, materials, job
parameters and job specifics prior to starting
the job (avoids wrong/inferior drilling fluids,
wrong densities, viscosities, etc.).
Pre-job planning and safety meetings should engage all applicable personnel.
There may be multiple simultaneous activities on location, so be sure to
communicate with other contractors onsite.
Follow the 10 critical upstream process safety requirements. Exercise Stop
Work Authority and follow Management of Change process and procedures as
required.
Complete mandatory visual inspection of materials/tools/equipment/
accessories before starting the job. Verify ratings, certifications, and
calibrations. Ensure they are fit for purpose and meet safety, quality, reliability,
and operational requirements.
Refer to the latest version of the Safety Data Sheet (SDS) prior to handling,
storing or shipping the product.
Continuous monitoring and frequent checks of critical parameters (mud density,
viscosity, temperature, pressure, etc.) is critical as it may reveal any early signs
of potential trouble.
Ensure familiarity with the site and local emergency response plans and
contact details.

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Communicate HSE concerns, including client HSE concerns or requirements,

or when barriers have been compromised or challenged.
Prevent contamination and exercise proper personal hygiene when working
around chemicals.
Wear appropriate Personal Protective Equipment (PPE) (for example,
respiratory, skin, hearing, head, eye, face, fall protection) for the hazards
present at all times in designated areas.

Well Site
Loss of well stability/well control (blowout)
could lead to:
Release of hydrocarbons or toxic substances
in an uncontrolled manner
Catastrophic event resulting in injury and/or
loss of life
Environmental damage
High pressure fluids handling - be aware of:
Injury due to the unexpected release of
trapped pressure
Spills and releases
Exposure to a high-pressure connection failure
Being struck by a pressurized line
Being struck by particles or fluid
Chemicals usage - be aware of:
Spills and releases
Burns or physical injury caused by contact with skin or eyes
Exposure to explosions or violent reactions from chemicals mixed improperly
Exposure to potential skin and respiratory hazards
When operating heavy equipment - be aware of:
Equipment failures
Be aware of moving equipment, which could lead to being struck/crushed by
falling equipment
Equipment handling injuries, including overexerting, sprains, strains, and pinch
points
Slips, trips, and falls (falling from heights)

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Responding to Emergencies
Keep unnecessary and unprotected personnel
away from the work area.
Follow local emergency plans in case of
accidental releases, exposures/contact, spills,
and other emergencies.
Be sure to know the location of emergency
equipment, such as eye washes, emergency
showers, spill response equipment, etc., for
use if required.

Lesson Summary
You have now completed the HSE in Wells Lesson, which consisted of the
following topics:
General Precautions
Well Site
Responding to Emergencies

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Lesson 2
Introduction to Barite Sag

Lesson Overview
This lesson consists of the following topics:
Definition of Barite Sag
Dynamic Barite Sag
Static Barite Sag
Other causes of density fluctuation

Definition of Barite Sag

The American Petroleum Institute (API) has defined barite sag as a variance in
nominal mud weight where lighter density fluid is followed by higher density fluid
after a period of non-circulation.

Barite sag is often described as the variation in mud density, which is caused by
settling of barite or other weight material. The barite sag problem is increasingly
seen in high angle wells with an increase in particle settling; which results when
barite separates from the liquid phase and settles down. Sag occurs from static or
dynamic settling and what often follows is the downward slumping of such weight
material. This decreases the mud density in a section of the wellbore while
increasing the mud density in a lower section. Barite sag is commonly noticed while
circulating bottoms up after a long period of non-circulating time.
Sag "Fingerprint"

Mud
Weight
(lbm/gal)

Circulating Time (hr)

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Barite sag of a drilling fluid predominately occurs where the following conditions are
found:
Deviated wells between 30° to 90°. The most difficult range is 40° to 60°.
Mud weight range between 12 - 16 lbm/gal (1.44-1.92 SG). (Sag can also
occur at higher densities when fluid temperatures are also high).
When flow rates are low. Dynamic sag has been found to be most severe,
when slow circulating rates are experienced. The recommended minimum
annular velocity is 100 ft/min.
When the drilling fluid contains a high level of coarse particles (new barite or
where emulsifier concentration is low, allowing barite agglomeration to occur).
The yield point and especially yield stress of the drilling fluid is low.

Dynamic Barite Sag

The combined effects of hole angle, low annular
velocity, and a stationary, eccentric drillpipe are
conducive to dynamic barite sag. Dynamic sag
is complex and occurs under conditions of low
shear. Low annular flow rates (without rotation)
and operations such as running logs and
tubulars overcome a fluid yield stress and can
induce dynamic sag. Not surprisingly barite sag
is more prevalent in the smaller hole sizes of
highly deviated wells under High Temperature/
High Pressure (HP/HT) conditions, as this is Barite Beds
where most of the contributing factors occur
together.

In deviated wells, the drilling assembly is

eccentrically positioned on the lower side of the hole, creating a skewed velocity
distribution in the annulus. Because of pressure drop and a restricted flow area, the
flow velocity underneath the eccentric drilling assembly is lower than that above the
assembly. Low annular velocity levels on the lower side of the hole create
conditions conducive to the formation of cuttings beds.

Shear Rate
This is defined as the difference in the velocities between two adjacent layers,
divided by the distance of separation between the two layers. Thus, shear stress
can be related to the force required to overcome the resistance of the fluid to flow,
while shear rate is the change in fluid velocity divided by the distance. Therefore, if
the shear rate increases, then the shear stress also increases.

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As can be seen in the figure, the settling of barite particles occurs at low shear
rates.

Static Barite Sag

Static sag occurs when the fluid in the container is not being moved. This can be
seen in storage tanks, the pit system of a rig, and in a wellbore.

Static sag can be greatly reduced by increasing the low shear viscosity and
thixotropic behavior of the drilling fluid. In a well however, there is a limit to what
can be achieved this way before other factors, such as Equivalent Circulating
Density (ECD), are compromised. Therefore some degree of sag should be
expected, and monitoring put in place so that it can be managed.

Other Causes of Density Fluctuation

Any process which results in a density change in the mud has the potential to be
misinterpreted as sag. Gas-cut mud, fluid influxes, and changes due to temperature
are examples of such processes.

During the drilling process, it is possible for gas or liquid to enter the mud from the
formation if the mud density is too low. Often this happens when a higher pressure
zone is unexpectedly drilled into, with the resulting influx known as a kick. In most
cases, a kick will result in a portion of the circulating system having a different
(usually lower) density than the rest and to the uninitiated, this could look like an
indicator of barite sag. Mud density also varies with temperature, in common with
most liquids. If densities are measured at differing temperatures without converting
them back to a standard reference temperature, then such variations could also
look like a mild form of barite sag.

On a drilling rig there can be fluctuations in the density of the drilling fluid during
different operations and these fluctuations may or may not be considered as barite
sag. Causes of density fluctuations that are not barite sag include, but are not
limited to, temperature changes, uneven density pumped down the drillstring, influx
of formation fluid, and entrained air or gas in the drilling fluid.

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Temperature inversely affects the density of both aqueous and nonaqueous fluids;
as temperature increases, density decreases. For this reason, temperature is
recorded with density measurements.

Example: 12.8 lbm/gal at 80°F

When temperature is changed, the density of a fluid can be expressed as:

()
ρ0
ρ1 = ......................... 1
{1 + β (t1 - t0)}
where:

ρ1 = Final density (lbm/gal)

ρ0 = Initial density (lbm/gal)
β = Volumetric temperature expansion coefficient (gal/gal °F)
t1 = Final temperature (°F)
t0= Initial temperature (°F)

After a period of non-circulation, the temperature of the fluid at the flowline (in
deepwater the temperature may dip before) increases to a higher temperature than
ambient temperature when the fluid is circulated (refer to the "Flowline temperature
in a deepwater well resuming circulation after a trip" image). In general, flowline
temperature will increase as the depth of the well increases. The temperature is
dependent on the hole and drill string geometry, geothermal temperature profile,
fluid composition, fluid circulating rate, drill string rotational speed, torque, etc. As
an example, a 20°F temperature increase can noticeably reduce the density of a
nonaqueous fluid, 12.834 lbm/gal at 75°F and 12.787 lbm/gal at 95°F or 0.00235
(lbm/gal)/°F. The image titled "Example of the variation of density of aqueous and
nonaqueous fluid with temperature" demonstrates the variation of density of two
fluids with temperature and can be easily determined with Baker Hughes
Advantage™ software.

Temperature
(Fahrenheit)

Hours

Flowline temperature in a deepwater well resuming circulation after a trip

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Density
(lbm/gal)

Temperature (°F)

Example of the variation of density of aqueous and nonaqueous fluid

with temperature

Uneven fluid density is often pumped down the drillstring during normal operations
then circulated out of the well where it is seen at the flowline. Slugs of higher
density fluid are pumped to remove the fluid from the drill string as it is being pulled
out of the hole. Slugs are normally 2-3 lbm/gal higher than the fluid density and
typically 30-50 bbl in size. If multiple slugs are pumped, they can be seen at the
flowline when circulation is resumed after tripping the drillstring. As the temperature
of the fluid changes in the surface system during circulation, weighting material
may be added to increase the density if the temperature effect is not accounted for.
This can cause the density of the fluid to be higher when the temperature is
returned to the initial temperature. Activities by rig personnel can also affect the
density of the fluid being circulated. Normal rig cleaning activities can result in
water or cleaning fluid being mixed with the drilling fluid, resulting in a lower density
fluid.

A downhole occurrence of an influx can cause the density of the drilling fluid to
fluctuate. Influxes of formation water, oil, or gas reduce the density of the fluid as
the density of the influx is normally less than the density of the drilling fluid. As seen
in the following equation, if 9 bbl of a 13.0 lbm/gal at 90°F drilling fluid incorporates
1 bbl of 6.8 lbm/gal at 90°F crude oil, the resultant density is reduced to 12.38
lbm/gal at 90°F.

(ρ1 × v1 + ρ2 × v2)
(v1 + v2) ()
= ρ3 ....................... 2

where:

ρ1 = Fluid density (lbm/gal)

ρ2 = Influx fluid density (lbm/gal)
ρ3 = Final density (lbm/gal)

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v1 = Fluid volume (bbl)

v2 = Influx volume (bbl)

Normally gas can be detected at the surface with gas detection equipment and is
mechanically removed from the fluid before it is recirculated down the drill string.
Liquid influxes, formation water, or oil may be more difficult to detect in small
quantities. In an aqueous fluid, formation oil may be measured with the use of the
retort during the standard determination of fluid properties (refer to the retort
collection cylinder image). In nonaqueous fluids, formation oil can be identified with
the use of Gas Chromatography-Mass Spectrometry (GC-MS), an analytical test
that can be conducted at a shore-based Field Service laboratory. For both aqueous
and nonaqueous fluids, an influx of formation water may be identified by a change
in the salinity of the fluid if the salinity of the formation water differs from the salinity
of the drilling fluid.

Read the water volume at the

lowest point of the meniscus
Example shown:
-7.8 cm^3 (78%) Total Liquid
-7.4 cm^3 (74%) Water
-0.4 cm^3 (4%) Nonaqueous

7.8

7.4
7.8-7.4=0.4 (Nonaqueous)

Retort collection cylinder indicating nonaqueous fluid contained in an

aqueous drilling fluid

Entrained air or gas in the drilling fluid reduces the measured density of the fluid
with standard density scales and can be mistaken for barite sag. Air can become
entrained in the drilling fluid by several means, like “kelly cut” while making
connections or tripping pipe, adding dry chemicals through the mixing hopper, or
low volume in a pit being stirred with a paddle agitator. To determine the density of
the fluid with a standard mud scale, a precise volume of fluid is placed in the fluid
receptacle and the density is determined by sliding a weight until the unit is
balanced. If the fluid is aerated, the required volume of fluid cannot be placed into
the mud scale, thus the density of the fluid is not measured accurately. The use of
a pressurized mud scale is thus recommended when determining the density of an
aerated fluid. A pressurized mud scale is used to force fluid into the fluid receptacle
under pressure to minimize the effect of entrained air or gas on the density
measurement.

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Pressurized Mud Scale

Use API RP13B-1 Recommended Practice for Field Testing Water-

based Drilling Fluids - Fourth Edition and API RP 13B-2
Recommended Practice for Field Testing Oil-Based Drilling Fluids -
Fourth Edition procedures for all API tests for daily mud reports.

Lesson Summary
You have now completed the Introduction to Barite Sag lesson, which consisted of
the following topics:
Definition of Barite Sag
Dynamic Barite Sag
Static Barite Sag
Other Causes of Density Fluctuation

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Lesson 3
Scientific Aspects of Sag

Lesson Overview
This lesson consists of the following topics:
Boycott Effect
Stokes Law

There are several laws that explain certain mud behavior. It is useful to know them
when addressing Barite Sag.

Boycott Effect
A curious settling phenomenon was first reported by Boycott (1920), who observed
that blood corpuscles in narrow tubes settled faster if the tubes were inclined rather
than vertical. Applied to a drilling situation, this means that light mud will travel up
the high side of the annulus and heavy mud will travel down the low side of the
annulus faster in an inclined well than in a near vertical well. A maximum settling
rate is more prominent in inclinations around 45°. Due to the Boycott effect, barite
sag potential reaches a maximum between 40° and 60° deviation.

In the vertical tube, the settling particles displace fluid, which in turn rises. Fluid
elements pass past more particles and accelerate and decelerate depending on
whether their paths are wide or narrow.

Fluid elements in the inclined tube escape from the particles more quickly and flow
more easily. Furthermore, as the particle suspension gets more concentrated, it
also gets more dense. This provides more driving force for settling. The overall
effect is that the particles slide down the wall while the clear liquid flows upward
with less interference than in the vertical tube.

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Settling of particles
happens with minor
interference from the tube
Clarified
Layer
Hindered
Settling Regime
Particle
concentration
systematically
increases with
time from top to
the bottom

45°

Compaction Regime
Sediment Bed

Boycott (left) and Hindered (right) settling kinetics under static conditions.

There are three regimes of particle sedimentation in a vertical tube:

Clarification regime
This is free settling of fewer remaining particles with minor interference
from nearby particles and also from the walls of the tube.
Hindered Settling Regime
High concentration causes the particles to crowd around each other and
interfere with the settling of individual particles. This reduces the settling
rate well below that of free settling.
Compaction Regime
The particles are now at the bottom of the tube and as the bed compacts
further, the excess fluid flows upwards while the particles support each
other mechanically.
The drawing on the right hand side above depicts the three regimes of particle
sedimentation in a vertical tube (Hindered Settling). The left hand diagram
represents Boycott settling.

In the inclined tube, the particles still settle vertically. However, the maximum
distance they can travel is highly reduced. Clear fluid forms quickly on the upper
side of the tube due to the increased buoyancy effect. Particles accumulate on the
lower side of the tube quickly and concentrate the sediment bed at the bottom of
the tube. Around 45°, the clarified layer velocity and settling rate is at its maximum.
Thus, for a higher well inclination the buoyancy effect reduces the free settling rate
and hindered settling starts to occur as the well approaches horizontal.

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Stokes' Law
One of the major factors that influences barite sag is the viscosity of the fluid.
Settling velocity of barite particles can be described by following equation:

V s = Cd 2

where:

C is constant
d is particle diameter.

( )
C = ρs - ρ f *
g
μ

where:

ρs equals density of solid

ρf equals density of mud
g is constant of gravity
µ is fluid viscosity.

Below is the example of Stokes' Law:

In order to compare the velocity of particle settling, low-viscosity fluid and high-
viscosity fluids were compared.

LOW-VISCOSITY FLUID HIGH-VISCOSITY FLUID Drilling

Water-AV=2cps Mud-AV=24 cps

Stokes' Law

Settling in a low-viscosity fluid happens much faster than in high-viscosity fluid.

Larger particles settle faster than smaller particles.

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LOW-VISCOSITY FLUID
Water-AV=2cps

HIGH-VISCOSITY FLUID Drilling

Mud-AV=24 cps

Stokes' Law

As seen in the following figure settling has occurred.

LOW-VISCOSITY FLUID HIGH-VISCOSITY FLUID Drilling

Water-AV=2cps Mud-AV=24 cps

Stokes' Law

Stokes' Law Simplified

If... Then Settling Velocity...

Particle diameter increases Increases
Specific gravity increases Increases
Mud viscosity increases Decreases
G-Force increases Increases

If two particles are the same size, and particle A has a higher specific gravity than
particle B, then according to Stokes' Law, particle A will settle faster.

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Lesson Summary
You have now completed the Scientific Aspects of Sag lesson, which consisted of
the following topics:
Boycott Effect
Stokes' Law

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Lesson 4
Consequences

Lesson Overview
This lesson consists of the following topics:
Lost Circulation
Well Control
Stuck Pipe
Wellbore Instability

It is important to recognize and mitigate the risk of barite sag as it can be the
source of severe drilling related issues and well control problems. These risks are
increased when drilling deviated wells.

In the upper sections of a well where barite sag occurred, the density of fluid will be
reduced. If the hydrostatic pressure is lower than formation pressure, a well control
situation can arise. Heavy mud at the bottom can increase the hydrostatic pressure
in the well, thus, fracturing the formation and resulting in lost circulation. This heavy
mud at the bottom can also cause differential sticking leading to stuck pipe. Lost
circulation can also be a result of pack off of the drill string from the slumped weight
material. Also, insufficient mud weight can cause stability issues in the wellbore,
causing it to collapse.

Lost Circulation
Barite sag is roughly defined as variations in mud weight caused by settling of
weight material. Such changes can cause downhole losses, known as lost
circulation. One of the main treatments for the lost circulation is adding Lost
Circulation Material (LCM) to the mud and pumping it down the well to seal the lost
circulation zone. Additionally, the fluid viscosity and/or density may be lowered to
reduce the ECD to minimize the potential of lost circulation in the future. However,
when doing so, it is important to remember how mud treatments can influence the
sag potential of a fluid, as well as what type of fluid is being treated.

Well Control
Barite sag can contribute to loss of well control in several ways. If a shallow,
pressured zone exists in the open hole, it may be possible for barite sag to
decrease the hydrostatic pressure above the pressured zone to the point that a

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formation influx occurs. Barite that was once suspended in the fluid may have
sagged to the inclined wellbore wall and slumped below the pressured zone, no
longer contributing to confining pressure (refer to the following image). In near-
vertical wells, density stratification may also result in a reduction of hydrostatic
pressure above the pressured zone.

Lighter Fluid

Permeable
pressured zone

Heavier Fluid

Occurrence of sag reduces the wellbore hydrostatic

pressure above the permeable zone

Loss of well control may also occur as a result of lost circulation. When circulating
out heavy mud resulting from barite sag, it is possible to exceed formation fracture
pressure in both shallow and/or deeper zones. Initially, deeper zones may see little
net change in hydrostatic pressure as heavy mud in the lower hole will be offset by
lighter mud in the upper hole. Deeper zones may be fractured when the lighter mud
at the top of the hole is circulated out, resulting with heavy mud in the upper hole
and correct density mud in the lower hole. Shallower zones may be fractured as the
heavy mud is circulated above the weaker zone. In either case, once lost circulation
occurs, the hole must remain full of the appropriate density fluid or else a formation
fluid influx may occur.

Stuck Pipe
Barite sag may also result in a stuck pipe incident, when the drillpipe, casing, or
other devices inadvertently become stuck in the hole. In deviated wellbores, due to
the Boycott effect, the lighter fluid moves up the wellbore as the heavier mud layer
slides downward, creating a sediment bed, which may result in stuck pipe. It is
important to keep in mind that stuck pipe can also be caused by static barite sag,
which occurs when the mud has not been circulated for a long period of time.

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Wellbore Instability
Wellbore stability and instability are related to the hydrostatic pressure applied to
the formations. The fluctuation of fluid density that occurs during sag can cause a
fluctuation of hydrostatic pressure to the degree causing shale to dislodge from the
wellbore causing cavings as seen in the following image. The instability of the
wellbore creates additional risk in drilling operations, which can lead to stuck pipe
(pack-off), poor cementing due to wellbore enlargement, or the overload of cuttings
handling equipment.

Shear Failure (Splintery "Pressure" Cavings)

Failure:
Effect of drilling direction Due to the stress in massive
shales

Mud Type:
Oil/Synthetic-based mud or
water-based mud

Solutions:
Raise mud weight, change
trajectory

Platy/Tabular Cavings
Failure:
Tendency for failure Due to rock strength anisotropy
(weakly bedded or fissile)

Mud Type:
Oil/Synthetic-based mud or
water-based mud

Solutions:
Adjust mud weight, increase
angle-of-attack to bedding,
change trajectory

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Blocky Cavings ("Rubble)"

Failure:
Due to the stress and time-
Effect of drilling direction dependent mud penetration into
fractures (e.g., fractured rocks,
around salt, along faults)

Mud Type:
Oil/Synthetic-based mud worse
than water-based mud

Solutions:
Adjust mud weight, change mud
type, prevent mud penetration,
reduce swabbing.
Shale Cavings Types and Wellbore Stability Prediction poster by GMI.

Lesson Summary
You have now completed the Consequences lesson, which consisted of the
following topics:
Lost Circulation
Well Control
Stuck Pipe
Wellbore Instability

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Module Summary
You have now completed Overview Module, which consisted of the following
lessons:
HSE in Wells
Introduction to Barite Sag
Scientific Aspects of Sag
Consequences
Having completed this module, you should be able to:
Identify the proper safety procedures that must be followed while working on
the well
Define barite sag and outline the other causes of density fluctuation
Define the Boycott Effect and Stokes' Law and the impacts they have on barite
sag
Outline problems that may occur due to barite sag

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Module Review Questions

1. List any three HSE General Precautions key points to remember.

2. Barite sag can occur under static and dynamic conditions.

a. True
b. False

3. Gas-cut mud, fluid influxes, and changes due to the temperature can cause a
density change in the mud, and potentially can be misinterpreted as sag.

a. True
b. False

4. If a particle diameter increases, then settling velocity_______.

a. Increases
b. Decreases
c. Does not change

5. Shear rate does not affect barite sag.

a. True
b. False

6. The following problems can occur due to barite sag. Choose all that apply.

a. Stuck Pipe
b. Sand Control Problem
c. Lost Circulation
d. Wellbore Instability

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Module 2
Variables for Barite Sag

Upon completion of this module, participants will be able to:

Identify the types of the fluids that can influence the likelihood of barite sag

Identify the influence that operational parameters have on barite sag

Lessons
1. Fluids Design
2. Operational Parameters

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Lesson 1
Fluids Design

Lesson Overview
This lesson consists of the following topics:
Fluid type
Mud Related Variables
Mud Treatments Which Can Affect Barite Sag
Sag of Other Weighting Materials

Fluid type
Sag of weight material is strongly dependent on the rheological characteristics of
the drilling fluids. A significant difference between oil- and water-based drilling fluids
arises from their different abilities to generate gels. In water-based drilling fluids, a
gel is typically observed in cases with very little motion only. Electrical double layer
forces create a solid-like structure of the particles within the drilling fluid. In oil-
based drilling fluids, the gel behavior tends to be weaker and more easily broken.
The composition and properties of the drilling fluid also have a major influence on
barite sag potential.

Barite sag phenomena are such that sometimes fluids with otherwise ideal
properties are incapable of suspending barite under certain conditions. Invert
emulsion drilling fluids are generally considered to be more prone to sag than
water-based muds due to the reduced ability to form strong gel structures under
static conditions and to exhibit high viscosities under low shear dynamic conditions.

Mud Related Variables

Sag of weight material in drilling fluids is linked to the viscosity of the fluid. This
relationship is not straight forward as drilling fluids exhibit non-Newtonian viscosity
and there is no direct relationship between viscosity and sag. There are numerous
terms used to describe the rheological properties of drilling fluids, both under
dynamic and static conditions. As a general statement, it is frequently, though not
always, true that more viscous muds tend to exhibit less severe sag than less
viscous muds. The viscosity parameter which most closely correlates with dynamic
sag severity is the low shear viscosity (see section on Dynamic Barite Sag) and this
property is not necessarily closely correlated with conventional parameters such as
yield point and plastic viscosity. A focus on the so-called “low shear readings”
obtained from a Fann 35 viscometer will usually provide a better indication of sag
potential. It is possible to have two fluids with the same yield point but with quite

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different values for the 6 RPM and 3 RPM dial readings as measured on a Fann
viscometer. In this situation, the mud with the higher readings will almost certainly
exhibit a lower sag potential.

In oil-based muds, general viscosity can come from a variety of sources:

organophilic clay, emulsion droplets, and drill solids. The relative mix of these will
affect the ratio of high shear to low shear viscosities and therefore, the sag
potential. Running the oil-water ratio at a value of 80:20-85:15 (for the typical mud
densities at which sag is a common problem) and minimizing the build-up of Low
Gravity Solids (LGS) will allow the maximum percentage of the total viscosity to be
derived from organophilic clay and this is a good method of reducing the risk of
sag.

Under static conditions, the gel structure of the mud is important in determining the
resistance to sag. The ideal fluid will build a gel structure quickly and the structure
built will be non-progressive with time. This allows particles of barite or other weight
material to be “caught” as soon as the mud becomes static, and kept in a state of
suspension by the structure of the gel formed. However the fluid still requires
relatively little energy to break these gels after being quiescent for a longer period
of time, and so does not present problems in terms of pressure spikes when
regaining circulation. This type of behavior is reflected in relatively high initial (10
second) gel strengths with longer time period (10 minute and 30 minute) values
which are not much greater than the initial values. As with low shear dynamic
viscosity, the gel behaviour of the mud under static conditions is affected by the
fluid’s composition and the maintenance of the correct oil-water ratio and a low
level of drill solids will help to ensure that the right gel profile is developed.

Mud Treatments Which can Affect Barite Sag

Mud treatments that reduce sag:

Organophilic Clay

Sag can be reduced by increasing the concentration of organophilic clay. Examples

of organophilic clays for this purpose include CARBO-GEL and RHEO-CLAY
PLUS. However, be aware that excessive clay treatments can increase viscosity
profiles to be detriment of drilling performance.

Oil-Water Ratio (OWR)

OWR is a key property in minimizing barite sag, as it can determine the amount of
organophilic clay that can be incorporated into the mud system. Fluids with lower
OWRs (e.g. 60/40 as opposed to 80/20) obtain a significant amount of viscosity
from the invert emulsion. This will result in the use of lower concentrations of quality
organophilic clay to obtain the programmed yield point and low shear viscosity
values. Viscosity derived from quality organophilic clays is far more effective in
reducing the likelihood of significant barite sag than viscosity derived from an invert
emulsion. Therefore, increasing the OWR (i.e., increasing the percentage of oil in

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the liquid phase) to approximately 80/20 (or higher for high density HTHP fluids) will
allow the addition of more organophilic clay and help to minimize barite sag while
maintaining the viscosity within programmed values.

Ultra Fine Calcium Carbonate

Sag tendency can be reduced by adding small quantities of ultra-fine calcium

carbonate (D50 approximately 5 micron), e.g. MIL-CARB 5. These fine, but
interactive, particles form part of the microscopic structure created under static or
very low shear conditions and help to make it more robust, thereby increasing the
ability to suspend weight material particles.

Treated Calcium Carbonate

Sag tendency may also be reduced by the addition of treated calcium carbonate.
MAGMA-PLEX is an example of a treated calcium carbonate.

Mud treatments that increase sag:

Oil-Wetting Agents/Thinners

Certain situations can arise (e.g., excessive viscosity through solids build up or
aqueous influx) where oil-wetting agents and thinners may be useful to combat
these effects. However, strong oil-wetters/thinners such as OMNI-COTE or BIO-
COTE can severely impact the structure formed by the organophilic clay. It is the
integrity of this structure which maintains barite suspension in the fluid.
Consequently, the use of oil-wetting agents/thinners is not generally recommended.
If they are used, great care should be exercised to minimize the potential for
inducing sag.

If problems with sag are envisaged, thinning the fluid prior to running
casing (either with the addition of neat base oil or with the addition of
the above mentioned oil-wetting agents/thinners) is not recommended.

If additional wetting is required when weighting up, the use of an emulsifier such as
CARBOMUL HT, OMNI-MUL, or OMNI-MUL II is recommended in place of an oil-
wetting agent/thinner. Avoid over-treatment as this may also negatively impact
barite sag.

Base Oil Dilution

Base oil dilution can increase the likelihood of sag by diluting the concentration of
structure building rheological agents in the fluid. The main structure building
product is usually organophilic clay.

Surfactants/Emulsifiers

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Over-treatment with emulsifiers can result in over-wetting of the fluid. The effect
can be similar to the addition of oil-wetting agents/thinners.

Asphaltic Shale Control Additives as Torque Reducers

The use of chemicals designed for shale control in water-based fluids are
sometimes used to reduce torque in synthetic oil-based/oil-based fluids and can
contribute significantly to an increase in barite sag. Asphaltic materials such as
SULPHATROL, PROTECTOMAGIC M, and BLACKMAGIC SFT all increase barite
sag in synthetic oil based/oil based fluids. The levels at which these products may
be used without significantly affecting barite sag vary according to mud weight,
base oil used, and other product concentrations.

Low End Rheology Modifiers

The use of dimmer/trimmer fatty acid low end rheology modifiers (e.g., CARBO-
TEC S) does not reduce the likelihood of significant barite sag. Although these
products boost low shear viscosity and yield point and may improve hole cleaning,
they do not build the type of structure required to reduce barite sag. They may even
induce sag by reducing the amount of organophilic clay which can be added to the
fluid while maintaining adequate viscosity.

Constant Viscosity Modifiers

Constant viscosity modifiers are used with other rheological agents such as
organophilic clay to provide a relatively constant rheological profile for an oil based
mud with respect to temperature changes. RHEO-LINE HT is an example of this
type of viscosity modifier. The presence of drill solids can greatly enhance the
effects of this type of product. Caution should be exercised with the use of these
products as they may not protect against sag as well as organophilic clay.

Sag of Other Weighting Materials

An API Grade Barite, MIL-BAR, is the dominant weight material used by Baker
Hughes in drilling fluids. Other, less common weighting materials can also result in
density fluctuations, lower and higher densities, and thus, sag is not unique to
Barite. Other weighting materials, including MIL-BAR UF, MICROMAX, and MIL-
CARB, are used as weighting materials for special drilling fluids and operating
conditions.

These materials have differing densities and particle sizing, thus, the sag tendency
varies. (Please refer to the following table.)

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Physical properties of weighting material

Particle Size, d-50
Product Name Chemical Specific Gravity (s.g.)
(micron)
MILBAR Barium Sulfate 4.2 10-20
MILBAR UF Barium Sulfate 4.3 2-4
MICROMAX Manganese 4.8 0.5-1.0
Tetraoxide
MIL-CARB Calcium Carbonate 2.7 10-20

Although MIL-BAR UF and MICROMAX have higher specific gravities compared to

barite, the bulk of the particles are significantly smaller in size (see the following
image). The significantly smaller particle size out-weighs the higher density as
related to the potential to sag, thus, both materials are significantly less likely to
experience sag. In addition, the higher density of the materials result in less
material needed to obtain a particular density compared to barite. The maximum
density achieved with MIL-CARB (calcium carbonate) is limited (±10.5 lbm/gal in
freshwater fluids) due to the density of the material, thus, the severity of sag is
reduced for a 100% calcium carbonate fluid.

Scanning electron microscopy of various weighting materials.

As stated by Stokes' Law, the settling velocity of a particle is directly proportional to

the square of the diameter of the particle and the density of the particle.(Refer to
the following equation). The smaller particle size of MIL-BAR UF and MICROMAX
reduces the sag tendency of the particles significantly compared to barite as seen
in the following image below, where the size of the bubble represents the settling
velocity of the material.

g × DS 2 × (ρs - ρl )
Vs =
18 × η

Where:

Vs= settling velocity

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g = force of gravity
DS = diameter of the solid
ρs = density of the solid
ρl = density of the liquid
η = viscosity of the liquid

Settling Velocity

MICROMAX
Barite

MILBAR UF
MIL-CARB

Particle Size

Comparison of settling velocity (reference Stokes' Law) of the D50 particles

for different weight material in a fluid of the same viscosity.

Lesson Summary
You have now completed the Fluids Design lesson, which consisted of the following
topics:
Fluid type
Mud Related Variables
Mud Treatments Which Can Affect Barite sag
Sag of Other Weighting Materials

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Lesson 2
Operational Parameters

Lesson Overview
This lesson consists of the following topics:
Density
Hole Angle and Hole Size

Density
Field experience has shown that barite sag can occur over a variety of densities,
with fewer consequences of sag at densities lower than 10.0 ppg and densities
greater than 16.0 ppg. Heavier muds can be more resistant to barite sag due to
solids crowding, a phenomenon known as "hindered settling", where the free fall of
particles due to gravity as predicted by Stoke's Law is lessened due to particle-
particle interactions. As discussed previously other weighting materials can be
utilized that have different densities and/or particle sizes, and therefore different
susceptibility to sag. Furthermore, proper wetting of weight materials combined with
adequate shear will reduce the potential for sag by reducing agglomeration of
particles. In muds with inadequate wetting and poor mixing, the effective size of the
weight material particles may be significantly greater than the theoretical size and
in these cases the risk of sag is greatly increased.

Hole Angle and Hole Size

Dynamic barite sag generally increases with increasing hole angle up to about 60°
and then decreases in more horizontal wellbores. Flow loop studies have shown
that barite sag in angled wells is correlated with low shear viscosity, specifically
viscosity at shear rates in the 0.1-1.0 reciprocal second range. This shear rate
range forms the basis of the RJF Window.
The angle when sliding of settled barite occurs depends on mud type. Barite beds
can avalanche when flow is stopped at connections. This may lead to pack-offs and
stuck pipe.

Hole Size

Dynamic barite sag is inversely proportional to annular flow rate. In holes with
multiple annular clearances, flow rate is normally determined by the smallest
annular clearance and, as a result, larger clearances higher up the well may
experience lower flow rates than those necessary to avoid barite sag. In some
wells, larger diameter drillpipe has been used to reduced annular clearances and

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decrease the risk of sag. Drillpipe rotation is known to influence barite sag, but the
effects are complicated. High rotational speeds can “stir up” barite beds, which may
have formed on the low side of the hole, while slower rates are thought in some
cases to concentrate solids underneath the pipe. Some of the more recent
hydraulics models now incorporate the ability to model the effect of drillpipe
rotation, and also drillpipe eccentricity, on cuttings bed formations. However these
models are only models and their output should always be treated with an element
of caution. Drag comparisons of calculated vs. actual when pulling out of hole
combined with observations following the pumping of hole-cleaning pills and
sweeps should always be taken into account when attempting to determine
whether cuttings or barite beds are present.

Lesson Summary
You have now completed the Operational Parameters lesson, which consisted of
the following topics:
Density
Hole Angle and Hole Size

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Module Summary
You have now completed the Variables for Barite Sag module, which consisted of
the following lessons:
Fluids Design
Operational Parameters
Having completed this module, you should be able to:
Identify the types of the fluids that can influence the likelihood of barite sag
Identify the influence that operational parameters have on barite sag

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Module Review Questions

1. Sag can be reduced by the addition of treatments of treated calcium
carbonate. Which of the following products is an example of this?

a. MIL-CARB 5
b. CARBO-GEL
c. MAGMA-PLEX
d. BIO-DRILL

2. If additional wetting is required when weighting up, the use of __________

is recommended in place of an oil wetting agent/thinner.

3. Sag can be reduced by increasing the concentration of organophilic clay

a. False
b. True

4. Dynamic barite sag generally __________ with increasing hole angle up

to about 60° and then __________ in more horizontal wellbores

5. The composition and properties of the drilling fluid have a major influence on
barite sag potential.

a. True
b. False

6. High temperatures cause the drilling fluid to thin, which can increase sag
tendency.

a. True
b. False

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Module 3
Testing and Recommendations

Upon completion of this module, participants will be able to:

List testing procedures that are used by Baker Hughes to measure sag

Identify measures that can be taken to prevent the likelihood of barite sag

Lessons
1. Testing
2. Recommendations

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Lesson 1
Testing

Lesson Overview
This lesson consists of the following topics:
Barite Sag Window Test
Static Sag Measurement
Static Shear Strength Test
Viscometer Sag Shoe Test

Barite Sag Window Test

The RJF Viscometer was developed in the late 1990s following a long period of
investigation into potential correlations between various viscosity parameters and
barite sag (both static and dynamic). The RJF Viscometer was designed to provide
the ability to measure low shear rates (below 1 RPM) accurately at the rigsite with a
view to monitoring the mud for dynamic barite sag potential. Numerous studies had
identified that dynamic sag was a more serious risk than static sag and that the
critical parameters were associated with viscosity at shear rates below those which
could be properly measured with a conventional rig-site viscometer (Fann 35).

Robinson and Jachnik introduced the RJF viscometer (U.S. Patent Number
5,763,766) in 1996. This novel instrument was considered an improvement over
conventional 6-speed viscometers because it possessed measuring capabilities at
ultra-low shear rates, featured separation of drive and measuring systems and
utilized a computer acquisition system to record, store and analyse the data. As the
industry recognized the need for commercially available ultra-low shear rate
viscometers, OFITE developed the Model 900 viscometer which can also operate
across the range of shear rates required for the RJF sag window test. Since the
withdrawal of the RJF Viscometer from commercial use, the OFITE Model 900
viscometer is routinely used to measure dynamic sag potential.

The “RJF Window” was developed based upon flow loop tests of field muds taken
from a variety of drilling environments from several locations. It is designed to
qualify the potential for severe dynamic barite sag in field muds, and can only be
used as a relative measure of viscosity in laboratory-prepared muds. The testing
conducted identified that the shear rate range between 0.1 and 1.0 reciprocal
seconds (using a conventional Fann 35 geometry) was sufficient to break the gel
structures capable of suspending barite under static conditions but insufficient to
fully suspend barite in a moving fluid. By testing muds with differing viscosities, the
four “corners” of the RJF Window were developed and these are illustrated in the
graph below.

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RJF Window

The RJF Window addresses severe barite sag, i.e., that arising from insufficient
ultra-low shear rate viscosity. Viscosity levels below the Lower Limit of the Window
correlate well with severe dynamic barite sag observed in the field and in flow loop
tests. Conversely, viscosity levels above the Window suggest that the mud is more
viscous than necessary to ensure adequate barite suspension. Fluids in this area
are unlikely to suffer from barite sag but could have higher than desirable ECDs.
Note that all interpretations of data analysed in relation to the RJF Window should
be made with caution as this approach is too simplistic to cover all variations in
conditions seen in the field. These analyses do, however, provide a useful guide.

An example plot from OFITE Model 900 Viscometer is shown below. The graph
shows a fluid with a viscosity curve passing through the RJF Window on the high
side, and therefore exhibiting a low potential for dynamic barite sag. The near
overlapping of the data from the Fann 35 and OFITE Viscometer Model 900
indicates that both machines are properly calibrated. Treating a mud system with a
high quality organphilic clay such as Carbo-gel or RHEO-CLAY will usually result in
a raising of a viscosity curve towards the top end of the RJF Window.

Interpretation of RJF Window

Viscosity levels below the Lower Limit of the “RJF Window” correlate well with
severe dynamic barite sag observed in the field and flow loop tests, and correspond
to a high potential for dynamic barite sag. Conversely, viscosity levels above the
Upper Limit indicate a low potential for dynamic barite sag, but are excessive in
terms of requirements for barite sag prevention. Viscosity levels within the limits of
the “RJF Window” are preferred, and indicate a low potential for dynamic barite
sag. For example, the data shown in the following graph would be that this drilling
fluid exhibits a low potential for dynamic barite sag. The slope of the line within the
RJF Window should not influence the interpretation. In addition, the curve should
exhibit a smooth, continuous profile such that the RJF Viscometer data is an
extension of the 6-speed (Fann 35) portion, and the two curves should over-lap
each other.

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RJF Window Fann 35

text
Vire B
Vire A
Upper

Low potential for dynamic barite sag

Lower

Viscosity
(cP)

High potential for dynamic barite sag

Shear rate (s-1)

Static Sag Measurement

Historically, sag potential in drilling fluids has
typically been measured in a static environment.
The technique is very simple and involves placing
a test fluid in a hot-rolling cell and aging it for a
period of time (typically 16 hours) in an oven with
the cell placed on its end. The cell will be sealed
with a nominal pressure inside of 100-200 psi and
the oven set to the static bottomhole temperature
of the well. After aging, any supernatant fluid
(called free oil if the mud is oil-based) is removed
with a syringe and then the densities of the top,
middle, and bottom thirds of the column of fluid
are removed separately for density measurement.
The portions of the aged fluid are typically
removed with some kind of spoon with the handle Static Aging Cell
bent to a 90° angle. Care has to be taken to
minimize disturbance of the fluid, which would result in the mixing of the layers.
From the densities of the top and bottom layers of fluid, the Sag Factor can be
calculated. This is done as shown in the following equation.

density of bottom third

Sag factor =
density of bottom third + density of top third

A perfect mud exhibiting no sag at all would therefore have a sag factor of 0.500. In
practice, a figure of between 0.500 and 0.530 is often judged to be acceptable with
lower numbers being preferred. Other calculations of the level of sag exist, but this
is the one in most widespread use.

The previous test method has the advantage of simplicity, but suffers from the fact
that the fluid is aged under bottom hole temperature while being exposed to only a
relatively small pressure. Particularly when working with oil muds, it is well known

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that temperature has a significant thinning effect while pressure has a thickening
effect. In some wells, these two effects more or less cancel each other out such
that the viscosity, and therefore the suspending characteristics of the fluid are
similar under downhole condition to those at the surface. This aging technique
therefore creates a worst case scenario as the fluid in the aging cell will be much
thinner than at any point in the wellbore. A recent approach to solving this problem
has been to determine the temperature at which the viscosity of the mud at the
applied pressure is the same as it would be under downhole conditions, and then to
conduct the sag testing at that temperature. In these cases, a separate test may be
needed to confirm the thermal stability of the fluid under downhole conditions. If this
is assured, this way of measuring sag performance is likely to give a much more
accurate depiction.

Static Shear Strength Test

Drilling fluids have the potential to develop excessive shear strength when left
downhole under static conditions. This frequently occurs when bottom hole
temperatures are high and can result in a number of downhole operational
problems and lead to a loss of returns. Since the rheology of the drilling fluid
directly affects the circulating system pressure losses, a high shear strength can
cause circulation problems which in turn result in high pump pressures. Examining
the tendency of drilling fluids to generate shear strength in the laboratory can help
with drilling fluid design and well planning.

Measuring static shear in the laboratory is done using a shearometer tube which
can be used along with weights to assess downwards movement of the shear tube
through the statically aged fluid. Static aging is performed to simulate bottomhole
temperatures using aging cells at a suitable pressure.

When testing oil based fluids it is recommended that shear strength measurements
are never conducted in isolation. In order to obtain a more complete evaluation, the
shear test should be accompanied by measurements of the volume of free
supernatant oil and a density differential profile of further samples of drilling fluid
taken at different heights in the fluid column.

Viscometer Sag Shoe Test (VSST)

This test measures the weight material sag tendency of drilling fluids under
dynamic conditions and has the advantage that it can easily be performed at the
wellsite. It is necessary to combine results of the test with operational factors to
provide a full interpretation of the sag potential of the fluid.

Equipment necessary to carry out a VSST consists of a thermocup, sag shoe with a
collection well and a 10 mL syringe fitted with a cannula for extracting mud from the
collection well. Samples are extracted from the collection well after a 30 minute
period at a standard temperature and under a consistent rate of shear. The sag
tendency is determined by the density increase of the samples.

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Viscometer Sag Shoe Test Procedure

Step 1
Preheat thermocup to 120°F or other selected temperature (180°F maximum).

Step 2
Pour 140 mL of mud into the thermocup. Mix at 600 RPM for 15 minutes and
until mud temperature has stabilized at the set point for at least 5 minutes.

Step 3
Using 10 mL syringe with 6 in. cannula (cleared of air), draw slightly more than
10 mL of mud from the collection well. The well can be found using the tip on the
cannula. Carefully clear syringe and cannula of residual air and push plunger to
the established true 10 mL calibration mark.

Step 4
Wipe the cannula and syringe surfaces clean until dry. Weigh and record as
VST1.

Step 5
Gently expel the previously sampled 10 mL of mud into the collection well of the
Shoe.

Step 6
Shift the viscometer to 100 RPM, and run for 30 minutes.

Step 7
Repeat steps 3 through 5, except record the syringe plus the cannula weight as
VST2.

Step 8
Convert VST1 and VST2 to lb/gal, subtract VST1 from VST2, and report as VST
Sag in lb/gal.

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Lesson Summary
You have now completed the Testing lesson, which consisted of the following
topics:
Barite Sag Window Test
Static Sag Measurement
Static Shear Strength Test
Viscometer Sag Shoe Test

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Lesson 2
Recommendations

Lesson Overview
This lesson consists of the following topics:
Philosophy for Non-Aqueous Fluid Design
Sag Reduction
Rig Site Monitoring

Philosophy for Non-Aqueous Fluid (NAF) Design

Regardless of the base oil type and the individual chemical components employed,
Baker Hughes Drilling Fluids has developed a range of current NAF formulations to
meet the needs of all operating areas around the world. These needs include the
requirement to minimize the risk of barite sag as far as possible. In this context, it is
important to realize that all NAF muds are inherently unstable in the absence of
shear and weight material sag is simply a function of time, viscosity, and gravity. It
is possible in many instances to reduce the magnitude of sag to a point where it
does not adversely affect drilling operation. However this cannot be achieved in all
cases.
A combination of field experience and laboratory research has resulted in the
development of the following guidelines for the formulation of NAF, which have a
low tendency to exhibit sag:
Select an oil-water ratio in the range 75:25 to 85:15 with the higher figures
being used in the highest density systems.
The reason for avoiding lower values is to ensure that a significant
percentage of the structure of the mud is derived from the viscosifier rather
than from the emulsion. Very high oil-water ratios should be avoided as the
organophilic clays required for viscosity need a certain quantity of
emulsified water to be present in order to achieve their full yield.
Use only high quality, wet-processed organophilic clays, preferably
based on hectorite rather than montmorillonite, to provide viscosity.
These disperse more effectively into the mud system than the cheaper dry-
processed clays, and this allows them to build a more effective structure
under low shear rate conditions.
Avoid the use of low shear rate viscosity modifiers.
These may actually reduce viscosity at the very low shear rates of
relevance to sag avoidance and they may also contribute to over-wetting of
solids.

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Keep excess emulsifier to a minimum.

Treatment of the mud with large quantities of emulsifier will result in
excessive oil-wetting of solids which makes them harder to suspend.
Avoid the use of oil-wetting agents for the same reason as above.
All of these guidelines have been widely implemented across the globe where NAF
is used.

Sag Reduction
There are certain sag reduction practices that can help to minimize sag:
Build the mud system from a high proportion of field mud.
Field muds exhibit not only a higher content of LGS than a newly
formulated mud system, but the Particle Size Distribution (PSD) will have a
higher fraction of fines. The coarse fraction will have been degraded down
through drilling operations. A higher LGS content will also be reflected in a
higher plastic viscosity. The greater the amount of fines in the mud, the
more they reduce internal settling rates. A certain level of LGS in the mud
is beneficial to the creation of fluid structure under low shear and static
conditions, but it should be borne in mind that at high levels, other negative
factors will outweigh these benefits.
Increase the level of LGS by introducing fine Calcium Carbonate (5
micron median sizing) to the system.
Sag can be minimized by ensuring that the 6 RPM dial reading is kept
high with the yield stress run at 14+ for a 12 1/4 in. hole.
Please keep in mind that these viscosity levels may not be possible where
ECD constraints are in place. Running the yield stress as high as possible
and at least above 7 will, in conjunction with the other methods being
followed, limit sag. Primary viscosity in oil-based mud systems should
come from CARBO-GEL viscosifier and not from high additions of low end
viscosity modifiers such as CARBO-TEC S. Low end viscosity modifiers
should only be used for minor viscosity adjustment.
A common practice is to reduce the viscosity of the active system prior to
running liner to ensure a successful primary cement job.
This however may be counterproductive. Once the NAF system has been
chemically thinned, it may be difficult to recover the low end viscosity.
Thinning of the mud prior to running a liner might prejudice a potential
following interval. However, operation requirements for a successful
primary cement bond may override these concerns.
Increasing the OWR will thin the fluid, increasing its potential for sag.
This should only ever be done slowly and preferably while drilling so that
there is plenty of high shear available (through the bit) to ensure that the
required additions of organophilic clay are fully yielded.

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Agglomeration of barite particles through insufficient oil wetting will also

increase the mud’s sag index.
Ensure that sufficient emulsifier is used, especially when barite is being
added. However, the overuse of oil wetting products must also be avoided,
as this can have a thinning effect.
Barite usually contains a small percentage of coarse material. Field
experience has shown that if this is removed prior to drilling, the mud
exhibits an increased resistance to sag.
The mud can be circulated over fine mesh screens (200 or 230 mesh) for a
minimum of two circulations prior to drilling. If barite loss is excessive,
consider increasing the screen mesh size or reducing circulating time while
carrying out this procedure.
The greatest sag occurs at low annular velocities.
Maintain minimum annular velocity of 100 fpm or greater.
Sag is reduced when rotary drilling is employed.
Data show that sag is worse when drill pipe is stationary. Consider using
rotary wiper trips if extended sliding drilling has been undertaken. Rotation
of 150 RPM or higher has been shown to virtually eliminate sag under all
conditions.
Ensure the mud is in good condition prior to conducting operations
which induce low shear (e.g., slow circulating rates, running casing, or
running logs) particularly, if they occur for significant time periods.
Barite sag is predominantly a dynamic phenomenon which occurs under
conditions of low shear in the annulus. Any operation which induces low
shear has the potential to accelerate sag.
Recognize that barite sag cannot always be minimized by mud treatment.
It may be necessary to stage in to the well following a trip, breaking
circulation and circulating bottoms up at several points. Only this way can
the pressure fluctuations caused through density imbalance be controlled
and leveled out. Consider pumping out of the hole to minimize swabbing
and, as a result, sag.

Rig Site Monitoring

There are several Rigsite Monitoring Procedures that can be done to minimize sag
while working on the rig:
Ensure mud weights are measured and logged, especially following a trip in the
hole or during critical operations.

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3 Testing and Recommendations

Record flowline mud weights every 3-5 minutes when circulating after a trip
until system is stable. Then revert to every 15 minutes. Correlate to SPM to
enable a trend chart to be drawn up.

A pressurized mud balance must be used for recording flow

line mud weights.

Use the OFITE Model 900 viscometer or equivalent to characterize the

potential for barite sag for the drilling fluid.
Consider mud sampling for lab-based PSD checks.
Fluctuations in stand pipe pressure may occur as slugs of light and heavy mud
pass through the bit nozzles. Changes can occur from both changes in
hydrostatic (U-tube effect) and differences in frictional pressure loss.
Ensure mud loggers accurately monitor active pit volumes.
Unexpected losses may occur as heavy spots of mud in the annulus reach
the near vertical sections of the well and rapidly increase hydrostatic
pressure. The opposite effect can occur with light mud, which may cause
the well to flow.

Lesson Summary
You have now completed the Recommendations lesson, which consisted of the
following topics:
Philosophy for Non-Aqueous Fluid Design
Sag Reduction
Rig Site Monitoring

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3 Testing and Recommendations

Module Summary
You have now completed the Testing and Recommendations Module, which
consisted of the following lessons:
Testing
Recommendations
Having completed this module, you should be able to:
List testing procedures that are used by Baker Hughes to measure sag
Identify measures that can be taken to prevent the likelihood of barite sag

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Module Review Questions

1. Viscosity levels within the limits of __________ are preferred, and indicate
a low potential for dynamic barite sag.

2. Sag is worse when the drillpipe is:

a. Stationary
b. Rotating
c. Tripping out of hole
d. None of the above

3. Agglomeration of Barite particles through insufficient oil wetting will

increase the _____ index.

4. As part of the Rigsite Monitoring Procedures which of the following are

recommended? (Choose all that apply)

a. Check mud weights through regular intervals, especially following a

trip
b. Monitor active pit volumes
c. Monitor low shear rate viscosities
d. All of the above

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 Self Study Guide

Appendices

Course Summary

Course Modules
This course consisted of the following modules:
Overview
Variables for Barite Sag
Testing and Recommendations

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Course Objectives
Having completed this course, participants should be able to:

Outline safety considerations, scientific knowledge, and issues relevant to barite

sag

Identify different variables that influence the likelihood of barite sag

Outline testing procedures and recommendations for barite sag mitigation

Course Post-Assessment

Step 1
Review each objective for the training that you just received. Consider your skill
level for each objective.

Step 2
Rate your level of comfort with each of the objectives using the rating scale.

1 2 3 4
Unsure Somewhat Informed Reasonably Skilled Expert
I'm not quite I know something about I feel confident in my ability I consider myself to be
sure what this this topic but would to perform this specific an expert/master in
means/what prefer not to be objective and would feel this particular skill and
this would look evaluated on my comfortable being evaluated would feel very
like. performance without first on it without receiving much comfortable training
receiving more training. in the way of further training. my peers and being
responsible for the
results of their
resulting evaluations.

Step 3
Record your rating for each objective and then compare it with the rating that
you assigned at the beginning of the training.

Step 4
After you have completed your rating, you will be asked to complete the course
quiz as a final test of your knowledge.

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Appendix

Next Steps
Congratulations on completing the Barite Sag Self-Study Guide! Once again, we
would like to express our gratitude for your commitment to continued learning that
both increases your own individual potential and enables BHI to continue
"Advancing Reservoir Performance."

To receive a credit for this course please go to Achieve and pass the Barite Sag
Quiz with 80% score or more. Good luck!
Appendix

Reference List
For more information on Barite Sag please see the following documents:
SPE 20423 "Investigation of Barite Sag in Weighted Drilling Fluids in Highly
Deviated Wells"
SPE 36670 “The Influence of Drilling Variables on Barite Sag”
SPE 56636 "Correlation of Ultra-low Shear Rate Viscosity and Dynamic Barite
Sag in Invert-Emulsion Drilling Fluids"
SPE 62051 "Barite Sag: Measurement, Modeling, and Management"
SPE 70128 "Correlation of Ultralow-Shear-Rate Viscosity and Dynamic Barite
Sag"
SPE 98167 "Field Proven Technology to Manage Dynamic Barite Sag"
For more information on Safety Requirements please see the following
documents:
10 Critical Upstream Process Safety Requirements
Web Page: https://inside.bakerhughes.com/sites/hse/Safety/Upstream
%20Process%20Safety/TPS_10%20Critical%20Requirements.pdf
Well Control Assurance Work Instructions
Web Page: https://inside.bakerhughes.com/sites/hse/Safety/Upstream
%20Process%20Safety/Well%20Control%20Assurance%20-%20Work
%20Instruction%209%20Aug%202013.pdf
Trapped Pressure Guidelines
Web Page: https://inside.bakerhughes.com/sites/hse/ProductsandSupport/
hazards/Pressure%20Testing%20Documents/BHI%20Trapped%20Pressure
%20Guidelines.pdf
Ideas to Improve Pressure Line Safety
Web Page: https://inside.bakerhughes.com/sites/hse/ProductsandSupport/
hazards/Pressure%20Testing%20Documents/Pressure%20Line%20Safety.pdf
Wellsite HSE&S Management
Web Page: http://bhidms/Tech_pubs/source/HSE%26S/HSES-EOC-
WELL-001.pdf

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Module Review Answer Keys

Overview
1. List any three HSE General Precautions key points to remember.
Tasks/activities may only be performed by trained/qualified/authorized
personnel e.g. personnel competent in mud design, monitoring and well
control procedures.
Verify data, equipment, materials, job parameters and job specifics prior to
starting the job (avoids wrong/inferior drilling fluids, wrong densities,
viscosities etc.,).
Pre-job planning and safety meetings should engage all applicable
personnel. There may be multiple simultaneous activities on location,
ensure you communicate with other contractors onsite.
Follow the 10 critical upstream process safety requirements. Exercise Stop
Work Authority and follow Management of Change process and procedures
as required.
Complete mandatory visual inspection of materials/tools/equipment/
accessories before starting the job. Verify ratings, certifications and
calibrations. Ensure they are fit for purpose and meet safety, quality,
reliability and operational requirements.
Refer to the latest version of the Safety Data Sheet (SDS) prior to handling,
storing or shipping the product.
Continuous monitoring and frequent checks of critical parameters (mud
density, viscosity, temperature, pressure etc.,) is critical as it may reveal
any early signs of potential trouble.
Ensure familiarity with the site and local emergency response plans and
contact details.
It is your responsibility to communicate HSE concerns, including client HSE
concerns or requirements, or when barriers have been compromised or
challenged.
Prevent contamination and exercise proper personal hygiene when working
around chemicals.
Wear appropriate personal protective equipment (for example -respiratory,
skin, hearing, head, eye, face, fall protection) for the hazards present, at all
times in designated areas.
2. Barite sag can occur under static and dynamic conditions.
True
3. Gas-cut mud, fluid influxes and changes due to the temperature can cause a
density change in the mud, and potentially can be misinterpreted as sag.
True

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Module Review Answer Keys

4. If a particle diameter increases, then settling velocity __________.

Increases
5. Shear rate does not affect barite sag.
False
6. The following problems can occur due to barite sag. (Choose all that apply.)
Stuck Pipe
Lost Circulation
Wellbore Instability

Variables for Barite Sag

1. Sag can be reduced by the addition of treatments of treated calcium carbonate.
Which of the following products is an example of this?
MAGMA-PLEX
2. If additional wetting is required when weighting up, the use of __________ is
recommended in place of an oil wetting agent/thinner.
emulsifier
3. Sag can be reduced by increasing the concentration of organophilic clay.
True
4. Dynamic barite sag generally __________ with increasing hole angle up to
about 60° and then __________ in more horizontal wellbores.
increases/decreases
5. The composition and properties of the drilling fluid have a major influence on
barite sag potential.
True
6. High temperatures cause the drilling fluid to thin, which can increase sag
tendency.
True

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Testing and Recommendations

1. Viscosity levels within the limits of __________ are preferred, and indicate a
low potential for dynamic barite sag.
RJF Vindow
2. Sag is worse when drillpipe is:
stationary
3. Agglomeration of Barite particles through insufficient oil wetting will increase
the __________ index.
sag's index
mud's sag index
4. As part of the Rigsite Monitoring Procedures which of the following are
recommended? (Choose all that apply)
All of the above

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Module Review Answer Keys

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