Stimulation Workflow Applied on LAPA Pre-Salt Carbonate Field Deep-Water Brazil

Lapa is a pre-salt deep-water field located around 270km off the coast of São Paulo, Brazil at Santos basin. This carbonate reservoir lies in water depths of around 2,100m and can produce good quality light 26° API oil. The stimulation in large carbonate reservoirs is very challenging, and techniques used for Lapa were based on chemical divergence. The development in offshore environments requires proper planning, execution, and monitoring to achieve the desired results and, of course, profitability. The matrix acidizing method was chosen to stimulate all wells of this campaign (2 producers and 2 injectors). This method consists of bypassing formation damage and stimulating the reservoir by creating wormholes via chemical pumping. In the design phase, stimulation operations previously performed at this field were reviewed, analyzed, and optimized. The main changes were regarding the completion strategy without the use of coiled tubing and placement during the completion phase as it could optimize the time and the cost for the project. The volumetric rate (gal/ft) was also reduced and the selection of the main fluid changed after several laboratory analysis and software simulations. The Lapa field requires high fluid volumes due to the length of the intended treatment interval. The assembly of a stimulation plant on a supply vessel from operator fleet (multi-purpose FSV – field support vessel) was the most cost-efficient approach to address the high volumes required as there was no Well Stimulation Vessel (WSV) available "on call" in the Brazilian offshore market at that time. This solution could also optimize the vessel fleet while the vessel was not required for pumping as FSV was also equipped with ROV and was mean to carry subsea planned task. The fluid test strategy was also a key point for this successful project as many tests were performed to make sure that the correct fluid system was selected. During this process, several fluid systems and different formulations were submitted for core flow tests and dual core flow tests to evaluate worm holing efficiency of retarded fluids and diversion performance of Chemical diverters. Compatibility tests were also performed, and a mud cake breaker was developed locally, especially for this project. This paper will bring an overview of all aspects regarding Lapa stimulation project since the conception, fluid system selection, laboratory tests, lessons learned and the potentially future strategy for this field.

A case study on TBM cutterhead temperature monitoring and mud cake formation discrimination method

The mud cake is easily formed during the tunnel boring machine (TBM) excavation in clay soils or rocks containing clay minerals. Mud cake will lead to soil disturbance of tunnel face, clogging cutterhead and even affect the construction efficiency and personnel safety. In this study, a discrimination method of mud cake formation based on cutterhead temperature was proposed. An online monitoring system was designed and installed on the slurry balance TBM. The results show that: (a) the cutterhead temperature data can be reliably detected and transmitted by the system; (b) in a tunneling cycle, the temperature at some positions of the cutterhead will increase first and then decrease; (c) during the field test, the temperature variation is around 2.5 °C under the normal condition, but the temperature variation will increase more than 50 °C due to the mud cake or geological change; (d) compared with the cooling rate, mud cake formation can be accurately discriminated.

Experimental Study on the Formation and Characteristics of Mud Filtration Cake in Large-Diameter Slurry Shield Tunneling

Multiple soil layers may be exposed simultaneously on the excavated surface of a large-diameter slurry shield. To study the formation and characteristics of mud filtration cake on the excavation surface during large-diameter slurry shield tunneling, penetration tests of mud slurries in different soils were carried out using a self-made device, and the microstructures of different mud filtration cakes were observed using scanning electron microscopy. The test results showed that there were three categories of filling forms for mud slurries permeating the soils: mud filtration cake, mud cake + permeation zone, and permeation zone; correspondingly, there were three types of filtration loss, which was mainly affected by the specific gravity of mud slurry. Finally, the porosity and the fractal dimension for the pore area of the mud filtration cake were calculated, and it is found that the fractal dimension of pore area is beneficial to classify the type of mud filtration cake.

Effect of Cleaning the Annular Space on the Adhesion of the Cement Sheath to the Rock

Drilling boreholes in gas zones and in zones with the possibility of migration or gas exhalation requires a high index of well tightness. An important parameter determining the effectiveness of sealing the annular space is the adhesion of the cement sheath to the rock formation. Low values of adhesion of the cement sheath to the rock formation and to the casing surface result in the formation of uncontrolled gas flows. The lack of adhesion also reduces the stabilization of the pipe column. To obtain the required adhesion, the annular space should be properly cleaned. Thorough removal of filter cake from the drilling fluid increases adhesion and reduces gas migration from the annular space. Therefore, in this work, the authors focus on determining the effect of cleaning the annular space on the adhesion of the cement sheath to the rock formation. The results of the research work allow for further research on the modification of spacers and cement slurries in order to obtain the required increase in adhesion. The article presents the issues related to the preparation of the borehole for cementing by appropriate cleaning of the rock formation from the residue of the mud cake. During the implementation of the works, tests of cleaning the rock surface are performed. The obtained results are correlated with the results of adhesion on the rock–cement sheath cleaned of the wash mud cake contact. When analyzing the obtained test results, a relationship is found between the cleaning of the rock surface and the adhesion of the cement sheath to it.

Experimental Research on the Adhesion Characteristics of Clay to Structures with Different Materials

When the shield machine passes through the clay layer, the clay debris cut by the cutter head usually adheres to the surface of the cutter head and is easy to form mud cakes after extrusion, which affects the safety and efficiency of construction. For the structure made of different materials, due to the different surface properties, the adhesion characteristics of clay are also different. So, selecting proper materials for the soil contacting parts in the shield machine can effectively reduce the adhesion between the structure and soil, decrease the clay adhering to the surface of the shield cutter, and reduce the possibility of further productions of mud cake. Therefore, studying the adhesion properties of clay to different materials and understanding the adhesion rule of clay to soil contacting structures are of guiding significance when selecting the materials of soil contacting parts. In this paper, the adhesion properties of cohesive soil to commonly used construction materials were studied by a self-made adhesion test device, including steel, iron, copper, aluminum, and engineering plastics (polyamide). According to the findings, the separation process of adhesion between soil and the structure by an external force can be divided into four stages, which are the adhesive elastic development stage, adhesive plastic development stage, failure stage, and detachment stage. The adhesion forces and the amount of soil adhered to the structures made of the selected materials are found to vary from each other. The adhesion forces ranked from high to low are, respectively, found on the iron, plastic, aluminum, steel, and copper surfaces. The material with the most amount of adherent soil is aluminum, followed by iron, steel, copper, and plastic.

Synthesis, Characterization and Filtration Properties of Ecofriendly Fe3O4 Nanoparticles Derived from Olive Leaves Extract

Recently, value-added nanomaterials including nanoparticles or nanofluids have been significantly used in designing drilling fluids with tunable rheological properties to meet specific downhole and environmental requirements. In this work, we report novel water-based drilling fluids (WBDF) containing eco-friendly Fe3O4 nanoparticles (Fe3O4-NPs) prepared by using olive leaves extract (OLE) as a reducing and capping agent. A series of economical and excellent performance of WBDF was obtained by introducing low, medium, and high concentrations of Fe3O4-NPs into the conventional WBDF. The synthesis of Fe3O4-NPs was accomplished through the thermal decomposition of iron precursors in an organic medium. NPs were added to the based fluid at concentrations of 0.01, 0.1, and 0.5 wt%. Emission scanning microscopy (FESEM), field- and Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), and Energy-dispersive X-ray analysis (EDX) were used for Fe3O4-NPs analysis. Compared to the conventional WBDF, the addition of Fe3O4-NPs as an additive in the based fluids has been investigated to help increasing viscosity and yield point, which is advantageous for hole cleaning, as well as decreasing fluid loss and mud cake thickness.

Application of Empty Oil Palm Bunches as CMC to Prevent Loss Circulation

Drilling is an activity carried out to obtain the desired target. Furthermore, drilling mud a very significant material involved in the drilling process, and must, therefore, obtain a rational value from the rheology. A suitable technique to achieve this goal is the use of additives, for instance, Carboxymethyl Cellulose (CMC) to improve the viscosity and air binding. This study, therefore, uses CMC produced from organic oil palm bunches as an alternative for industrial CMC. CMC of Oil Palm Empty Bunches have been tested by Energy Dispersive X-ray Spectroscopy (EDS) to determine its composition. The Empty Oil Palm Oil which uses Tenera type was taken from Riau Province, Rokan Hulu Regency, Kunto Darussalam District. In this study, this experiment used CMC Empty Oil Palm and industrial CMC to find the value of viscosity, plastic thickness, melting point, gel strength, mud cake, and filtering volume of drilling mud and prevent the loss circulation with adding each CMC composition to mud samples with amount of 2 gr, 4 gr, 6 gr, 8 gr and 10 gr. According to the EDS analysis, the Carbon (C) and Oxygen (O) content of CMC from empty oil palm bunches were 58.85% and 41.15%, respectively. In addition, the industrial standard for plastic viscosity and yield point were not attained by using 8 gr and 10 gr of this CMC.

Comparison of Efficient Ways of Mud Cake Removal from Casing Surface with Traditional and New Agents

The tightness of the casing-rock formation interface is one of the most important elements of drilling and cementing jobs. In the absence of the required tightness, there is a risk of gas migration directly to the ground, groundwater or atmosphere. In order to eliminate this type of uncontrollable and unfavorable gas flows, the casing column is sealed with cement slurry in the annular space or beyond casing. Cement slurry displaces mud present in the annular space, although the mud cake cannot be completely removed, which is required for obtaining proper binding of cement slurry with the casing surface and the surface of the drilled formation. Therefore, it is important to prepare the well and remove the mud cake from the annular space with spacer fluid. An occasional lack of wellbore tightness requires continuous improvement of the cementing technology. Accordingly, analyses are conducted on mud cake removal with modified or new spacer fluids. Properly designed fluid should efficiently clean the surface of the casing and of the rock mass. One of the basic measurements is the analysis of the efficiency of mud cake removal from the surface of a rotational viscometer. The efficiency of traditional and newly designed fluids for mud cake removal from the casing surface with new and traditional agents has been compared further in this paper. The methodology of mud cake removal with the use of a rotational viscometer was also presented. Tests were performed for various concentrations of agents already used for spacer fluids and for a group of new agents. The efficiency of annular space cleaning was determined on the basis of a comparison with the results obtained for the reference sample, i.e., water which was used for mud cake removal from the rotor surface. The analysis of the results of experiments created bases for the comparison of the efficiency of the analyzed spacer fluids and finding the most suitable ones for mud cake removal from casing columns.