Lab and Pilot-Scale Evaluation of Stable Foam for Drilling in High Temperature Environment

Using foams to drill in low pore pressure reservoirs is attractive because of their low density, high viscosity, and ability to transport cuttings. However, in high temperature reservoirs (240 °F) with H₂S gas present, there are concerns with the long-term stability of a foam drilling fluid. In this work, we highlight a lab program to develop a stable drilling foam for drilling in a low pore pressure, high temperature reservoir. The work also includes pilot-scale experiments to evaluate foam performance.

Aqueous nitrogen-in-water foams were stabilized with a preferred foaming surfactant formulation, and the rheology and stability of the foams were measured at representative drilling conditions (temperature and pressure) at the lab and pilot-scale. The foams were also evaluated for their compatibility with current drilling fluids used on site and for stability in the presence of H₂S gas (at 1900 psi and 140 °F). The drilling foam was also evaluated using a pilot-scale flow loop comprised of a rheology flow loop and a model drilling wellbore. The experiments included measuring the foam rheology, foam stability in the model wellbore, and gas migration tests to understand how the foam suppresses upwardly migrating gas bubbles.

We successfully developed a surfactant stabilized foam designed for a high-temperature reservoir with H₂S gas present. We found that H₂S can negatively impact foam stability if proper surfactants are not selected. Our foam showed less than 10% liquid drainage after 12 hours at 240 °F and showed no significant degradation upon contact with 17 mol% H₂S gas. Additionally, the foam was compatible with all drilling fluids (both water-based and oil-based) currently used at the drill site and demonstrated good stability in a model pilot-scale drilling wellbore. Interestingly, when the wellbore was angled at 30 degrees from vertical with the eccentric drill pipe rotating at 100 RPM, the foams were susceptible to degradation compared to an equivalent scenario of a vertical wellbore with concentric rotating drill pipe. The gas migration tests at the pilot-scale showed the foam was capable of significantly slowing down an upwardly moving gas bubble with and without pipe rotation.