Optimize Internal Phase Salinity to Improve Wellbore Stability and Mitigate Lost Circulation

Wellbore instability and lost circulation are two major sources of non-productive time (NPT) in drilling operations worldwide. Non-aqueous fluid (NAF) is often chosen to mitigate this and minimize the chemical effect on wellbore instability in reactive shales. However, it may inadvertently increase the risk of losses. A simple method to optimize internal phase salinity (IPS) of NAF is presented to improve wellbore stability and mitigate the increased possibility of losses. Field cases are used to demonstrate the effects of salinity on wellbore instability and losses, and the application of the proposed method.

IPS is optimized by managing bidirectional water movement between the NAF and shale formation via semi-permeable membrane. Typically, higher shale dehydration is designed for shallow reactive shale formation with high water content. Whereas, low or no dehydration is desired for deep naturally fractured or faulted formation by balancing osmotic pressure with hydrostatic pressure difference between mud pressure and pore pressure.

The simple approach to managing this is as follows:

1. The water activity profile for the shale formation (a_w,shale) is developed based on geomechanical and geothermal information

2. The water activity of drilling fluid (a_w,mud) is defined through considering IPS and thermal effects

3. The IPS of NAF is manipulated to manage whether shale dehydration is a requirement or should be avoided

   • If the main challenge is wellbore instability in a chemically reactive shale, then the IPS should be higher than the equivalent salinity of shale formation (or a_w,shale > a_{w, mud})

   • If the main challenge is losses into non-reactive, competent but naturally fractured or faulted shale, then IPS should be at near balance with the formation equivalent salinity (or a_{w, shale} ≈ a_{w, mud})

It is important that salt (e.g. calcium chloride – CaCl₂) addition during drilling operations is done judiciously. The real time monitoring of salinity variations, CaCl₂ addition, water evaporation, electric stability (ES), cuttings/cavings etc. will help determine if extra salt is required.

The myth of the negative effects of IPS on wellbore instability and lost circulation is dispelled by analyzing the field data. The traditional Chinese philosophy: "following Nature is the only criteria to judge if something is right" can be applied in this instance of IPS optimization. A simple and intuitive method to manage IPS is proposed to improve drilling performance.