-a new generation/green lost circulation control...
TRANSCRIPT
- A New Generation/Green Lost /Circulation Control Material !
ContentContent
Lost Circulation/LCMs Lost Circulation/LCMs TigerBullets® Manufacturing Ti B ll t ® B i P ti TigerBullets® Basic Properties TigerBullets® Lab Testing TigerBullets® Commercial Production TigerBullets® Field Testing TigerBullets Field Testing TigerBullets® Advantages C t t I f ti Contact Information
“Gumbo”
Problem Sand
Sand/t
Problemstone
Sand/shale Lost
D-Sand
Lost CirculationProblem:
~$800M/yr
LostCirculationMaterial:
l/
Sand/shale/l. stone
Material:~ $200M/yr
Oil/gas
Lost Circulation Lost Circulation Materials
Cellulose fibers (wood/paper) Calcium carbonate/mica Calcium carbonate/mica Ground battery case/tires
h l / h Synthetic polymers/Starch Resilient graphite carbon Polymer Composite Blend
(TigerBullets®)
TigerBullets®TigerBullets®
ManufacturingManufacturing
® TigerBullets® - Green LCM
Plastic matrix - any virgin and recycled, common and engineering plastics including high-density polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene (HDPE), low density polyethylene (LDPE), polypropylene (PP), polyesters poly (ethylene terephthalate – PET), Polystyrene (PS), nylon, and their mixture.
Cellulosic materials - fibers/particles from softwood (e.g., southern pine), hardwood (e.g., maple), bamboo, rattan, rice straw, wheat straw, rice husk, bagasse, cotton stalk, jute, hemp, flax, kenaf, and banana trees.
Functional additives - minerals calcium carbonate mica Functional additives - minerals, calcium carbonate, mica, talc, ceramics, and their mixture; any materials (e.g., clay, starch) with high water absorbing and swelling capability; and coupling agents.
Recycled/Mixed PlasticsRecycled/Mixed Plastics
Post Industrial Post Consumer (BTR Center)
Motor Oil Containers – HDPE Plastics 36M lbs/year“Sinker” material from plastics recycling plants – over 200M lbs/year
Cellulose Fiber SourcesCellulose Fiber Sources
Waste Paper (BTR Center) Wood Shaving/Particles
Large quantity of fiber from straw; bagasse; bamboo, etc…
Functional AdditivesFunctional Additives
ClayCoupling
CaCO3Clayp g
Agents
Engineering TigerBullets®
Bri
Hydrophilic(Cellulose)
Hydrophobic(Plastics)Bridging
Process Engineering
Plastic-Matrix
AdditivesTigerBullets®
- StrongComposite
Cellulosic-Fiber
BondingPhase
CompositeParticulate
Blend Extrusion TechnologyBlend Extrusion Technology
Extrusion condition (PE):Extrusion condition (PE):Temperature Profile – 140, 150, 170, 180, 190, 190, 190, 180, 170, 160, and 160oC
TigerBullets®TigerBullets®
Basic PropertiesBasic Properties
Basic Properties
Strength – How strong it is! Modulus – How stiff/flexible it is! Impact strength – Impact fracture load! Compression strength – Compressibility! Compression rebound – Resilience! Compression rebound Resilience! Water swelling – Size expansion!
Blend Strength/Modulusg /
2.535Bending Strength Modulus
1 5
2.025
30
GPa
)
Pa)
Bending Strength Modulus
1.0
1.5
15
20
odul
us (G
ngth
(M
P
0.55
10 Mo
Stre
n
0.00
Bl d NBlend Name
TB1 to TB7 are seven different formulations of TigerBullets.
Blend Impact Fracture StrengthBlend Impact Fracture Strength
6
4
5
m2)
2
3
4
ngth
(kj/m
1
2
act S
tren
0
Imp
Bl d NBlend Name
TB1 to TB7 are seven different formulations of TigerBullets.
Blend compression strength at 20% compression rate
10
8
10
1000
PSI
)
4
6
n St
reng
th (
0
2
Com
pres
sion
0TB1 TB7 TB6 TB2
C
Material Type
Material can sustain a compression stress up to 7,000 PSI (at 20% compression rate).
Blend rebound after 20% compression
30
20
25
30
sion
(%)
10
15
20
r Com
pres
s
0
5
10
boun
d af
ter
0TB1 TB7 TB6 TB2R
eb
Material Type
Material rebounded over 20% after large compression load.– resilient allowing movement with pressure over the crack.
Blend water-swellingBlend water swelling– showing progressive expandability
7
5
6
7
g (
%)
3
4
5
Sw
ellin
g
TB1
TB2
TB3
1
2
3
hic
kn
ess
TB4
TB5
TB6
TB7
0
1
0 1 2 3 4 5
Th
Water Adsorption (%)
Screened blends
4/6 mesh 6/8 mesh 8/12 mesh
12/20 mesh 20/40 mesh 40/60 mesh
Theoretical Blend Particle Size Distribution for a Given Crack Size
100
80
90
100
tag
e
50
60
70
ve p
erc
en
t
Established Rules:
90% particle: @ crack size50% particle: ~>1/3 crack size
20
30
40
Cu
mu
lati
v 50% particle: ~>1/3 crack size
0
10
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Particle size (mm)
0.08Slot
Targeted Blend Particle Size DistributionTargeted Blend Particle Size Distribution
100
70
80
90
100
nta
ge
40
50
60
70
tive
perc
en
10
20
30
Cu
mu
lat
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Particle size (mm)
0.04Slot 0.08Slot 0.12Slot
Actual Blend Particle Size DistributionWPC2 - TB®; Wood – Wood Particles
100
70
80
90
100
en
tag
e
Cmp
0.04” (1 mm)Slot
40
50
60
tive
perc
e
Mesh mm % %200 0.074 0.69 0.69100 0.149 0.84 1.5360 0 25 1 79 3 32
10
20
30
Cu
mu
lat 60 0.25 1.79 3.32
40 0.42 9.02 12.3420 0.84 11.80 24.1516 1.19 28.43 52.58
0
0 0.5 1 1.5 2 2.5 3 3.5
Particle size (mm)
12 1.68 35.96 88.548 2.38 11.05 99.586 3.36 0.42 100.00
Wood WPC2
TigerBullets®TigerBullets®
PermeabilityPluggingTestingPermeabilityPluggingTesting
Permeability Plugging Test
350 ml mud
20 g LCM = 20 PPB
Permeability Plugging TestPermeability Plugging Test
PPT T t P t PPT Test Parameters
70
80
90
100
)1000 PSI pressure
40
50
60
70at
ion
Loss
(ml)
T t l
10
20
30
40
Filtr
Spurt Loss
TotalLoss
00 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Testing Time (Minute)
Laboratory Comparative PPTs
Materials1) TB® Wood Plastic Blend LSU
TB®-LSU1) TB®- Wood Plastic Blend - LSU.2) Wood particles
Loading level5 10 15 and 20 grams per 350 ml 5, 10, 15, and 20 grams per 350 ml
mud Water-based Mud Synthetic Mud Synthetic Mud Oil Mud
Wood Particle
TigerBullets®TigerBullets®
Water-based Mud Water based Mud
W t b d Md F l ti Water-based Mud Formulation
MaterialType
MaterialAmount
Gram/2-G water
Cup Mud Viscosity (second)water (second)
Water 2 GAL
Caustic sodaSodium Bentonite (GEL)
5.44432 00
38Sodium Bentonite (GEL)
LignitePolyanionic Cellulose (PC)
Rev Dust
432.0021.5610.76108.00
+ Sodium Bentonite 25.00 45+ Sodium Bentonite 25.00 54
Cup Viscosity of Test Mud: 52, 54, 57, 60, and 64 Seconds
M d Vi it 52 S d Mud Viscosity – 52 Seconds
350 350325325
250
300
350 325325
250
300
350
94.4100
150
200
purt
Los
s (m
l)
84 4
116.4104.4
100
150
200
at 3
0 M
in (m
l)
58.438.436.435.6
70.4
0
50
100Sp 60.478.484.4
37.6
0
50
100
Tota
l Los
s a
0 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/52Sec Wood/52Sec
0 5 10 15 20 25LCM Loading (g/350ml mud)
TB/52Sec Wood/52Sec
Significantly better performance for Wood-plastic blend (TB®).(compared with pure wood particles )
Mud Viscosity – 54 Seconds Mud Viscosity – 54 Seconds
325
250
300
350 325
250
300
350
102.480 4100
150
200
urt L
oss
(ml)
107.484 4100
150
200
at 3
0 M
in (m
l)
39.420.421.2
40.4
68.480.4
0
50
100
Spu
44.422.423.2
62.474.484.4
0
50
100
Tota
l Los
s a
0 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/54Sec Wood/54Sec
0 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/54Sec Wood/54Sec
Better performance for TB® blend at lower loading levels.
LCM L di (54 d)LCM Loading (54 sec mud)
120
150
20G 10G
90
on L
oss
(ml)
30
60
Filtr
atio
00 5 10 15 20 25 30
Testing Time (Minute)
WPB (TB® ) led to quick seal and smaller mud cake at reduced loading level.
M d Vi it 57 S d Mud Viscosity – 57 Seconds
250
300
350 336.4
250
300
350
94 4
158.4
150
200
250
urt L
oss
(ml)
110.4103.4150
200
250
t 30
Min
(ml)
84.4
42.421.6
3619.6
84.494.4
0
50
100Spu
90.464.4
25.652
23.6
103.4
0
50
100
Tota
l Los
s at
0 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/57Sec Wood/57Sec
00 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/57Sec Wood/57Sec
Significantly better performance for WPB - TB®.
M d Vi it 60 S d Mud Viscosity – 60 Seconds
250
300
350
250
300
350
100
150
200
purt
Los
s (m
l)
102.4100
150
200
at 3
0 M
in (m
l)
6.486.414.2 930
44.464.4
0
50
100
0 5 10 15 20 25
Sp
7.689.234.2
1430
56.4
0
50
100
0 5 10 15 20 25To
tal L
oss
a0 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/60Sec Wood/60Sec
0 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/60Sec Wood/60Sec
Significantly better performance for TB®.
Mud Viscosity – 64 Seconds Mud Viscosity 64 Seconds
350 350
250
300
350
250
300
350
150
200
purt
Los
s (m
l)
150
200
at 3
0 M
in (m
l)
7.28.49.634.4
12.410.424.4
68.4
0
50
100Sp
7.28.410.4
44.4
15.410.430.4
84.4
0
50
100
Tota
l Los
s 0 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/64Sec Wood/64Sec
0 5 10 15 20 25
LCM Loading (g/350ml mud)
TB/64Sec Wood/64Sec
Significantly better performance for TB®.
LCM loading = 15 g/350 ml mudLCM loading 15 g/350 ml mud
250
300
350
250
300
350
150
200
250
urt L
oss
(ml)
110.4104.4150
200
250
t 30
min
(ml)
10.430
84.468.470.4
8.48
42.439.438.4
0
50
100Spu
10.430
74.40
8.48
64.444.4
78.4
0
50
100
Tota
l Los
s at
050 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Mud Viscosity (sec)
Wood 15G WPC 15G
050 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Mud Viscosity (sec)
Wood 15G WPC 15G
Significantly better performance for WPC-TB®.
LCM loading = 10 g/350 ml mudLCM loading 10 g/350 ml mud
325
250
300
350 325
250
300
350
94 4150
200
250
urt L
oss
(ml)
103.4150
200
250
t 30
min
(ml)
24.444.4
94.480.4
9.66.421.620.4
36.4
0
50
100Spu
30.456.4
84.4
10.49.225.622.4
84.4
0
50
100
Tota
l Los
s at
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Mud Viscosity (sec)
Wood 10G WPC 10G
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Mud Viscosity (sec)
Wood 10G WPC 10G
Significantly better performance for WPC-TB®.
LCM loading = 5 g/350 ml mud
336 4
LCM loading 5 g/350 ml mud
325325
250
300
350 336.4325325
250
300
350
158.4
150
200
Spu
rt Lo
ss (m
l)
84 4102.4
150
200
at 3
0 m
in (m
l)
68.464.4
34.414.2
3621.2
35.6
0
50
100S 84.4
44.434.252
23.237.6
0
50
100
Tota
l Los
s 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Mud Viscosity (sec)
Wood 5G WPC 5G
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Mud Viscosity (sec)
Wood 5G WPC 5G
Better performance for WPC-TB® even at 5 g/350ml mud loading.
Maximum Breaking Pressure
170017001700
1500
1900
1500
2000
15001800
2100
e (P
SI)
19002000
180018001700
1900
1500
19001800
1800
2100
re (P
SI)
150015001500
900
1200
1500
reak
ing
Pres
sure 1500
900
1200
1500
Bre
akin
g Pr
essu
r00
0
300
600
max
imum
B
00
300
600
Max
imum
B0
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Mud Viscosity (sec)
Wood 5G TB- 5G
050 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Mud Viscosity (sec)
Wood 10G TB- 10G
Multi-slot disc testMulti slot disc test
10
8
9
10
54 Sec Mud/10G WPB-TB® - LoadingMaximum Breaking Pressure = 4000 PSI
(Blowed the safety plug of PPT !!!)
5
6
7
on L
oss
(ml) - (Blowed the safety plug of PPT !!!)
2
3
4
Filtr
atio
0
1
0 5 10 15 20 25 30
Testing Time (Minute)Testing Time (Minute)
RepeatabilityRepeatability
10
12
14
WPB-TB® 10g/350ml mud
5.6 5.25.6
8
6.46
8
10
on L
oss
(ml)
3.2
2
4
Filtr
atio
016 22 24
Test Number
Spurt Loss Loss at 30MSpurt Loss Loss at 30M
TigerBullets®gSynthetic Mud
Synthetic MudSynthetic Mud
Mud Ingredients
Calcium chlorideAlkenesBarium sulfateCrystalline silica, cristobaliteCrystalline silica, tridymiteCrystalline silica quartzCrystalline silica, quartz
Synthetic Mud Testing (Electrical Stability – FANN Model 23D)
Synthetic Mud Testing (Plastics Viscosity/Gel Strength)
h i dSynthetic Mud Property
Oil/water ratio=72/28
Mud weight =13.3 PPB
Plastic viscosity (PV) at 600 RPM/120F=98
Plastic viscosity (PV) at 300 RPM/120F=56
PV/Yi ld P i t 42/14 PV/Yield Point = 42/14
Gel strength at 120F (3 sec) = 7
Gel strength at 120F (10 min) = 16 Gel strength at 120F (10 min) = 16
Electric stability = 463 volts
Synthetic Mud Testing (Electrical Stability – FANN Model 23D)
400
500
olts
)
200
300
Sta
bilit
y (V
o
0
100
Mud Mud/Wood Mud/TB1 Mud/TB2 Mud/TB3 Mud/TB3 2Ele
ctric
al S
Mud Mud/Wood Mud/TB1 Mud/TB2 Mud/TB3 Mud/TB3-2
Material Type
Mud – 350 ml; Wood or TB loading: 10g; TB3-2 : 2hr after blending – No Effect on Electrical Stability !!!
Synthetic Mud TestingTB® vs Wood
50
40
50350 ml Synthetic Mud : 13.3 ppbWood 10 - 10 g wood particleTB10 - 10 g TB blendWood5/TB5 - 5 g of each
20
30
on L
oss
(ml)
0
10Filtr
atio
0Wood10 TB10 Wood5/TB5
Test Material SpurtLoss Loss at 7.5M Loss at 15M Loss at 30M
Better performance for TB® and combined TB® /Wood blends.
Synthetic Mud Testing‐ Combined TB®/Wood Blend
30
20
25
30
(m
l)
SpurtLossLoss at 7.5MLoss at 15MLoss at 30M
5 g Wood and 5 g TB in 350 ml Mud
10
15
trat
ion L
oss
0
5
Filt
Wood-5/TB1-5 Wood-5/TB7-5 Wood-5/TB2-5
LCM Type
Combined TB®/wood system worked better with reduced material loading and enhanced seal breaking pressures.
Synthetic Mud Testing ( d k )(Mud Cake at 120F)
Synthetic Mud TestingTemperature Effect (120F vs 200F)
40
30
35
0
s (m
l)
SpurtLossLoss at 7.5MLoss at 15MLoss at 30M
350 ml Mud : 13.3 ppbW5 - Wood particle 5gT5 and T10 - Tiger bullet 5g/10g
15
20
25
ati
on
Lo
ss
0
5
10
Filt
ra
0
120F-W5/T5 200F-W5/T5 200F-W5/T10
Temperature and Material
Performed well at 200F temperature!Mud is less viscous at high temps ‐> Increasing LCM loading for a more complete seal.
Synthetic Mud Testing (Mud cake at 200F)
Synthetic Mud Testing (Electrical Stability – FANN Model 23D)
400MUD
300
400
Volts
)
MUD+GSeal20g-AMMUD+GSeal20g-AT
200
cal S
tabi
lity
(V
100
Ele
ctric
0MUD MUD+GSeal20g-AM MUD+GSeal20g-AT
Material Type
Mud – 350 ml; LCM loading: 20g; AM‐ after mixing; AT‐after PPT testing
Synthetic Mud Testing TB® vs G‐Seal
300
210
240
270
ml)
350 ml Synthetic Mud: 13.1 PPBLCM: GSeal, TBLoading: 10, 15, and 20 g0.04 Inch Slot
120
150
180
210
tion L
oss
(m
30
60
90
120
Filtra
t
0
30
GSeal10 GSeal15 GSeal20 TB10
LCM Type and LoadingLCM Type and Loading
SpurtLoss Loss at 7.5M Loss at 15M Loss at 30M
TigerBullets®TigerBullets®
Oil MudOil Mud
Diesel based MudDiesel‐based Mud
Mud Ingredients
1. Diesel oil2. Water3. Weight material3. Weight material4. Calcium chloride5. Emulsifier6. Lime7. Filtration control agent8. Gellant
i l b d dDiesel‐based Mud Property
Diesel Oil Fraction = 80%
Mud weight =16.5 PPB
Plastic viscosity (PV) at 600 RPM/120F=135
Plastic viscosity (PV) at 300 RPM/120F=72
PV/Yi ld P i t 63/9 PV/Yield Point = 63/9
Gel strength at 120F (3 sec) = 16
Gel strength at 120F (10 min) = 31 Gel strength at 120F (10 min) = 31
Electric stability = 430 volts
Lost Circulation Material ®TB® vs G-seal
G-SealTB
Diesel‐based Mud Testing (El i l S bili FANN M d l 23D)(Electrical Stability – FANN Model 23D)
G Seal TB LSU
400
500
olts
)
G-Seal TB-LSU
200
300
Sta
bilit
y (V
o
100
200
Ele
ctric
al S
0Mud Mud-LCM10g-AM Mud-LCM10g-AT
Material Type
Mud – 350 ml; LCM loading: 10g; AM‐ after mixing; AT‐after PPT testing
Material Type
Diesel‐based Mud Testing TB® vs G‐Seal
120
150
350 ml Diesel Mud : 16.1 ppbTB10 - 10 g TB-LSUGSeal10 - 10g GSeal0 04-inch Slot
90
Loss
(ml)
0.04-inch Slot
30
60
Filtr
atio
n L
0TB10 GSeal10
Test Material
SpurtLoss Loss at 7.5M Loss at 15M Loss at 30M
Diesel Mud Cakes for 0.04‐inch SlotTB® G S l (10 l di )TB® vs G‐Seal (10g loading)
LSU TB G-Seal
Diesel‐based Mud Testing ‐ Different WPB ‐ TB® Formulations
150
120
150
350 ml Diesel Mud : 16.5 ppbLCM: WPB, KYBCC, KYB, TB, GSealLoading: 10 g0.04-inch Slot
60
90
Los
s (m
l)
30
60
Filtr
atio
n
0WPB10 KYBCC10 KYB10 TB10 GSeal10
Test Material
SpurtLoss Loss at 7.5M Loss at 15M Loss at 30M
- WPB10, KyBCC10,KYB10, and TB10 – different TB formulations.
Diesel‐based Mud Testing ‐ Effect of WPB (TB®) Material Loading
70
50
60 350 ml Diesel Mud : 16.5 ppbWPB- TB® - Wood Plastic BlendWD - Wood2 5 5 7 5 d 10 l di
30
40
n Lo
ss (m
l) 2.5, 5, 7.5, and 10 g loading0.04-inch Slot
10
20
Filtr
atio
0WPB5 WPB7.5 WPB10 WPB5WD2.5
Test Material
S tL L t 7 5M L t 15M L t 30MSpurtLoss Loss at 7.5M Loss at 15M Loss at 30M
Diesel‐based Mud Testing ‐ Effect of Calcium Carbonate in WPB‐TB®
180
120
140
160
)
Diesel Mud : 16.5 ppb with 0.04-inch SlotKYBCC – WPB-TB® with 20% CCKYB – WPB-TB® with no CC5, 7.5, and 10 g loading level
60
80
100
on L
oss
(ml)
0
20
40
60
Filtr
atio
0KYBCC5 KYB5 KYBCC7.5 KYB7.5 KYBCC10 KYB10
Test Material SpurtLoss Loss at 7.5M Loss at 15M Loss at 30M
CC led to better performance at low material loading levels.
TigerBullets®TigerBullets®
Commercial ProductionCommercial Production
Tiger-Bullets®
TigerBullets®TigerBullets®
Field TestingField Testing
Oil Field Testing – Colorado and Arkansas
Ignacio Blanco Fruitland, La Plata, CO – Water-based Mud
12/12/2008 Farmington/Durango• Pre-treat with a sack of Tiger
Bullets every 15 minutes at the top of the coal (+/- 2,663’).
• Obsrved reduced torque• Easy to handle at site• No any seepage• No any seepage
12/26/2008 Farmington/Durango• Pretreated 1 sack of TIGER
BULLETS every hour while drilling the coal and PC section
• No any seepage or whole mud lossloss
• Worked as anticipated
Fayetteville Shale Arkansas Shale, Arkansas – Over 21 Wells (Oil-based Mud) ( )
Tiger Bullets is the majoroperator’s choice to preventp pseepage and is added withother common materials iftotal losses are encountered!
This Major Operator is doing the following:
• Using a GREEN material to help clean up the environmentUsing a GREEN material to help clean up the environment.• Putting plastics back into wells where the oil was originally generated to make the plastics.• Aiding employment of special needs people through Recycle the Gulf Program.
Bottom Line: A cost effective GREEN commercial product works in the field because of controlled particle size distribution, particle strength, flexibility, compressibility, resilience, and expandability. It helps decrease the overall well cost by allowing the operator to drill ahead without repeated shutdowns due to major losses. The material does not affect any drilling fluid (water, oil, and synthetic) properties, except in preventing excessive mud seepage.
Advantages
R l d/ i l Recycled/green materials Combined rigidity and visco-elasticity Controllable formulation Controllable formulation Controllable strength properties Controllable particle size Controllable particle size Dual functions - Lubricants and LCM Compatible with synthetic/water-based muds Improved field handling and performance Reduced material loading Scale-up production can be done <easily>!
4/6 mesh 8/12 mesh 12/20 mesh
Contact:Contact:
Dr. Qinglin Wu, LSU AgCenterPh: 225‐578‐8369; E‐mail: [email protected]
Todd Hovey, Solimar Drilling FluidsPh: 505‐330‐6412E‐mail: [email protected]