Laboratory Development of a Novel, Synthetic Oil-Based Reservoir Drilling and Gravel-Pack Fluid System That Allows Simultaneous Gravel-Packing and Cake-Cleanup in Open-Hole Completions

Abstract In this paper, we present a novel approach for drilling and completing open hole horizontal wells with a fully compatible synthetic/oil-based fluid system utilizing shunt tube technology. The proposed RDF is a synthetic/oil-external emulsion that is reversible through exposure to a fluid of pH less than 7. A surfactant package included in the RDF water- wets the bridging/weighting agents (e.g., CaCO3) upon reversal of the emulsion. The synthetic/oil external emulsion developed for gravel packing typically contains 50-75% by volume aqueous phase as the internal phase and is completely solids-free. The internal phase can either be brine or a pH- reducer as well as a fit for purpose dissolver for the bridging agents. The pH-reducing property of the internal phase provides the required break mechanism for the S/OB-RDF emulsion remaining in the RDF filtercake under leakoff conditions allowing the bridging agents and drill solids to be water-wet, ensuring dissolution of the bridging agents. Laboratory data are provided for filtercake removal kinetics as a function of temperature, overbalance during gravel packing, gravel mesh size, and drill solids concentration in the RDF. Rheological data are given. Retained permeabilities and flow initiation pressures measured with the combined core and gravel-pack system are presented. Implications of the laboratory results on field practice are discussed.