Rheology of Various Drilling Fluid Systems Under Deepwater Drilling Conditions and the Importance of Accurate Predictions of Downhole Fluid Hydraulics

Abstract Previous rheological studies of water-base and oil-base muds have concentrated on fluid viscosities at elevated temperatures and pressures. This paper extends the data available to cold temperature regimes which can be expected to occur in the riser for deepwater wells. The rheology of eighteen different drilling fluids covering WBM, OBM and SBM have been evaluated between -1° to 90°C and 1 to 344.7 bar. The Herschel-Bulkley and Casson models both fitted the OBM and SBM rheograms very well. For the different WBM systems, the Herschel-Bulkley model also fitted the salt/polymer fluids and unweighted bentonite-based fluid rheologies, however, the Casson model best described the weighted bentonite-based fluid rheologies. The effect of the cold fluid viscosity in the riser on ECD for deepwater wells was assessed using a software model which uses a transient temperature simulator in conjunction with a hydraulic model which accounts for different mud viscosity throughout the wellbore. Comparing the ECD predictions with those calculated where the mud rheology is independent of temperature and pressure, the ECD was found to be underestimated by up to 6.1% for a SBM and overestimated by 3.1% for a WBM. If there are formations with small differences in the fracture and pore pressure gradients, then these variations in ECD could cause well control problems.