Abstract
Pressurized Mud Cap Drilling (PMCD) technique is typically applied for drilling formations with natural fractures and large vugs that result in severe or total losses. The density of the drilling fluid used in PMCD is slightly below reservoir pore pressure. In the case of very low reservoir pressures below base oil densities (~6.7 ppg), foam can be an option. This paper presents a methodology to develop an oil-based foam system for a PMCD application. The scope includes the descriptions of a foam PMCD application, functional requirements of foam, the development workflow, testing procedures, and modeling that are necessary to qualify a foam for PMCD application. The development methodology first involves identifying the constraints and well conditions of a given PMCD application; these include wellpath, hole and casing sections, reservoir pressure and temperature, surface pumping pressure limits (typically a rotating control device limit), foam stability requirements, etc. The above constraints drive the performance requirements for the foam. Next comes the design of the foam formulation and evaluating its performance against these requirements through various lab tests and modeling efforts, which can include ambient pressure half-life tests for initial screening, static and rotational stability tests at in-situ well conditions, rheology tests, solubility tests, pressure transmission estimates, gas migration estimates, and hydraulics modeling. Example results from the lab tests and modeling are shown to provide more insights into the development process. The proposed methodology may be used as a guide to design a foam drilling fluid for a PMCD application. The iterative nature of the development method is shown and is driven by the functional requirements that are coupled to each other. For example, a more viscous foam may be more stable but it may not be pumpable. Likewise, a less viscous foam may be pumpable but may not be sufficiently stable. Similarly, a highly compressible foam may not be good at pressure transmission to monitor downhole pressure variations as compared to a less compressible foam. In summary, the methodology described in this paper explains the development of an oil-based foam for a PMCD application that satisfies a set of operational constraints and functional requirements while highlighting the major factors that could impact foam performance. The application of foam to PMCD is a new concept and to our knowledge has not been applied in the field; in significantly depleted reservoirs this may become a viable option.