Vellore Institute of Technology, Vellore

School of Chemical Engineering

Oil and Natural Gas Corporation (ONGC)

Institute of Drilling Technology, Dehradun
Completion Fluid (Research & Development)

“Identification and Development Brine-based High Pressure - High Temperature Viscosifier

(around 221°C) having Thermal Stability and High Holding Capacity”

DAY-TO-DAY REPORT
(June 3rd,2019 to July 2nd,2019)

Submitted by:
Ambuj Gupta (17BCM0060),
Vellore Institute of Technology,
Vellore, Tamil Nadu

Mentor:
Mr. B.S.S. Rao
Chief Chemist,
IDT, ONGC, Dehradun
Date Day Activity

03- MON DAY 1: On the first day, paperwork and all other formalities were completed. The
06- candidates were assigned to various departments of ONGC Academy, situated at
2019 KDIMPE Campus, Dehradun. Due to my Chemical Engineering background, and
keen interest in upstream processes, I was assigned to the Completion Fluid R&D
Lab, Institute of Drilling Technology, ONGC, Dehradun, under the mentorship of
Mr. B.S.S. Rao (Chief Chemist, IDT). The Completion Fluid Lab, is exclusively
dedicated to the development, production and test of new Completion fluids.
After consultation with HOD, Mr. P.S. Pangtey and mentor, Mr. Rao, my project
was to work in collaboration to “Develop a new Viscosifier for Brine-based
completion fluids, that could work efficiently in HTHP conditions, thus to match
the requirement of Oil rigs in Agartala and Offshore Mumbai.” Concepts of
Petroleum industry, Drilling procedures, Completion fluids, need of Viscosifier,
Safety and Lab SOP were discussed.

04- TUE DAY 2: Literature survey was done to find new indigenous materials with
06- thixotropic properties, that may act as a suitable viscosifier. Numerous research
2019 papers were referred to come up with materials that were easily available,
economically feasible, compatible with brine-based fluid and could act as
potential viscosifier. Besides, a separate lecture was hosted to give the trainees an
insight into the world of petroleum industry and various drilling procedures and
components of a drilling rig. Other upstream processes were also taken up. After
survey, Sepiolite clay was found to meet the requirements. It showcased
thixotropic properties, along with High melting point, thus could potentially serve
as HTHP Viscosifier. Due to its clay origin, it was proposed to be inert and thus
compatible with high concentration brine systems. The chemical was procured
from supplier have specifications of 70nm particle size. Separately, brines of
CaCl2, CaBr2, KHCO2, CaHCO2, CsHCO2 were prepared up to desired
concentrations, using appropriate instruments.

05- WED DAY 3: Experimentation was conducted to visualise the use and performance of
06- already implemented completion fluids. XC Gum was used as viscosifier in
2019 CaCl2 and CsHCO2 brine, with Mangnese tetraoxide (Micromax) as weighing
agent. Parameters such as Rheology, pH, Specific gravity and Gel time were
evaluated. The formulations were tested at bottom-hole temperatures of 150-200C
and 300psi. A polysaccharide secreted by the bacteria genus Xanthomonas
campestris, also known as xanthan gum. XC in water muds provides non-
Newtonian mud rheology, highly desirable because of the flat velocity profile it
produces in annular flow, which is required for efficient cuttings lifting in lower
density muds. XC polymer is anionic, with tolerance for salinity and fair tolerance
for hardness ions. XC is a finely powdered material that can vary in the amount of
residual bacteria debris and the ease with which it disperses into water.
06- THU DAY 4: Prelimnary testing of XC Polymer viscosifier with KHCO2. Potassium
06- formate was used as the substrate brine for this formulation. Brine itself has a
2019 sp.gr. of 1.562 (13.0111 ppg) with an initial pH of 8.7; 600 ml of this formate
brine was further mixed with 0.3% w/v of XC-Polymer viscosifier, and mixed at
high rpm and shear rate in a Hamilton-Beach mixer for 25 minutes, until a
homogenous mixture is obtained. Rheological properties and pH were evaluated
and tabulated as shown below. Similarly, sp.gr. was calculated using the rhetor kit
and mud balance and was found to be 1.602;
Further, weighing material a.k.a Micromax was added to achieve the desired
sp.gr. of 1.63, as required by a certain well in the Agartala Region. The
formulation was mixed for another 30 minutes to achieve a smooth homogenized
composition, void of any lumps, granules and bubbles. Rheology, pH and Specific
gravity was taken again and results were tabulated. It was found that although pH
increased with the addition of Micromax, but AV, PV and YP decreased
consistently before hot rolling at 120°C for 16hrs in accordance to API standards.
The mixture was filled in two aging cells and pressurized up to 100psi with
nitrogen gas and kept for hot rolling in a roller oven for 16hrs in dynamic
conditions.
07- FRI DAY 5: After a period of 16hrs, one of the cells was taken out of the oven, cooled
06- to room temperature and de-pressurized slowly. Contents were taken out and
2019 properties such as pH, specific gravity and Rheology were evaluated. The other
cell was further kept in an oven for 72hrs at same temperature to calculate SAG
factor. In the contents of 16hr cell, slight fluid loss was observed that accumulated
on the top. To prevent this, a filtration aid PAC (Poly Anionic Cellulose) was
added to the 72hr cell. Properties were again observed after addition of PAC to
the mixture. Expert Lecture on 'Downstream Processing of Petroleum' was
oganised for all trainees during the later half of the day.

08- SAT DAY 6: After the completion of 72hr period the cell was cooled to room
06- temperature, depressurized and opened. The contents were decanted into 4
2019 separate beakers. The top 20-25 ml were marked at clear fluid. The rest was
divided into 3 segments: top, middle and bottom sections. The specific gravity for
each section was calculated to evaluate SAG factor. Corrosion study was carried
out with last day’s formulations using NAT50 steel coupons at 90C. Lecture on
‘Directional Drilling’ was organised for all IDT trainees, to explain about various
equipment and latest technologies used in production of a strategically located oil
well. After the lecture, corrosion parameters were evaluated to see the rate of
corrosion of steel structures exposed to completion fluids. Further to test the
effectiveness of corossion inhibitors, the coupons were cleaned again, and put
back into the prepared competion fluid along with 0.2% Slumberger corrosion
inhibitor.
09- SUN SUNDAY
06-
2019

10- MON DAY 7: Prelimnary testing of XC Polymer viscosifier with CaBr2. Calcium
06- Bromide was used as the substrate brine for this formulation. Brine itself has a
2019 sp.gr. of 1.982 (18.064 ppg) with an initial pH of 8.7; 600 ml of this formate brine
was further mixed with 0.3% w/v of XC-Polymer viscosifier, and mixed at high
rpm and shear rate in a Hamilton-Beach mixer for 25 minutes, until a
homogenous mixture is obtained. Rheological properties and pH were evaluated
and tabulated as shown below. Similarly, sp.gr. was calculated using the rhetor kit
and mud balance and was found to be 1.992; Further, weighing material -
Micromax was added to achieve the desired sp.gr. of 2.1, as required by a certain
well in the Mumbai High Region. The formulation was mixed for another 30
minutes to achieve a smooth homogenized composition, void of any lumps,
granules and bubbles. Rheology, pH and Specific gravity was taken again and
results were tabulated. It was found that although pH increased with the addition
of Micromax, but AV, PV and YP decreased consistently before hot rolling at
120°C for 16hrs in accordance to API standards. The mixture was filled in two
aging cells and pressurized up to 100psi with nitrogen gas and kept for hot rolling
in a roller oven for 16hrs in dynamic conditions.
11- TUE DAY 8: After a period of 16hrs, one of the cells was taken out of the oven, cooled
06- to room temperature and de-pressurized slowly. Contents were taken out and
2019 properties such as pH, specific gravity and Rheology were evaluated. The other
cell was further kept in an oven for 72hrs at same temperature to calculate SAG
factor. In the contents of 16hr cell, slight fluid loss was observed that accumulated
on the top. To prevent this, a filtration aid PAC (Poly Anionic Cellulose) was
added to the 72hr cell. Properties were again observed after addition of PAC to
the mixture. Expert Lecture on 'Well Displacement and Completion Fluids' was
oganised for all trainees during the second half of the day.
12- WED DAY 9: After the completion of 72hr period the cell was cooled to room
06- temperature, depressurized and opened. The contents were decanted into 4
2019 separate beakers. The top 20-25 ml were marked at clear fluid. The rest was
divided into 3 segments: top, middle and bottom sections. The specific gravity for
each section was calculated to evaluate SAG factor. Corrosion study was carried
out with last day’s formulations using NAT50 steel coupons at 90C. Lecture on
‘Cementing issues and new technologies’ was organised for all IDT trainees.
After the lecture, corrosion parameters were evaluated to see the rate of corrosion
of steel structures exposed to completion fluids. Further to test the effectiveness
of corossion inhibitors, the coupons were cleaned again, and put back into the
prepared competion fluid along with 0.2% Slumberger corrosion inhibitor.

13- THU DAY 11: Preliminary testing of Sepiolite viscosifier with CaBr2. Calcium
06- Bromide was used as the substrate brine for this formulation. Brine itself has a
2019 sp.gr. of 1.7055 (14.20 ppg) with an initial pH of 7.5; 300 ml of this brine was
further mixed with 6% w/v of Sepiolite viscosifier, and mixed at high rpm and
shear rate in a Hamilton-Beach mixer for 25 minutes, until a homogenous mixture
is obtained. Rheological properties and pH were evaluated and tabulated as shown
below. Similarly, sp.gr. was calculated using the rhetor kit and mud balance and
was found to be 1.7112; Further, weighing material (Micromax) was added to
achieve the desired sp.gr. of 2.1; The formulation was mixed for another 30
minutes to achieve a smooth homogenized composition. 1gm of Lime was added
to maintain a desired pH of 8.5 and 1ml of Schlumberger Corrosion Inhibitor was
also added to prevent corrosion at HTHP in aging cell. Rheology, pH and Specific
gravity was taken, samples were filled into 2 aging cells

14- FRI DAY 12: After a period of 16hrs, the cell was taken out of the oven, cooled to
06- room temperature and de-pressurized slowly. Contents were taken out and
2019 properties such as pH, specific gravity and Rheology were evaluated. It was
closed again, pressurized and further kept in an oven for 72hrs at same
temperature to calculate SAG factor
15- SAT DAY 13: After the completion of 72hr period the cell was cooled to room
06- temperature, depressurized and opened. The contents were decanted into 4
2019 separate beakers. The top 20-25 ml were marked at clear fluid. The rest was
divided into 3 segments: top, middle and bottom sections. The specific gravity for
each section was calculated to evaluate SAG factor.

16- SUN SUNDAY

06-
2019

17- MON DAY 15: Final testing of Sepiolite viscosifier with CaBr2. The final testing
06- formulation was carried with 6% Sepiolite clay nanoparticles as viscosifier.
2019 Calcium Bromide was used as the substrate brine for this formulation. Brine itself
has a sp.gr. of 1.7055 (14.20 ppg) with an initial pH of 7.5; 600 ml of this brine
was further mixed with 6% w/v of Sepiolite viscosifier, and mixed at high rpm
and shear rate in a Hamilton-Beach mixer for 25 minutes, until a homogenous
mixture is obtained. Rheological properties and pH were evaluated and tabulated
as shown below. Similarly, sp.gr. was calculated using the rhetor kit and mud
balance and was found to be 1.7212; Further, weighing material (Micromax) was
added to achieve the desired sp.gr. of 2.1; The formulation was mixed for another
30 minutes to achieve a smooth homogenized composition. 1gm of Lime was
added to maintain a desired pH of 8.5 and 1ml of Schlumberger Corrosion
Inhibitor was added to prevent corrosion at HTHP in aging cells
18- TUE DAY 16: The previous mixture was filled in two separate aging cells of 300ml
06- each and pressurized up to 300psi with nitrogen gas and kept for hot rolling in a
2019 roller oven for 16hrs in dynamic conditions at 220°C. After a period of 16hrs, one
cell was taken out of the oven, cooled to room temperature and de-pressurized
slowly. Contents were taken out and properties such as pH, specific gravity and
Rheology were evaluated. The other cell was further kept for 72hrs at same
temperature to calculate SAG factor.

19- WED DAY 17: After the completion of 72hr period the cell was cooled to room
06- temperature, depressurized and opened. The contents were decanted into 4
2019 separate beakers. The top 20-25 ml were marked at clear fluid. The rest was
divided into 3 segments: top, middle and bottom sections. The specific gravity for
each section was calculated to evaluate SAG factor. After evaluation of SAG
factor, contents were again mixed together and kept for corrosion study with
NAT50 Steel coupons in water bat at 90C

20- THU DAY 18: Corrosion study was carried out with last day’s formulations using
06- NAT50 steel coupons at 90C. Parameters were evaluated to see the rate of
2019 corrosion of steel structures exposed to completion fluids. SAG Factor was found
to be 0.528 which is very close to the desired result of 0.522 according to API
standards.
21- FRI DAY 19: Preliminary testing of Sepiolite Viscosifier with KHCO2. The
06- preliminary testing formulation was carried with 6% Sepiolite clay nanoparticles
2019 as viscosifier. Potassium Formate was used as the substrate brine for this
formulation. Brine itself has a sp.gr. of 1.55 (12.9115 ppg) with an initial pH of
8.6; 300 ml of this brine was further mixed with 6% w/v of Sepiolite viscosifier,
and mixed at high rpm and shear rate in a Hamilton-Beach mixer for 25 minutes,
until a homogenous mixture is obtained. Rheological properties and pH were
evaluated and tabulated as shown below. Similarly, sp.gr. was calculated using
the rhetor kit and mud balance and was found to be 1.5801; Further, weighing
material (Micromax) was added to achieve the desired sp.gr. of 1.98; Along with
this 0.2% PAC was added as fluid loss additive to the mixture. The formulation
was mixed for another 30 minutes. The mixture was filled in an aging cell
pressurized up to 300psi with nitrogen gas and kept for hot rolling

22- SAT Day 20: The mixture was filled in an aging cell pressurized up to 300psi with
06- nitrogen gas and kept for hot rolling in a roller oven for 16hrs in dynamic
2019 conditions at 220°C, directly followed by 72hr static heating at same parameters.
After mixing all the components a sp.gr. of 1.9312 was achieved before heating.

23- SUN sunday

06-
2019

24- MON DAY 21: After the completion of 72hr period the cell was cooled to room
06- temperature, depressurized and opened. The contents were decanted into 4
2019 separate beakers. The top 20-25 ml were marked at clear fluid. The rest was
divided into 3 segments: top, middle and bottom sections. The specific gravity for
each section was calculated to evaluate SAG. Although the sample gave
promising results after mixing, yet due to addition of PAC resulted in settling
after 72hrs. HTHP conditions resulted in degradation of Pac and caused drastic
settling, thus SAG factor unable to be calculated.
25- TUE DAY 22: Final testing of Sepiolite viscosifier with KHCO2. The final testing
06- formulation was carried with 6% Sepiolite clay nanoparticles as viscosifier.
2019 Potassium Formate was used as the substrate brine for this formulation. Brine
itself has a sp.gr. of 1.56 (12.9948 ppg) with an initial pH of 8.5; 500 ml of this
brine was further mixed with 6% w/v of Sepiolite viscosifier, and mixed at high
rpm and shear rate in a Hamilton-Beach mixer for 25 minutes, until a
homogenous mixture is obtained. Rheological properties and pH were evaluated
and tabulated as shown below. Similarly, sp.gr. was calculated using the rhetor kit
and mud balance and was found to be 1.5832; Further, weighing material
(Micromax) was added to achieve the desired sp.gr. of 1.98; The formulation was
mixed for another 30 minutes. The mixture was filled in two separate aging cells
of 300ml each and pressurized up to 300psi with nitrogen gas and kept for hot
rolling in roller oven for 16hrs in dynamic conditions at 220°C

26- WED DAY 23: After a period of 16hrs, one cell was taken out of the oven, cooled to
06- room temperature and de-pressurized slowly. Contents were taken out and
2019 properties such as pH, specific gravity and Rheology were evaluated. The other
cell was further kept for 72hrs at same temperature to calculate SAG factor.

27- THU DAY 24: After the completion of 72hr period the cell was cooled to room
06- temperature, depressurized and opened. The contents were decanted into 4
2019 separate beakers. The top 20-25 ml were marked at clear fluid. The rest was
divided into 3 segments: top, middle and bottom sections. The specific gravity for
each section was calculated to evaluate SAG factor as described before. SAG
Factor was found to be 0.50 which is very close to the desired result of 0.522
according to API standards.
28- FRI DAY 26: Corrosion study for final testing of Sepiolite with KHCO2 was carried
06- out with last day’s formulations using NAT50 steel coupons at 90C. After
2019 calculation of SAG Factor, contents were mixed again and set up for corrosion
study in water bath at 90C. Parameters were evaluated to see the rate of corrosion
of steel structures exposed to completion fluids.

29- SAT DAY 27: Completion of Report and Data entry

06-
2019

30- SUN SUNDAY

06-
2019

01- MON DAY 29: Presentation of Report to Mentor, HOD and HoI of IDT, ONGC
07- Academy. Detailed discussion on impementation of Sepiolite clay nanoparticles
2019 at site and pilot testing at facilities

02- TUE DAY 30: Completion of Internship Period. Submission of Training Report and
07- Presentation of Certificate of Completion at ONGC Academy, KDIMPE Campus.
2019 Farewell get together