Tuesday, 29 August 2017

A SEMINAR ON EFFECT OF SHALE SWELLING ON THE SUBSURFACE


INTRODUCTION
Shale or Clay swelling has been long known as one of the major causes for formation damage in hydrocarbon reservoirs. In conventional hydrocarbon production, most of the clay related problems occur in the near well region, and are associated with well operations (drilling, completion, workover, etc.). Krueger  has provided an excellent review on this subject. In enhanced oil recovery (EOR), the potential for formation
damage to occur is in many instances much greater because incompatible injection fluids often cause clay swelling or fines migration and thus impair the formation permeability. Even formations which do not contain smectite can have smectite-related formation damage because smectite clays can be synthesized through mineral/fluid reactions during thermal recovery . The formation of smectite was responsible for the reduction in porosity, permeability, and oil recovery rate at the Great Plain Pilot Project, Cold Lake . It was also partly responsible for the low steam sweep at the Ipiatik Heavy Oil Pilot, Cold Lake .
Coreflood experiments have been used to characterize the effect of clay swelling on reservoir quality . In the coreflood experiments, a decrease in permeability (or an increase in injection pressure) is used as a measure of formation damage. However, a fair amount of core, which is not always available, is required to run coreflood experiments. In addition, coreflood experiments can be expensive.

Shale Clay swelling affects not only reservoir quality but also many aspects of drilling operations in conventional oil production and in enhanced oil recovery. Swelling clays include two groups of layer silicate: smectites and vermiculites.
 Two types of clay swelling are identified: crystalline swelling and osmotic swelling. Osmotic swelling is the major cause for permeability reduction due to smectites in hydrocarbon reservoirs.
Problems caused by shales in petroleum activities are not new. At the beginning of the 1950s, many soil mechanics experts tried to find out more about the swelling of clays, which are important for maintaining wellbore stability during drilling, especially in water-sensitive shale and clay formations. The rocks within these types of formations absorb the fluid used in drilling, which causes them and may lead to a wellbore collapse. The swelling of clays and the problems that may so arise have been reviewed in the literature (Durand et al., 1995a,b; Van Oort, 1997; Zhou et al., 1995).
Shales or clay are known to make up above 70% of the drilled formations, and over 70% of the borehole problems are all associated with shale instability. The petroleum industry are continually fighting borehole problems. The problems usually involve well collapse, tight hole, stuck pipe, poor hole cleaning, hole enlargement, plastic flow, fracturing, lost circulation, well control. Most of the drilling problems that do increase the drilling costs are most times related to wellbore instability. These problems are mainly caused by the imbalance created between the rock stress and strength when a hole is drilled. The stress-strength imbalance results when cuttings are removed from the hole, replaced with drilling fluid, and the drilled formations are exposed to drilling fluids. While drilling, shale becomes unstable when the effective state of the stress near the drilled hole exceeds the strength of the hole.  A complicating factor that differentiates shale from other rocks is its predisposition to certain drilling constituents, particularly water. Shale stability is affected by properties of both shale (e.g. mineralogy, porosity) and of the drilling fluid contacting it (e.g. wettability, density, salinity and ionic concentration). The existence and creation of fissures, fractures and weak bedding planes can also destabilize shale as drilling fluid penetrates them.  Drilling fluids can cause shale instability by altering pore pressure or effective stress-state and the shale strength through shale/fluid interaction. Shale stability is also a time-dependent problem in that changes in the stress-state and strength usually take place over a period of time. This requires better understanding of the mechanisms causing shale instability to select proper drilling fluid and prevent shale instability. The basic shale stability problem can be stated as follows: Shale with certain properties (including strength) normally lies buried at depth. It is subjected to stresses and pore pressure, with equilibrium established between the stress and strength. When drilled, native shale is exposed suddenly to the altered stress environment and foreign drilling fluid.  The balance between the stress and shale strength is disturbed due to the following reasons:
·        Stresses are altered at and near the bore-hole walls as shale is replaced by the drilling fluid (of certain density) in the hole.
·        Interaction of drilling fluid with shale alters its strength as well as pore pressure adjacent to the borehole wall.As fluid enters the shale, its strength decreases while pore pressure increases.
When the altered stresses exceed the strength, shale becomes unstable, resulting to various stability related problems. To prevent shale instability, it is important to restore the balance between the new stress and strength environment. Factors that influence the effective stress are wellbore pressure, shale pore pressure, far away in situ stresses, trajectory and borehole angle, etc. The effective stress at any point on or near the borehole is generally described in terms of three principal components,namely;
·        A radial stress component that acts along the radius of the wellbore,
·         hoop stress acting around the circumference of the wellbore (tangential), axial stress acting parallel to the well path, and
·        additional shear stress components.
 To prevent shear failure, the shear stress -state, obtained from the difference between the stress components (hoop usually largest and radial stress - smallest), should not go above the shear strength failure envelope. To prevent tensile failure causing fracturing, hoop stress should not decrease to the point that it becomes tensile and exceeds the tensile strength of the rock. The controllable parameters that influence the stress-state are drilling fluid, mud weight, well trajectory, and drilling/ tripping practices. For example, radial stress increases with mud weight (wellbore pressure) and hoop stress decreases with mud weight causing mechanical stability problem. The near wellbore pore pressure and strength are adversely affected by drilling fluid/shale interaction as shale is left exposed to drilling fluid  (chemical stability problem). Mechanical stability problem can be prevented by restoring the stress-strength balance through adjustment of mud weight and effective circulation density (ECD) through drilling/ tripping practices, and trajectory control. The chemical stability problem, on the other hand, is time dependent unlike mechanical instability, which occurs as soon as we drill new formations. Chemical instability can be prevented through selection of proper drilling fluid, suitable mud additives to minimize/delay the fluid/shale interaction, and by reducing shale exposure time. Selection of proper mud with suitable additives can even generate fluid flow from shale into the wellbore, reducing near wellbore pore pressure and preventing shale strength reduction.

Understanding Subsurface Shale

The term shale is normally used for the entire class of finegrained sedimentary rocks that contain substantial amount of clay minerals. Sedimentologists find shale hard to work with since shale is fine grained, lacks well-known sedimentary structure , and readily applicable tools and models are not available to study shale.The important features of shale in the oil industry are ;
·        its clay content,
·        low permeability (independent of porosity) due to poor pore connectivity through narrow pore throats (typical pore diameters range 3 nm-100 nm with largest number of pores having 10 nm diameter), and
·         large difference in the coefficient of thermal expansion between water and the shale matrix constituents.
 To understand drilling fluid interaction with shale, one must start from basic properties of in situ shale (e.g. pre-existing water in shale, mineralogy, porosity), and then analyze the impact of changes in stress environment on the properties of shale. Several factors affect the properties of shale buried at various depths. The amount and type of minerals, particularly clay, in shale decide the affinity of shale for water. For example, shale with more smectite (surface area - 750 m2/gm) has more affinity for water (adsorbs more water) than illite (surface area - 80 m2/gm) or kaolinite (25 m2/gm). Three different types of water are found associated with clays, although each clay will not contain all of the types.
1.     Intercrystalline water is found in associated with the cations neutralizing the charge caused by elemental substitution.
2.     Osmotic water is present as an adsorbed surface layer associated with the charges on the clay. The swelling associated with this type of mechanism occur when sedimentary rocks are unloaded as occurs in drilling.
3.     Bound water is present in the clay molecule itself as structurally bonded hydrogen and hydroxyl groups which under extreme conditions, temperatures of 600-7000 C, separate from the clay to form water.
 The free water exists only within the pore space within  the grains. The porosity of shale is normally defined as the percent of its total volume that water. This value is normally measured by drying a known volume of shale at elevated temperature. Porosity then is a measure of free water, osmotic water and to a lesser extent inter-crystalline water. Chemically bound water is not measured in this procedure. Properties of shale and drilling fluid/shale interaction are strongly influenced by the bound water and to a lesser extent by the free water. Some of water associated with clay can also be removed using pressure. The majority of the loosely held osmotic water can be removed with an overburden pressure of about 290 psi. In the inner-crystalline case, up to four layers of water may be found. The third and fourth layer can be removed with about 3900 psi. Approximately, 24000 psi is required for second mono-layer and according to various estimates,3-4 pressure over 50,000 psi is required to squeeze water in single monolayer of clay platelets. It  requires temperatures in excess of 200o C to remove all bound water from clay. It is, therefore, doubtful that shale is ever completely void of water in typical drilling environment. Prior to drilling, the exact amount of bound and free water in shales buried at depth, however, depends on the past compaction history. Compaction of clay proceeds in three main stages.5 The clays are removed from land by water and deposited in quiescent locations. Clays, at their initial state of deposition and compaction, have both high porosity and permeability; pore fluids are in communication with the seawater above; sediments consisting of hydratable clay with absorbed water layers prevent direct physical grain-to-grain contact. At the time of deposition, mud water contents may be 70-90%. In the normal compaction process as clay/shale sediments are buried with pore water being expelled, porosity (sonic travel time) decreases. However, any disruption of this normal compaction and water expulsion process can lead to increase in both porosity (sonic travel time) and pore pressure. In the first stage of compaction, free pore-water, osmotic water and water inter-layers beyond two layers are squeezed out by the action of overburden. After a few thousand feet of burial, the shale retains only about 30% water by volume, of which 20-25% is bound interlayer water and 5-10% residual pore water. In the early stages compaction strongly depends on depth of burial, grain size (fine-grain clays have more porosity but compact easily), deposition rate (high rate results in excessive pore pressures and under-consolidation), clay mineralogy (monmorillonitic shale contain more water than illitic or kaolinitic shale), organic matter content, and geochemical factors (e.g. concentration of sodium salts affects porosity). In the second stage of compaction, pressure is relatively ineffective for dehydration that is now achieved by heating, removing another 10 to 15% of the water. The second stage begins at temperatures close to 100 0C and diagenetic changes in clay mineralogy may also occur. The third and final stage of compaction and dehydration is also controlled by temperature but is very slow, requiring hundreds of years to complete and having only a few percent of water left. To sum up, the properties of drilled shale formation, which are important for shale/fluid interaction and shale stability, are determined by the past compaction history and the current stresses and temperature. For example, affinity for water of the shale at any depth depends on compaction/ loading history, stresses, clay composition, and temperature. These factors also determine;
·        shale porosity,
·        permeability and
·        the amount of water squeezed out .

Shale/Fluid Interaction Mechanisms

Analysis of the available experimental data (O’Brien-GoinsSimpson Associates and University of Texas, Austin, Shell and Amoco sponsored Projects) purely explains that the shale strength and the pore pressure near the bore-hole are indeed affected by fluid versus shale interaction. Basic results confirmed by this explanation can be summarized as follows:
·        Activity imbalance causes fluid flow into/or out of shale.
·        Different drilling fluids and additives affect the amount of fluid flow in or out of shale .
·        Differential pressure or overbalance causes fluid flow into shale .
·         Fluid flow into shale results in swelling pressure .
·        The moisture content affects shale strength. Moisture content relates to sonic velocity. The instability and shale/fluid interaction mechanisms, coming into play as drilling fluid contacts the shale formation, can be summarized as follows.
1.     Mechanical stress changes as the drilling fluid of certain density replaces shale in the hole. Mechanical stability problem caused by various factors is fairly well understood, and stability analysis tools are available.
2.     Fractured shale - Fluid penetration into fissures and fractures  and weak bedding planes.
3.     Capillary pressure, pC, as drilling fluid contacts native pore fluid at narrow pore throat interface.
4.      Osmosis (and ionic diffusion) occurring between drilling fluid and shale native pore fluid (with different water activities/ ion concentrations) across a semi-permeable membrane (with certain membrane efficiency) due to osmotic pressure (or chemical potential), PM.
5.     Hydraulic (Advection), ph, causing fluid transport under net hydraulic pressure gradient because of the hydraulic gradient.
6.     welling/Hydration pressure, ps, caused by interaction of moisture with clay-size charged particles.
7.     Pressure diffusion and pressure changes near the wellbore (with time) as drilling fluid compresses the pore fluid and diffuses a pressure front into the formation.
8.     Fluid penetration in fractured shale and weak bedding planes can play a dominant role in shale instability, as large block of fractured shale fall into the hole. A lot of works have been written on this phenomenon. In Norway Valhall field, this phenomenon is suspected to be one of the major causes of shale instability. Preventive measures include use of effective sealing agents for fractures, e.g. graded CaCO3, high viscosity for low shear rates, and lower ECD.
9.     Capillary phenomenon also is now fairly well understood, and an interesting exposition is given in a recent paper. Increasing the capillary pressure for water-wet shale has been successfully exploited to prevent invasion of drilling fluid into shale through use of oil base and synthetic mud using esters, poly-alpha-olefin and other organic low-polar fluids for drilling shale. The capillary pressure is given by
                  pC = 2γ cosθ/r .................................................................(1)
where, γ is interfacial tension, θ is contact angle between the drilling fluid and native pore fluid interface, and r is the pore radius. When drilling water-wet shale with oil base mud, the capillary pressure developed at oil/pore-water contact is large because of the large interfacial tension and extremely small shale pore radius. It prevents entry of the oil into shale since the hydraulic overbalance pressure, ph (=Pw-po), is lower than the capillary threshold pressure, pC. In such a case, advection (and pressure diffusion) cannot occur. However, osmosis and ionic diffusion phenomena can still occur under favorable conditions. Capillary pressure thus modifies ph and the net hydraulic driving pressure ph‘is given as follows:

             ph = ph – pc, 0<pc<ph..................................(2)
          ph=0, pc>ph
Capillary pressures for low permeability water-wet shales can be very high (about 15 MPa for average pore throat radius of 10nm). This is one of the key factors in successful use of oil base muds or synthetic muds using esters, poly-alpha-olefin and other organic low-polar fluids.
Osmotically induced hydraulic pressure or differential chemical potential, PM, developed across a semi-permeable membrane is given by 10-12,
PM = - ηPπ = - η (RT/V)ln(Ash/Am)..................................(3)
where, η is membrane efficiency, Pπ is the theoretical maximum osmotic pressure for ideal membrane (η=1), R is the gas constant, T is the absolute temperature, V is the molar volume of liquid, and Am, Ash are the water activities of mud and shale pore fluid, respectively.
Various expressions have been obtained for the membrane efficiency in terms of parameters that are difficult to measure. Two such expression are:

η = 1-(a-rs)2 /(a-rw)2.............................................(4a)
η = 1-vs /vw.......................................................... (4b)

In this, ‘a’ = pore radius, rs=solute radius, rw = water molecule radius, and νs and νw are the velocities of solute and water, respectively. According to non-equilibrium thermodynamics principles, assuming slow process near equilibrium and single non electrolyte solute, the linear relations between the pressure and flow can be written as 11-12
Jv ∆x = Lpph – Lp η Pπ...................................................... (5)
Js ∆x = Cs(1- η)Jv+ ωPπ....................................................(6)
Jv =JwVw + JsVs................................................................ (7)
Equation. 5 states that the fluid flux Jv into shale is the superposition of fluxes due to hydraulic pressure gradient ph (advection) and due to osmotically induced pressure, PM (=η Pπ), related through the hydraulic permeability coefficient Lp. The coefficient Lp is related to the shale permeability, k, and filtrate viscosity, µ, as Lp= k/µ. Eq. 6 describes the net salt flux Js into the shale. Eq. 7 simply expresses the mass balance in terms of the water and salt flux and partial molar volumes of these components. Note that for perfect membrane, η =1, since only water can flow across the membrane, Js=0 and thus ω =0. Hydraulic (Advection), ph, is implicitly included in Eq. 5. If the test fluid is the same as shale pore fluid (which implies equal activity and Pπ =0 - no osmosis), Eq. 5 reduces to the familiar Darcy’s law which gives volume flow as:
Jv ∆x = Lp ph................................................................... (8)
where as Lp= k/µ.; k denotes shale permeability and µ denotes viscosity. Such an experiment was performed by van Oort to characterize the permeability of shale and estimate Lp. As stated earlier, a recent study on osmotic and hydraulic effects was conducted at O’Brien-Goins-Simpson & Associates, Inc. as part of the work sponsored by the Gas Research Institute (GRI). General conclusions from the study can be summarized as follows: • Increased hydraulic potential can increase the amount of transport of water into shales and reduce rock strength

Improving Shale Stability

Thus far, we have seen that there are several mechanisms which cause or affect shale/fluid interaction. There is an intense effort under way in the oil industry to get a better understanding of each of these mechanisms. The stakes are high in that understanding and quantification of each of these phenomena is critical for designing benign drilling fluids which would stabilize shales. Rapid progress is being made and more results will become available in the near future. The current understanding of various mechanisms responsible for shale/fluid interaction indicates certain basic principles for improving shale stability. Based on current understanding of various shale/fluid interaction mechanisms, we can discuss some general principles for improving shale stability. The main objective to improve shale stability is to prevent, minimize, delay or use to our advantage the interaction of the drilling fluid with shale. As our understanding of the various interaction mechanisms improves, so will the mud systems designed to improve shale stability. We can list the following means of improving shale stability corresponding to various mechanisms contributing to shale/fluid interaction:
·        For fractured shale stability, use effective sealing agents, thixotropic drilling fluid (high viscosity for low shear rates), and lower mud weight /ECD. This would minimize fluid penetration into fractures.
·        Increase the capillary pressure, pC(>ph’) to prevent fluid entry into shale pore throats.  Eq. 1 suggests that increasing interfacial tension and contact angle θ can increase the capillary pressure for given shale pore throat radii.  Increasing capillary pressure through γ and θ for water-wet shales has been successfully exploited through use of oil base muds or synthetic muds using esters, poly alpha-olefin and other organic low-polar fluids.
·         Reduce the total net driving force (pressure) for shale/fluid interaction. The net effective driving force (pressure) at t=0+ for pC<ph(=Pw-po) can be written as:
       ph‘= Pw - po - pC+ PM......................................................(18)
which brings about the changes with time in the near wellbore pore pressure through pressure diffusion or transmittal and fluid transport into (or out of) the shale. The near wellbore pore pressure, pn, can be expressed in terms of the original virgin pore pressure, po, and time changes, δp(t), as:
pn = po + δp(t)............................................................... (19)
to minimize δp(t), we need to minimize ph′ , which can be accomplished by increasing capillary pressure pc, as discussed above, or making osmotic pressure PM equal to (or less than) zero by matching (or making drilling fluid activity, Am, lower than) shale water activity, Ash. If the activity of the mud is higher than that of the shale, we need to reduce membrane efficiency as much as possible. However, when drilling fluid activity is made lower than shales, resulting in negative osmotic pressure and causing pore fluid to flow out of shale into the wellbore, the membrane efficiency needs to be increased. Reduction of drilling fluid activity, Am, is at the heart of most inhibitive muds 14. This reduction is brought about by adding electrolytes: seawater bentonite muds, saturated saltpolymer (xanthan, guar), KCl or NaCl-polymer (PHPA, xanthan), fresh water calcium treated muds (lime, gypsum). A new type of drilling fluid based on a substituted sugar, methyl gluocide, is currently being looked at because of its ability to form low activity muds with high membrane efficiency. The dispersed water phase in oil base muds is treated to adjust the activity, usually with CaCl2, to make activity Am<Ash.
·        Reduce the rate of fluid transportion and rate of pressure diffusion. It is difficult to balance water activity of shale with mud exactly everywhere in a well because shale activity is not known and varies with depth and mineralogy. We can, however, control parameters that enable us to reduce the fluid transportion and pressure diffusion rates by increasing the fluid viscosity and reducing the permeability of shales. Regarding the viscosity increase, the problem is to find solutes that increase the fluid viscosity significantly and yet can pass through the narrow shale pore space to maintain high viscosity. Most mud polymers are too large to enter shale but some low molecular weight polymers might achieve the desired results. As regards reducing permeability, one solution is to form permeability barrier at shale surface or within micro-fractures. Oil base mud achieves this as water is made to diffuse through continuous oil phase to reach the shale. Silicate and ALPLEX muds, for example, attempt to reduce the permeability
Cationic polymers, which are strongly adsorbing, can also act in the same way. In the extreme, shale formation could be completely isolated by creating an impermeable hydrophobic seal, using asphaltine derivatives like gilsonite. Use of charged emulsifiers for binding the oil droplets of oil-in-water emulsions to the clay surface and organophilic clays in oil base muds could achieve similar results. Although changing the clay cation with less hydratable K+ or Ca2+ can reduce intrinsic swelling, these ions lead to more open structure and thus increase permeability. Work is currently underway to formulate drilling fluids containing cesium, Ce+ for stabilizing the shale. While this fluid would be very expensive to formulate, increased stability and rate of penetration could compensate for this cost. • Preserve mechanical integrity of the shale cuttings. As damage control, certain measures can be taken to limit the dispersion of cuttings or spallings by binding the clay particles together, if shale failure or erosion is initiated. Polymers that can reduce shale disintegration must adsorb onto clay platelet surface and have high enough energy to resists mechanical or hydraulic forces pulling them apart. PHPA and strongly adsorbing cationic polymers and components like polyglycerol can limit the dispersion of shale cuttings or spallings in the well. To achieve similar results within the shale formation, polymer must be able to diffuse into the bulk shale, requiring short flexible chains. Future work on shale stability and understanding shale/fluid interaction is bound to lead to better means to stabilize shales and design of environmentally acceptable effective mud systems. As new additives for drilling fluids are studied to stabilize shales, major challenge would be to make them compatible with preserving other desirable mud properties such as, rheology, drilled solids compatibility and drilling rates. Finally, even if we could design the best mud system for shale formations, continuous monitoring and control of drilling muds are critical elements for successful drilling. The mud composition continually changes as it circulates and interacts with formations and drilled solids. Unless concentrations of various mud additives are continually checked and maintained, the results could not be achieved. The development and introduction of improved monitoring techniques for chemical measurements should proceed simultaneously with the development of more effective mud systems for shale stability, based on improved understanding of shale/fluid interaction.











References
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