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Abstract
Drilling a shale formation with no borehole problems can be a challenging task. With high content of
clays, shale formations are prone to swelling, dispersion, tight hole and other problems. Those problems
are well-documented in literature. Different types of clays give different types of problems. For example,
when it is exposed to water, a shale sample with a high percentage of smectite tends to swell while another
shale sample with a high percentage of kaolinite tends to disintegrate and disperse. The mechanism that
destabilizes reactive shale when it comes in contact with water differs from on shale sample to another.
It is important to know which mechanism is taking place in order to be proactive and inhibit the drilling
fluid with the appropriate inhibitor. It is also important to characterize the shale sample in terms of its
geological structure, mineralogical composition and interaction potential.
Shale characterization and testing methods include but not limited to the following: X-ray analysis,
degradation and reorientation evaluation using scanning electron microscope (SEM), cation exchange
capacity (CEC) determination, swelling test, dispersion test, slake durability test, bulk hardness test,
accretion test, shale membrane test, inhibition durability test and uniaxial and triaxial compression tests.
Different types of shale inhibitors and stabilizers have been used in the industry such as: potassium
chloride, calcium chloride, silicates, polyamines, glycol and lignosulfonate. Each of them has a mechanism by which it can inhibit the hydration, disintegration and dispersion of clays in the presence of water.
This paper discusses the physio-chemical and chemico-mechanical effects of shale-drilling fluid
interactions and the associated drilling problems that are most frequently encountered while drilling shales
formations. It also reviews the most common shale testing methods used to evaluate the interaction
potential of various shale-drilling fluid systems. Moreover, the paper describes different mechanisms by
which shale can be inhibited and wellbore stability problems can be mitigated.
Introduction
About 75% of the formations drilled worldwide are shale formations with a high sensitivity to water-based
muds. These formations are well-known for their high clay content and associated wellbore instability
problems (Steiger, 1992). When clay-rich rocks are exposed to water, they start to react and behave like
unconsolidated rocks. The extent of reaction, the mechanism and the consequences differ from one type
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of clay to another. For example, kaolinite clay tends to disperse in water, illite clay tends to disperse but
to a lesser extent while smectite clay tends to swell. Because shales from different zones have different
clay mineralogy, the response of every shale zone is usually different when exposed to water.
In addition to swelling and dispersion, another source of wellbore instability while drilling shale
formations is the disturbance of stresses around the borehole. The stresses around the borehole can be
resolved into three main stresses: vertical stress, minimum horizontal stress and maximum horizontal
stress. These stresses are altered and rearranged depending on several factors such as hydrostatic pressure
of drilling fluid, swelling and hydration pressure effect and the overbalance pressure used to support the
borehole wall. Because of the low permeability and high capillary suction of shale matrix, a phenomenon
called mud pressure penetration develops when drilling shale with overbalance pressure. An increase in
the pore fluid pressure will result from the small volume penetrating into the wellbore and, therefore,
wellbore instability will be triggered (Riley et al., 2012)
It is important to characterize shales in terms of morphology and mineralogy in order to understand the
mechanisms of shale-drilling fluid interactions when exposed to water-based drilling muds. Evaluation of
shale-drilling fluid interactions is essential in mitigating wellbore instability problems attributed to shale
reactivity and sensitivity. Different standard and non-standard experimental methods are available in the
industry to assess shale reactivity and predict potential problems in advance. Based on this, inhibition
mechanisms can be utilized to inhibit shale-water interaction and reduce the non-productive time
associated with reactive shale formations.
Types of Clay
There are five main groups of clays: kaolinite, smectite, illite, vermiculite and chlorite with the first three
being the most relevant groups to the drilling activities. Clay structure consists of sheets containing planes
of atoms. These sheets can be tetrahedral or octahedral. In the case of kaolinite, the structure is arranged
so that one tetrahedral sheet is followed by one octahedral sheet in a ratio of 1:1. For other types of clays,
every octahedral sheet is sandwiched between two tetrahedral sheets in a ratio of 2:1. The clay should be
neutral, i.e. number of anions is equal to the number of cations to avoid any interaction with water or
water-based muds. If this is not the case, interlayer materials such as individual cations or hydrated cations
work to neutralize the clay (Brindley and Brown, 1980). The variation in clay structure can be one of the
factors governing the response of each clay type to the hydration process when exposed to water. Every
shale sample has some percentage of one or more types of clay in addition to quartz and other minerals.
Therefore, the mineralogy of the shale sample determines its response when it comes in contact with
water. While the permeabilities of sandstones, for example, are in the range of Darcy to millidarcy, typical
permeabilities of clays are in micro or nano-Darcy range (Deville et. al., 2011).
Frenkel and Levy (1992) conducted a study to test kaolinite, illite and smectite for dispersion tendency.
Clays were stacked in columns and drilling fluids were circulated through the clays. Drilling fluids
containing anions play an active role in destabilizing and dispersing the clays in the water phase. The
saturation of each clay type in the effluent is monitored. As the saturation increases, the clay type has
higher tendency to dispersion. It was found that kaolinite was the most dispersive followed by illite while
smectite did not show high tendency to disperse.
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Swelling is the expansion of clay particles due to water hydration. As described above, clays are
composed of sheets of aluminosilicates. The negatively charged ions are concentrated on the surfaces of
the shale while the positively charged ions are concentrated in the edges. Due to the high concentration
of negative charges, there will be cation exchange where the positively charged ions are adsorbed on the
surfaces.
In literature, different shale swelling mechanisms are described including crystalline swelling and
osmotic swelling. Smectite structure is composed of two tetrahedral sheets and one octahedral sheet in
between. Since clay is negatively charged, interlayer cations are required to neutralize it. There will be
cation exchange reaction. This results in an increase in the spacing distance between the layers which, in
turn, results in the expansion of clay (Zhou and Law, 1998, Norrish, 1954).
Osmotic swelling is due to difference in salinity of the shale rock fluid and the drilling fluid. For low
salinity drilling fluids, water tends to move and diffuse into the higher salinity shale rock and thus hydrate
shale particles. The absorption of water also creates a double layer with repulsive potential leading to the
expansion of the clay matrix.
Dispersion is the progressive disintegration of reactive shales in the presence of water or a noninhibitive mud. Shales having kaolinite as the major clay component usually have high dispersion
tendency in a reactive fluid environment. As a result, shale heaving problems will be encountered and
borehole cleaning efficiency will be significantly reduced.
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Figure 1Results for inhibition durability test for two types of drilling fluids
Mechanical Aspects
This section looks into the shale rock interactions with drilling fluids from mechanical point of view and
links the chemical and mechanical factors that are affecting wellbore stability in shale formations. These
factors include but not limited to: water content and activity, membrane efficiency, cation exchange
capacity, clay content, mineralogical composition, mud type and properties, pore pressure, stresses
around borehole and geological environments. For example, water movement into the shale formation
cause the pore pressure to increase and the rock strength to decrease which may give rise to rock failure.
If the rock-fluid interactions alter the near wellbore in-situ stresses and exert stresses on borehole walls
that exceed rock strength, the rock starts to deform and eventually, fails. Shales are considered as weak
rocks. Even with inhibitive muds, shale compressive failure can occur due to the change in the in-situ
stresses.
Mody and Hale (1993) studied the physics and chemistry of the mud-shale interactions to come up with
an integrated borehole-stability model. They suggested that water movement is controlled mainly by two
mechanisms: hydraulic pressure difference between the wellbore pressure and pore pressure and, also,
chemical potential difference between the drilling fluid and pore fluid. Depending on the drilling fluid
activity, water moves into or out of the shale formation and, as a result, stresses around borehole and rock
strength will be affected as well as pore pressure.
Effect of the Water Activity
Water activity, or salinity, of the mud compared to that of the pore fluid is one of the factors to be
considered in controlling shale reactivity. For a drilling fluid with a high water activity, i.e. low salinity,
water will be driven from the drilling fluid into the shale formation with the aid of osmosis phenomenon.
As a result, pore pressure increases, confining pressure decreases, shale starts to swell and willbore will
be destabilized. Because water activity is inversely related to salinity, raising salinity of drilling mud can
enhance wellbore stability (Chenevert, 1970). However, previous experimental work showed that increasing salinity above an optimum value can have adverse effects due to the possibility of fracturing the shale
and thus can cause wellbore instability. This is because too high salinity will cause pore pressure to drop
down significantly due to water movement from formation into the wellbore leading to the formation of
cracks and fissures within the shale matrix.
Sometimes mud weight is increased for mechanical stabilization of the borehole wall. Because the
effect of high mud weight is time-dependent, it is usually increased step-wise, e.g. mud weight is increased
by 0.5 ppg for every step. The mud weight is increased until the weight that is capable of stabilizing the
shale is reached. Breakout widths can be significantly reduced when the mud weight is increased for a
constant mud activity (Zoback, 2007). Raising mud weights can stabilize wellbore by reducing the
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Figure 2(a) Wellbore breakouts of 100 (more than half of the wellbore walls fail wellbore unstable)
(b) Wellbore breakouts of 60 (less than half of the wellbore walls fail wellbore stable)
wellbore stresses below the shale strength. However, excessive increases in the mud weight can result in
low rate of penetration and can create induced lost circulation problems. Therefore, mud weight should
be optimized to the minimum that is just sufficient to achieve wellbore stability without inducing mud
losses or causing other drilling problems (Steiger and Leung, 1992)
An equation was developed by Mody and Hale (1993) to determine the pore pressure increase as a
function of water activity. Parameters considered in this equation include: membrane efficiency, temperature, molar volume of water and the activities of both the pore fluid and mud. However, time was not
considered although shale instabilities are dependent on time in many cases. Time was considered as a
factor in other models. These models allow the estimation of the time duration that a mud with a known
activity can support the wellbore formation with a known pore fluid activity before failure. As a result,
plot of failure vs. time can be generated and based on these plots, mud chemistry can be adjusted to
enhance the wellbore stability.
Effect of the Membrane Efficiency
Membrane efficiency can be measured by taking the pressure difference across an ideal membrane in the
presence of two fluids with different activities on each side of the membrane, then dividing that by the
theoretical pressure difference between the two sides of the membrane. For low membrane efficiency,
there will be more ion exchange which leads to weakening of the shale. When membrane efficiency is
plotted against water activity of the mud, it can be shown that wellbore becomes more stable as membrane
efficiency increases and water activity of the mud decreases. Here, wellbore stability is measured in terms
of breakout widths. For example, for any breakout width that is greater than 90, more than half of the
wellbore walls fail, Fig 2. As a rule of thumb, wellbore instability is considered to be a major problem
when more than half of the borehole fails (Zoback, 2007). Therefore, it is necessary to keep the breakout
width below 90 to achieve wellbore stability.
Effect of Filtrate Invasion on Cohesive Forces
Cohesive forces are the forces that keep the rock particles sticking to each other. When the filtrate, i.e.
water, penetrates shale rocks, cohesive forces will be broken, reduced or damaged. Thus, there will be a
decrease in the shear stress that is required for failure to occur. This results in movement along the existing
fracture or along the weak planes leading to hole enlargement problem. Furthermore, when the filtrate
invades the shale and the osmotic swelling starts, the rock will be softened and an increase in the rock
volume is noticed because osmosis triggers swelling of particle surface as well as the shale layers
(Hayatdavoudi and Apande). Another effect of osmosis is the pressure created in the rock due to the flow
of fluid into the shale matrix. This will weaken the cohesive structure further.
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grains together acting as an additional shale stabilization mechanism (Gomez and Patel, 2013, Bailey et
al., 1998).
Chrome and ferrochrome lignosulfonate have been used as shale inhibitors. With high tolerance to
sodium and calcium ions, they are able to tolerate salt contamination while drilling subsurface formations
containing brine. However, at temperatures above 300 F, the concentration of chrome lignosulfonate
decreases significantly due to thermal degradation. Hence, these additives are not suitable for high
temperature application.
Calcium and potassium ions can work by another mechanism to reduce the reactivity of the shale by
the cation exchange reaction. For smectite clay, the replacement of Na ions by the calcium ions of a mud
can turn a high swelling shale into a low swelling shale. This is the reason for the lower hydration
tendency in the shale when sodium montmorillonite is converted into calcium montmorillonite (Bourgoyne, 1986).
Saltwater muds can reduce the reaction between clay and water. With an increase in the salt
concentration, bentonite viscosity decreases exponentially. This is the reason for pre-hydrating the
bentonite with water to have a reasonable viscosity when using sea water or salt water as the fluid phase.
Potassium chloride salt is frequently used in water-based mud design to inhibit reactive shale due to the
ability of K ions to replace the sodium ions. The swelling tendency of the shale is reduced significantly
by the clay fixation property of K cations along with its ability to lower hydration tendency of smectite.
Due to their small size, the K ions can induce inhibition as they fit into the montmorillonite structure
(Bourgoyne, 1986). Another inhibition mechanism is to use heavy brines to increase the water phase ionic
concentration. This high ionic concentration reduces the hydration by minimizing the osmotic effect
(Gomez and Patel, 2013).
Amines and polyamines have been recently used as shale inhibitors. By attaching strongly to the
negatively charged faces of the clay, the positively charged amine particles dramatically reduce the water
affinity of the shale. Due to the low molecular weight and small size, it is possible for these molecules
to enter into the clay structure and inhibit both the internal and external hydration of reactive shale
(Amanullah 1993). The inhibition mechanism of polyamines is similar to the inhibition mechanism of
amines. However, due to the presence of multiple active sites in the long chain, they can better neutralize
clay charges in shale matrix (Patel et al., 2007).
Methyl glucoside works by reducing the water activity. It differs from other commonly used salts by
forming a semi-permeable membrane inside the shale matrix. This is a result of its particle size that makes
it possible to diffuse into shale pores and allows hydroxyls to adsorb on surfaces of clay. During the
hydroxyls adsorption, ordered structures of methyl glucoside are formed after the water is displaced from
the surfaces (Ismail and Huang, 2009)
Based on the type of shale, amount of clay and types of clays present, a shale inhibitor can be identified,
evaluated and compared to other inhibitors. Huadi et al. (2010) performed different shale inhibition tests
on two polyamine systems to compare with pure and modified KCl-based systems. The polyamine
systems out performed two KCl systems while they gave comparable results to KCl/silicate systems in
two tests: shale dispersion and shale bulk hardness tests.
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transportation, cuttings transportation and disposal. Another consideration when formulating an inhibitive
water-based mud is to overcome the inherited sensitivity to temperature, salinity, pH and different
contaminants.
After comprehensive characterization of the shale sample, inhibition additives such as potassium
chloride, silicates, polyamines and others can be utilized for this particular shale sample. Since every shale
formation differs in mineralogy than other formations, customization of the mud is necessary to achieve
best results. It is almost impossible to develop a universal inhibitive water-based mud that has high
performance in all types of shales (Deville et. al., 2011)
Frieheim and Sartor (2003) developed a new inhibitive water-based mud in an attempt to achieve
comparable performance to oil-based muds. Their approach was based on three mechanisms: shale
hydration inhibition, shale dispersion inhibition and shale accretion inhibition. They identified and
developed three additives to formulate an inhibitive mud with the desired properties. First, the hydration
inhibitor polyamine-based additive was designed to fit between clay sheets and minimize the water
imbibed into the shale formation. Second, the dispersion inhibitor was designed to effectively bind to clay
surfaces and also tolerate high salinity and hardness. This additive was able to inhibit dispersion as well
as swelling of the clays with no adverse effects on the mud rheological properties. Third, the accretion
inhibitor was designed to coat drill cuttings and the metal surfaces of the drilling assembly so that the
accretion tendency is reduced. Also, it helps in preventing the drill cuttings agglomeration and accumulation.
Recent developments in nanotechnology showed that nano-sized particles can play a vital role in shale
stabilization through plugging the shale pores, reducing the permeability and minimizing water penetration into the shale structure. This is due to their small particle size that enables them to enter into the clay
matrix and do the required inhibition (Amanullah and Al-Tahini, 2009)
Conclusions
1. Types and percentage of clay present in the shale rock affect its behaviour under chemical and
hydro-mechanical action of fluids.
2. Every clay type has its own structure and behaves differently when exposed to water. Hence,
comprehensive characterization and testing for the shale should be conducted to develop an
inhibitive drilling fluid with the desired properties.
3. Different types of shale inhibitors have different mechanisms to inhibit and stabilize the shale. A
combination of several inhibition mechanisms can provide effective control on reactive shalerelated drilling problems.
4. Mechanical aspects of shale-drilling fluid interactions play a major role in the wellbore stability
of shales. A study of the mechanical factors is essential to avoid any stability problems.
5. Some high performance water-based muds can provide the required inhibition in controlling
reactive shale problems and thus can provide an alternative to oil-based mud.
Acknowledgment
The authors acknowledge the support from EXPEC Advanced Research Center management and Petroleum Engineering Department at KFUPM for their support and encouragement to carry out innovative
research and development activities and also for granting permission to publish this paper.
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