Mud Engineer’s Handbook

Drilling Mud & Solids

Control Manual

For
Mudsim – Mud Treatment
Simulator
Drilling Management Trainer –
Mud Engineer’s Station

3rd Edition
November 2003
Drilling Mud & Solids Control Manual

Table of Contents

1. Introduction 3

2. Chemical Catalogue 5

3. Circulating System & Solids Control Equipment 6

a) Mud Pits 7
b) Mud Pumps 7
c) Annulus 8
d) Shale Shakers 9
e) Settling Pits or Sand Traps 10
f) Desander 11
g) Mud Cleaner / Hydrocyclones 12
h) Centrifuges 13
i) Dump Valve 14

4. Cuttings & Annular Loading 15

a) Volume of cuttings generated & their removal 15

b) Cuttings Description 16
c) Cuttings removal & losses 17
d) Dilution Co-efficient 21

5. Drilling Procedures 22

a) Good Drilling Practice 22

b) Leak off tests 23

6. Mud Recipes 24

a) Spud Mud & Sweeps 24

b) Basic Gel Mud 24
c) Gel & Gyp Mud 25
d) Gel & CMC Mud 25
e) Gyp Lig Mud 25
f) Salt Saturated 26
g) KCL XC Polymer Mud 26
h) KCL PAC Mud 26
i) NACL CMC Polymer Mud 26
j) NACL PAC Mud 27

7. Chemical Addition Tables 28

8. Mud Treatments & Troubleshooting 29

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1. Introduction
This manual is designed to provide assistance and advice for students using the following simulators;

MUDSIM Mud Treatment Simulator

Drilling Management Trainer – Mud Engineer’s Station.

This simulator is the result of a team of highly trained mud engineers working for 3 years and performing
4800 individual mud tests to provide over 48,000 individual data points comprehensively describing the way
in which chemical additions will affect drilling mud systems (for instance the result of allowing Bentonite to
hydrate for any given amount of time). The data collected as a result of these tests was then used as the
basis for a complex mathematical model which forms the heart of the simulator you will be using. If during
the course of the exercise, the simulator will not allow you to add a particular chemical to a mud system, it is
a deliberate feature backed up from the results of the tests, for instance, the simulator will not allow you to
add Barite to a pit where the Yield Point of the mud is too low to suspend the material.

The function of all drilling mud is the successful completion the well being drilled, even though all drilling
fluids have the same functions, their properties can be altered to facilitate a speedy, safe and satisfactory
completion of the well.

These functions include:

• Removal of cuttings from the hole
• Cleaning the bottom of the hole
• Controlling the subsurface pressure
• Cooling & lubricating the drill bit & drill string
• Allowing the cuttings to removed once at surface
• Forming adequate filter-cake on the walls of the hole
• Preventing the caving-in of the formations
• Avoiding damage to the formations
• Assist in supporting the weight of the Drill string
• Reducing the Casing costs
• Preventing corrosion
• Allowing the interpretation of wireline logs
• Transmission of hydraulic power from the surface to the bit
• Suspension of cuttings and weighting materials when circulation has been broken.
• Act as a medium for obtaining and transmitting information from downhole tools (e.g. MWD)

In order to perform the above functions, the fluid must exhibit certain controllable properties, such as:
• Suspension Capacity (rheology & thixotropy)
• Pseudo-plastic behaviour (shear thinning)
• Provide the required fluid gradient
• Protect the borehole wall (fluid loss control)
• Minimise the degradation of cuttings

In addition, the fluid should not be:

• Harmful to personnel
• Harmful to the environment
• Corrosive
• Detrimental to Drilling Equipment
• Erosive to unconsolidated formations
• Reactive with drilled formations.

In order to drill safely and economically, the correct fluid should be chosen before drilling commences. The
selection of the drilling fluid should depend on the following:
• Type of formations to be encountered
• Required Fluid Gradient
• Hole Angle
• Previous experience in similar areas / formations

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• Expected temperatures
• Coring / Logging requirements
• Platform / rig capabilities
• Economic Climate / Financial restrictions
• Casing scheme
• Environmental Pressures

The simulator you will be using takes in to account all of these features and combined with the complex
mathematical modelling of the drilling process and the various chemical reactions between different types of
drilling fluids and the various geological formations found in the exercises means that you will be exposed to
a highly realistic simulated environment, complete with all the problems and practical difficulties facing
engineers in the field.

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2. Chemical Catalogue
This is a list of the chemicals and items which are available within the Mudsim / DMT system and the
maximum concentrations in which they should be used.

Max.
CHEMICAL Purpose
Concentration
Increases the pH of the mud (ideal value – 9 to 10), beyond
Caustic Soda
pH of 12, any polymers in the mud will be “burnt” out. Very Additions until
(Sodium
caustic mud also risks damaging the drilling equipment and pH = 13
Hydroxide)
may cause harm to the rig crew. Is also used as a Biocide.
Prevents & treats fluid loss, also increases the viscosity
CMC Low 3-5 lbs/bbl
slightly. Relatively cheap polymer.
Increases the viscosity of the mud with slight effect on fluid
CMC High 3 lbs / bbl
losses. Relatively cheap polymer.
Similar to CMC High except that it encapsulates solids and
PACR 3 lbs / bbl
is more expensive.
Similar to CMC Low except that it encapsulates solids and
PACL 3 lbs / bbl
is more expensive.
Encapsulates solids (no effect on viscosity) to prevent
PHPA reaction between the drilling mud and a reactive formation. 3 lbs / bbl
Relatively cheap.
Pure fluid loss (needs Caustic to prevent bacterial growth /
Starch 7 lbs / bbl
digestion). Relatively cheap.
XC Polymer Extreme Viscosification of the mud. Expensive 3 lbs/bbl max
Swelling clay mineral – adds natural viscosity when left in
Bentonite 30 lbs / bbl
freshwater for long periods of time (hydration).
Barite (Baryte) Inert mineral used to add weight of the mud (S.G. of 4.2) Not applicable
Used to thin out the mud (requires the presence of drilled
solids to react with). Is also acidic so should be added in
Lignosulphonate 10 lbs / bbl
ration of 4:1 with Caustic. Has diminishing returns and
should therefore be used as a last resort.
Treats calcium / cement contamination, less aggressive
Sodium than Soda Ash. Can be used to reduce the “hardness” of
Bicarbonate water before adding bentonite to fresh water – this will
have the effect of speeding up the hydration time.
Treats calcium / cement contamination but far more
aggressively than Sodium Bicarbonate. Can also be added
Soda Ash
to unhydrated bentonite to speed up hydration time but will
cause the mud to “age” much faster.
Used as an inhibitor in a Bentonite mud when drilling
5lbs / bbl
Gypsum through evaporite mineral Formations or through Chalk.
maximum
Also adds viscosity.
NaCl Inhibits washouts when drilling through salt formations. Saturation
Excellent inhibitor in Clay Formations – need to maintain
KCl 80% KCL to retain active inhibition. Is also very expensive Saturation
and carcinogenic.

When building new drilling mud, it is important to note that not all chemicals can be combined – for instance,
you cannot combine XC Polymer and CMC / PAC Polymers. This is a deliberate function of the simulator
although in real-life, you may be able to add these chemicals together, the simulator you are using was
designed to work within a certain set of boundaries & parameters and was produced to an exacting client
specification.

For a series of standard mud recipes, please consult Chapter 6 of this manual.

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3. Circulating System & Solids Control Equipment

The Circulating system is the way in which the Mud Engineer controls the properties of the drilling fluids
during circulation.

There are so many different combinations of the equipment used to circulate the mud and then remove the
cuttings from the drilling fluid that this manual will examine each piece of equipment individually.

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a) Mud Pits
This is where all additions to the mud system should take place. These screens allow the student to add
any of the chemicals and compounds mentioned in the Chemical catalogue (provided of course that
sufficient quantities have been ordered and have been delivered to well site).

To add a chemical to a pit, simply click on the desired pit, which will bring up a small drop down menu
with 2 options “Pit Checks” (which allows the student to perform a mud check and to dump / transfer
mud) and “Add to Mud”. Selecting the “Add to mud” option will bring up a menu listing all the chemicals
within the catalogue – please note that some of them may be greyed out – this is because the item may
not have been ordered or delivered yet, or because that chemical can not be added to the chosen pit.

It is considered to be very poor practise to mix / add chemicals in the active pits with the exception of the
addition of Barite. If the student wishes to add any materials to the mud in the active pits, he / she should
first tell the driller that they are about to add the chosen volume, as otherwise, the driller may interpret
the sudden rise in the pit volumes as having just seen an influx into the well bore (taken a kick) and shut
the well in.

It is also highly recommended that the student always retains at least one pit of mud which is ready to be
made up, for instance if the student is using a gel based mud system, there should always be at least
one pit of pre hydrated Bentonite ready to be weighted up and used.
(For further information, see also section 3e – Settling pits)

b) Mud Pumps
The Mud Pumps are the means by which the drilling fluids are forced around the annulus. Each exercise
in the simulator will have 2 or more mud pumps installed with differing capabilities and capacities.

In Mudsim, this data can be found by going to the “Rig Info” item on the menu bar and selecting the
Pump Data option, which will bring up a small display detailing the following information, the Pump Type
and model, the Liner Size, the Liner Displacement and the Maximum pressure that the Liner can hold.

In DMT, the Mud Engineer can determine these values by simply clicking on the Mud Pump buttons,
which will bring up a display with the following data fields;
Pump Description, Pump Efficiency (Usually set to 98%), Pop-off setting (usually set to 95%), the Pump
Speed, the Liner Size, the Liner Displacement and the liner pressure.

The student should take note of these figures, as they will prove essential for many tasks throughout the
exercise, such as spotting pills, calculating cement displacements etc.

Example

A National 12-P-160 Pump with 7” Liners installed will displace 6 gallons per stroke, however it is
running at 97% efficiency. If the mud engineer wishes to pump a 50 bbl viscous pill, how many
strokes would they require to displace the pill and at 80 strokes per minute, how long would it take?

50 bbls = (50 x 42 gallons) = 2100 gallons

6 (gallons per stroke) x 0.97 (efficiency) = 5.82 gallons per stroke

2100 gallons ÷ (5.82 gallons per stroke ) = 361 strokes

361 strokes ÷ 80 strokes per minute = 4.51 minutes or 4 minutes, 30 seconds

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c) Annulus
The Annulus is the entire hole section and in terms of the drilling fluids, extends from the Standpipe
down through the drill string to the bit and then up to the surface again. As such, it is important that the
student ensures that there is enough mud available to fill and maintain the level of mud in the annulus.

Open Hole Oilfield Units Metric units

Size (Bbls/ft) (m3/m)
30 0.8743 0.4560
26 0.6567 0.342534
24 0.5595 0.291864
20 0.3886 0.2026
17 ½ 0.2975 0.155179
16 0.2487 0.129717
14 ¾ 0.2113 0.110241
13 3/8 0.1738 0.090645
12 ¼ 0.1458 0.076038
9 5/8 0.0732 0.0382
8½ 0.0702 0.036610
6 0.0350 0.018241
5 0.0335 0.017489

By using the table above, the annular volume can easily be calculated, for instance;
Example
A well has been drilled with the 20 inch casing shoe set at 750ft MD (228.6m). The well was then
drilled ahead to 1000ft (304.8m) using a 17-½ inch bit. Calculate the annular volume of the hole.

Cased section
750 x 0.3886 = 291.4 bbls

Open Hole section

(1000 – 750) x 0.2975 = 74.4 bbls

Therefore, the volume of the annulus will be 365.8 bbls

As a general rule, you should be prepared to produce 4 times the annular volume of the predicted hole
section during the drilling of the well, this is generally used to factor in any losses to the formation, losses
to the solids control equipment and to cover any mud which has to be dumped. To continue the example
above, to drill the hole to 1000ft MD, you should expect to have to build 1463.3 bbls of mud (minus the
volume of clean mud built before the section is drilled).

An actual figure of 1 to 2 times the expected hole volume is considered an excellent result, a figure of 3
to 4 times the expected hole volume is considered an average result and a result of 5 or more times the
expected hole volume is considered to be a poor result (unless for a specific reason, for instance drilling
through a very fractured formation.)

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d) Shale Shakers
The Shale Shakers are the primary means of cuttings removal and the correct configuration of the
Shakers can prove vital to the drilling of the well. As a student you should be constantly aware of any
losses occurring over the shakers and use your judgement to decide if any changes should be made.
Drilled solids are by far the main cause of the drilling fluids becoming contaminated and the Shale
Shakers are your main means of preventing this from occurring.

Before circulation can begin, the student should decide which size shaker screens they wish to use.
There are 2 screens which have to be fitted, the Upper and the Lower screens.

Upper Screen – the sizes available to choose from are as follows;

Mesh Size Microns

10
20
30
40

Lower Screen – the sizes available to choose from are as follows;

Mesh Size Microns

40 380
50 279
60 234
80 178
100 140
120 117
150 105
200 95
230 74

It is important that the correct choice of shaker screen is made (this depends upon the flow rates, the
cutting size and the ROP & Flow rates– otherwise, if the mesh is too coarse, the cuttings will simply pass
through the screens back into the circulating system. If the screens are too fine, none of the cuttings will
pass through and will be lost, prompting large mud losses to occur
If the student selects a screen with the same size mesh as the cuttings that are coming to the Shakers,
then the screen will quickly become “blinded” and the efficiency will drop dramatically, as the individual
particles lodge themselves in the mesh. If this happens, large mud losses may develop.

The student should also determine the angle at which they want the Shale Shaker to operate, the
simulator allows a range of +3 degrees to –15 degrees. A high value means that the time that the
cuttings will spend on the screen (the residence time) will be increased – this leads to cuttings
degradation but at the same time reduces mud losses, conversely, a low value means that the residence
time is reduced and the cuttings are shaken less – as a result, more mud remains of the cuttings and
mud losses will develop but the cuttings will be cleared quickly. If the flow rate is too high or the cuttings
are not being cleared quickly enough, then the shaker may become jammed with cuttings and the
efficiency of the cleaning will be impaired.

Low Mud losses Some mud losses Large mud losses

Cuttings Degradation Little degradation No degradation
Poor Clearance Rapid clearance
+3 +2 +1 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

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e) Settling Pits or Sand Traps

The Sand Trap should usually receive the liquid slurry passing through the shale shaker as well as any
liquid slurry bypassing the shale shaker and flowing into the active mud tanks

These pits are used to allow time for the larger suspended solids to drop out of the fluid and settle to the
bottom of the tank. Once again, the flow rate will determine how long the residence time will be and the
effectiveness of the settling.

Because of the nature of the solids which will settle out in this tank, it should be cleaned regularly when
using weighted mud (because high gravity solids such as Barite are sufficiently dense to drop out of
suspension and may collect on the bottom of this tank). This tank should also be cleaned out when the
mud system is being switched from one regime to another to prevent cross contamination of the different
mud types.

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f) Desander
The Desander is comprised of a series of “cones” which take a set volume of drilling fluid and force it to
pass around a funnel shaped housing (the cone itself) at high speed, forcing the sand particles out of
suspension, the solids are removed from the bottom and the cleaned fluids from the top. The cones are
functionally very similar to those found in a Hydrocyclone but are on a far larger scale and are designed
to remove larger particles.

There can be either 1,2 or 4 cones can be installed at any one time, each capable of dealing with a
capacity of 500 gallons per minute (1892 litres per minute).

The Desander will require maintenance at regular intervals to ensure that any damaged cones are
replaced and the system is cleaned. In this simulator, there is a settling pit associated with this device,
which should be cleaned out when the student wishes to change mud systems to prevent cross
contamination of the different mud types. Because of the nature of the solids which will settle out in this
tank, it should be cleaned regularly when using weighted mud as due to the density of the Barite, it may
easily collect on the bottom of this tank. This tank should also be cleaned out when the mud system is
being switched from one regime to another to prevent cross contamination of the different mud types.

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g) Mud Cleaner / Hydrocyclones

The Hydrocyclone is comprised of a series of “cones” which take a set volume of drilling fluid and force it
to pass around a funnel shaped housing (the cone itself) at high speed, forcing the sand particles out of
suspension, the solids are removed from the bottom and the cleaned fluids from the top. The Mud
Cleaner / Hydrocyclone is designed to remove silt sized particles from the mud and as such, large scale
mud losses can be experienced to this piece of equipment. It is therefore important that the engineer
closely monitors this device.

There can be either 8,10,12, 16, 18, 20, 22 or 24 cones can be installed at any one time, each capable
of dealing with a capacity of 50 gallons per minute (189 litres per minute).

The Hydrocyclones can be used as a Mud Cleaner by installing a fine shaker screen beneath the outlet
of the cones (mesh size of either 117 Microns, 105 Microns or 95 Microns) to further remove any solids.
In a weighted mud, the Hydrocyclones remove mostly sand, some coarse silt and minute amount of
medium silt as well as a large amount of free liquid film, which is loaded with clay and a small amount of
fine silt particles. The fine screen placed under the solids discharge port will return most of the medium
silt and a major part of the clay material and fine silt back into the system. This process will reducer
Barite usage compared to operating the Hydrocyclones without screens. It is worth noting that this
saving may be counteracted by a poor screen size selection and that if centrifuges are being used to
control the viscosity of the weighted mud, it would be logical to stop returning the clay material back into
circulation by using the Mud Cleaner screen.

When the Hydrocyclone / Mud Cleaner is running, large amounts of drilling fluids may be lost, however,
the function that the equipment provides is considered to be a worthwhile compromise.

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h) Centrifuges
There are 2 separate centrifuges featured in both the Mudsim simulator and the DMT Mud Engineer’s
station. The centrifuges are used to remove the finest material (clay sized particles) from the drilling
fluids and to quickly and efficiently return the cleaned fluid back to the flow line so that it can be returned
to the pits. There are several options available with the centrifuges:

Speed
This is the speed at which the centrifuge will turn – there are 2 options, 1600rpm and 2500rpm

Scroll Speed
This is the speed at which the conveyor rotates within the centrifuge and will get rid of the solids
removed from the drilling mud by the centrifuge(s). If this speed is set too high, then the fluid will not
have sufficient residence time and will be discharged with drilling mud still attached, if the speed is set
too low, then the solids will not be removed quickly enough and the centrifuge will overflow, risking
losses. The scroll speed can be set between the values of 0 to 37 rpm.

Bowl Depth
The Bowl Depth is the level at which the overflow ports are set (which allow the cleaned fluids to
escape), if they are set too low then the fluids my still retain a portion of the solids and if set too high, not
enough of the fluids will escape. The bowl depth can be set between 0 and 5.375 inches (136.5mm).

Alignment
The centrifuges can either be lined up in Serial (e.g. one after the other) or in Parallel. If the centrifuges
are set to run parallel to each other, the flow rate which can be treated can be maximised, however, if
the centrifuges are set to run in serial mode, then the flow rate will be reduced but the cleaning will be
increased.

Barite Recovery Mode

The centrifuges can be set to Barite recovery mode if so desired (this mode enables the mud engineer to
recover much of the barite from the mud and re-use it later or to reduce the amount of drilled solids). To
set the centrifuges up in this way, the centrifuges should be set to run in Serial mode, with the first
centrifuge speed being set to 1600rpm and the second centrifuge set to 2500 rpm.

The centrifuges will require regular maintenance and if not properly maintained, will cease to function.

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i) Dump Valve
The Dump valve is used to remove drilling fluid from the otherwise closed circulatory system and literally
dumps the mud over the side e.g. into the sea or to a support boat.

If you wish to displace a mud system from the annulus before switching to a new system, the dump valve
is often used, in effect, the new mud system is being pumped into the hole and the old system is being
discharged. You will not need to open the dump valve if you wish to drain one of the mud pits, the
simulator assumes that the pit room crew will perform the necessary tasks automatically.

It is important to remember to check the status of the dump valve regularly – on the Mudsim simulator,
the flow paths will be shown lined up to the dump valve, whereas on the DMT Mud Engineer’s Station,
the dump valve icon will have a green centre when open and a black centre when closed.

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4. Cuttings & Annular Loading

a) Volume of cuttings generated & their removal
The removal of cuttings from the face of the well bore is still one of the most important functions of any
drilling fluid. The circulation fluid rising from the bottom of the well bore carries the cuttings towards the
surface. Under the influence of gravity the cuttings tend to sink through the ascending fluid; but by
circulating a sufficient volume of mud fast enough to overcome this effect, the cuttings are brought to the
surface. The effectiveness of mud in removing the cuttings from the hole depends on several factors:
• Velocity – Velocity is the rate at which the fluid circulates and the annular velocity is an important
factor in transporting the cuttings to the surface. Annular velocities between 100 and 200
feet/min are frequently used. Velocity is dependant upon the pump capacity, pump speed,
borehole size and the size of the drill string.
• Density – Density is the weight per unit volume of mud and has a buoyant effect upon the
particles. Increasing mud density increases it’s carrying capacity due to the buoyant effect
created by the additional solids.
• Viscosity – Viscosity is highly significant in affecting the lifting power of drilling mud. Viscosity
depends upon the concentration, quality and dispersal of the suspended solids.

It is important when devising the drilling programme and the proposed mud programme for a particular
well to calculate the volume of cuttings which will be generated by the drilling of the hole section, for
instance, a 26 inch drill bit will generate far more cuttings than an 8 ½ inch bit. This has a direct effect
upon the drilling programme as well as the desired mud program, for instance, if a hole section will
generate a lot of cuttings, there will have to be adequate solids control equipment capacity to deal with
the drilled solids – the speed at which the formation is drilled will also have an effect on the solids control
equipment required, for instance, if a section is to be drilled at 10ft/hour then there will be a far lesser
volume of cuttings in the mud which will need to be treated per minute than if the same section was
drilled at 100ft/hour.

To calculate the volume of cuttings being generated, you will need to determine the hole capacity and
then multiply that value by the distance to be drilled.

Example
A student wishes to drill their 26” hole section to 750ft MD (228.6m).
(26” hole capacity = 0.6567bbls/ft or 0.342534m3/m)
0.6567 x 750 = 492.5 bbls or 0.342534 x 228.6 = 78.30 m3

If the hole section detailed in the example is to be drilled at an average ROP of 100ft/hour then each
hour, there will be 65.7 barrels (10.44m3) of cuttings for the Solids Control Equipment to deal with, a
large number which may well outstrip the capacity of the solids removal system. Conversely, when
drawing up the plans for the hole section, the mud engineer and the driller should determine a maximum
rate at which the solids can be removed and then work out the maximum ROP that will allow the hole to
be kept clear. It may well be quicker and less expensive in the long term to drill ahead at a slower rate
with good hole cleaning than to drill ahead recklessly and spend days trying to circulate the hole clean.

Example Continued
The Solids Control System designed by the student can safely remove 29.55 bbls of cuttings
per hour and the student wishes to determine a safe ROP to use when drilling ahead.

29.55 bbls/hour ÷ 0.6567bbls/foot = 44.99ft/hour

By determining a safe rate at which the hole can be kept clean (assuming good quality drilling mud and
adequate pump rate to lift the cuttings to surface), it is possible to prevent a great deal of stuck pipe
problems caused or aggravated by poor hole cleaning, such as packing off.

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b) Cuttings Description
The type and size of bit being used will also determine the size and shape of the cuttings being
generated, for instance, a roller cone bit will generate cuttings of a different size and shape to those
being generated by a PDC bit in the same formation. It is worthwhile for the student to take regular
formation samples (or on a DMT exercise, ask the Geologist) to determine the size and shape of the
cuttings. The same formation samples should be checked for details and characteristics which may
affect the mud programme, for instance if a sample disperses easily in fresh water then it may be a “mud
making” formation, which will have the effect of viscosifying the mud and behaving as though a greater
volume of Bentonite has been added. Similarly, the type of material from which the cuttings are made
can help determine the actions of the mud engineer, for example, a marly chalk formation may mimic the
effects of an anhydrite layer, a sandy sample may prompt a different choice of solids control equipment
(e.g. use a Desander instead of the Mud Cleaner). In this way, close communication between the Mud
Engineer and the Geologist is essential for the smooth and rapid drilling of the well with a minimum of
stuck pipe problems.

Throughout the exercise, there may be messages associated with the sample, for instance, “Large
Orthogonal cuttings” (This can be interpreted as being symptomatic of an overpressured formation which
is breaking apart) or “Heavy drill string vibration”. These messages should be reported to the whole
drilling team and appropriate actions or precautions should be taken.

Throughout the exercises you will be carrying out, there will be a variety of warning messages and
pieces of information which are associated with the cuttings description, for instance, the presence of
gas cut mud, shallow gas or H2S. It is important that this information is recorded and acted upon
accordingly (if the well was being drilled in the real world, the presence of large amounts of H2S could
not be ignored!)

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c) Cuttings removal & losses

A properly designed Solids Removal programme will result in some degree of losses. It is important that
the student is not afraid to take losses to the solids control equipment and instead, views the losses as a
normal and desirable event. Should losses become excessive, then intervention may be required, for
instance switching off a particular device or modifying a device’s operating parameters.

As stated earlier in this manual, it is considered by many field engineers to be worth preparing 4 times as
much drilling mud as the expected hole volume for each section, especially in open or permeable
formations where severe losses may occur. This is in many cases considered essential, as the losses to
the formation help to develop a layer of filter cake on the sides of the well bore and prevent or reduce
further losses.

For details on the volume of cuttings generated and the steps required to dilute the volume of drilled
solids to reduce the possibility of packing off, please consult the chapter below (4d)

If during the drilling of the well, a formation is encountered which causes persistent hole cleaning and
solids control problems with your chosen drilling fluid, it is often a good idea to change the mud system
to match the parameters to match the formation, for instance if a thick bed of anhydrite was encountered
and caused severe problems with the mud, changing to a Gel & Gyp or Gyp Lig mud would be suitable,
similarly if a reactive shale is causing severe problems with your mud regime, switch to a drilling mud
which will suit that formation (a highly inhibitive mud for example). A good rule of thumb is that “If you
can’t beat it, join it.”

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d) Hole Cleaning
Hole cleaning is one of the basic functions of any drilling fluid. Cuttings generated by the bit, plus any caving
and/or sloughing, must be carried to the surface by the mud.

Failure to achieve effective hole cleaning can lead to serious problems, including stuck pipe, excessive
torque and drag, annular pack-off, lost circulation, high mud costs and slow drilling rates. Cuttings transport
is affected by several interrelated mud and drilling parameters.

Removing cuttings from below the drill bit is still a crucial function of a drilling fluid. The circulatory fluid rising
from the bottom of the well bore carries the cuttings toward the surface.

Under the influence of gravity, these cuttings tend to fall through the ascending fluid. This is known as slip
velocity.

The slip velocity will depend upon the viscosity (thickness) and density of the fluid. The thicker the fluid, the
lower the slip velocities. The more dense the fluid, the lower the slip velocity. For effective cuttings removal,
the fluid velocity must be high enough to overcome the slip velocity of the cuttings.

This means that fluid velocity can be lowered in a highly viscous (thick) or very dense fluid and cuttings still
effectively removed from the well bore.

The density of a fluid is determined by other factors and is not usually considered a factor in hole cleaning;
therefore we limit adjustment of hole cleaning properties to viscosity and velocity adjustments to the drilling
fluid.

The viscosity desired will depend upon the desired hydraulics and the size of the cuttings contained in the
fluid. The velocity will depend on several factors - the pump (capacity, speed, efficiency), the drill pipe size
and the size of the borehole.

The velocity of a fluid will determine its flow characteristics, or flow profile. There are five stages, or different
profiles, for a drilling fluid:
• No flow,
• Plug flow,
• Transition,
• Laminar,
• Turbulent.
The ideal velocity is one that will achieve laminar (or streamline) flow because it provides the maximum
cuttings removal without eroding the well bore.

On the other hand, turbulent flow (resulting from too high a velocity or too low fluid viscosity) not only
requires more horsepower but can also cause excessive hole erosion and undesirable hole enlargement.
The proper combination of velocity and viscosity is a must for the right hydraulics and efficient hole cleaning.
Cuttings will have a tendency to collect at points of low fluid velocity in the well bore annulus.

These areas are found in washouts and where the drill pipe rests against the wall of the well bore. To that
end, it is a good practice to rotate and work (raise and lower) the drill string while just circulating to clean the
hole, as this will help keep the cuttings in the main flow of the fluid and not allow them to gather next to the
wall or pipe.

Hole angle, annular velocity and mud viscosity are considered to be the most important. Cuttings and
particles that must be circulated from the well have three forces working on them:
• A downward force due to gravity,
• An upward force due to buoyancy from the fluid and
• A force parallel to the direction of the mudflow due to mud flowing around the particle.
The hole-cleaning process must counteract gravitational forces acting on cuttings to minimize settling during
both dynamic and static periods. Three basic settling mechanisms can apply:
• Free
• Hindered
• Boycott settling.
Free settling occurs when a single particle falls through a fluid without interference from other particles or
container walls. The larger the difference between the density of the cutting and the density of the liquid, the
faster the particle will settle.

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The larger the particle is the faster it settles and the lower the liquid’s viscosity, the faster the settling rate.
Hindered settling is more realistic settling mode for near-vertical and near-horizontal intervals.
Hindered settling occurs when fluid displaced by falling particles creates upward forces on adjacent particles,
thereby slowing down their settling rate.

The net result is still an overall downward movement, but the settling rate is always less (hindered), thus the
name. Boycott settling is an accelerated settling pattern that can occur in inclined well bores.
Boycott settling is the consequence of rapid settling adjacent to the high and low sides of inclined well bores.
This causes a pressure imbalance, which drives the lighter, upper fluid upwards, and any cutting beds on the
low side downwards.

At relatively low flow rates, mud flows mainly along the high side and accelerates or enhances the Boycott
effect. High flow rates and pipe rotation can disrupt the pattern and improve hole cleaning.
If not properly supported, cuttings can accumulate at the bottom of the hole or on the low side of inclined
intervals. "Plugs" and stuck pipe can be caused by dragging bottom hole tools up through pre-existing beds.
Cuttings accumulations can be difficult to erode or re-suspend, so mud properties and drilling practices
which will serve to minimize their formation should be emphasized.

Cuttings transport efficiency is largely a function of annular velocity and the annular velocity profile.
Increasing annular velocity will always improve hole cleaning, though it still must work with other hole
parameters. In fully concentric annulus, flow is evenly distributed around the drill string.

Thus there is an equal distribution of fluid energy for cuttings transport. However, the drill string tends to lay
on the low side of the hole in inclined sections, shifting or skewing the velocity profile, the results of which is
not conducive to cuttings transport.

Cuttings accumulate on the bottom of the hole adjacent to the drill pipe where the mud flow is minimal. In this
situation, pipe rotation is critical to achieve effective hole cleaning. However, there are times when drilling a
directional hole that pipe rotation will not be possible.

All is not lost at this point since we can offset the detrimental effects of not rotating with different mud types
and changing certain mud properties.

Generally speaking, different drilling fluid types provide similar cuttings transport if their down hole properties
are similar.

Properties of particular interest to hole cleaning include mud weight, viscosity and gel strengths. Mud weight
helps buoy cuttings and slow their settling rate but it is really not used to improve hole cleaning. Instead, mud
weights should be adjusted based only on pore pressure, fracture gradient and well-bore stability
requirements.

Mud viscosity helps determine carrying capacity. Yield points historically has been used as the key
parameter which was though to affect hole cleaning.

More recently, evidence concludes that Fann 6 and 3 RPM values are better indicators of carrying capacity.
These values are more representative of the Low Shear Rate Viscosity (LSRV) which affects hole cleaning in
marginal situations. One common rule of thumb is to maintain the 3-RPM value so that it is greater than the
hole size (expressed in inches) in high angle wells.

Gel strengths provide suspension under both static and low shear rate conditions. The ideal situation is for
the fluid to have high, fragile gels that develop quickly and are easily broken. Excessive high, progressive
gels, on the other hand, should be avoided as they cause high transient pressures that cause a number of
serious drilling problems.

Listed below are practical hole-cleaning guidelines aimed at field use on directional bores.

Use hole-cleaning techniques to minimize cuttings-bed formation and subsequent slumping that can occur in
30-60 degree hole sections.

Utilize elevated-viscosity fluids from the start because cuttings beds are easy to deposit but difficult to
remove.

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Maintain LSRV between 1.0 and 1.2 times the hole diameter when in laminar flow. This requirement will be
easier to accomplish if the fluid is treated with a super or high viscosity polymer. This product is a bio-
polymer that elevates the LSRV in fluids.

Treat mud to obtain elevated, flat gels for suspension during static and low flow rate periods. Consider using
the mud system that will give you excellent LSRV values and superior suspension abilities. The system uses
an untreated bentonite and a mixed metal hydroxide additive.

Schedule periodic wiper trips and pipe rotation intervals for situations where sliding operations are extensive.
Rotate pipe at speeds above about 50 RPM if possible to prevent bed formations and to help remove pre-
existing beds.

Expect little help from viscous sweeps, unless they are accompanied by high flow rates and pipe rotation

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d) Dilution Co-efficient
The Dilution co-efficient is a mathematical formula designed to help the mud engineer deduce the
volume of drilling fluids that will be required to dilute a given volume of cuttings to match the desired limit
of drilled solids in the mud.

The dilution co-efficient is calculated using the following formula:

VOH * (1 − SCE )
VDIL =
fD

Where: VDIL = Volume to Dilute

VOH = Volume of Open Hole (volume of cuttings)
SCE = Solids Control Efficiency (normally 50 to 60%)
fD = working limit of drilled solids

Example
VOH = 100 bbls
Efficiency = 50% (expressed as a decimal = 0.5)
fD = 5% (expressed as a decimal = 0.05)

100 * (1 − 0 .5)
V DIL =
0 .05
This gives a value of VDIL (the amount of dilution required) of 1000. So if the volume of cuttings
drilled in the section will be 100 bbls, then 1000 bbls of mud will be required.

To continue the example started in section 4a, the volume of cuttings was calculated to be 492.526bbls and
using the efficiency value of 55% and a max limit of drilled solids of 5%, the amount of mud required to dilute
the volume of cuttings (value of VDIL) will be 4432.734 bbls (minus the volume of clean mud built before the
section is drilled)

In a very large diameter hole section such as that illustrated by the example calculated above, it may be
cheaper & easier to drill this section with the dump valve open and thereby lose the cuttings overboard.
Should you wish to proceed in this manner, this will influence your choice of drilling mud for this section, as
there is no point is effectively throwing expensive polymer mud away, instead the choice of a cheaper mud
system would prove to be both prudent and logical.

An easy way to calculate the most cost effective mud system for any section is to work out the “cost per
barrel” of the mud required for the section, this is simply worked out by listing the costs and amounts of each
chemical used in the proposed system and then dividing the cost by the volume of mud required for the
section.

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5. Drilling Procedures
The Mud Engineer should liase closely with the driller at all parts of this exercise and especially so in the
field and at well site.

a) Good Drilling Practice

There are a number of simple steps the driller can take to ensure that the drilling program will be
implemented with the minimum of problems.

• Correct bit choice for the hole section – choosing the correct bit type for the formation being
drilled will have an important effect on not just the ROP but also the stability and predictability of
the well path.
• Correct choice of BHA for the hole section – if there is a risk of drilling through a shallow gas
zone then the student should consider the choice of BHA carefully – for instance, a packed
assembly with many full gauge stabilisers is far more likely to swab formation fluids than a slick
assembly. Similarly, a carefully designed BHA will optimise the hydraulic flow and result in
smooth laminar flow around the drill string.
• Drill ahead at an ROP which will allow adequate hole cleaning (for details, please consult
chapter 4.1). In many cases, the drilling engineer can increase the ROP up to a certain point,
after which, the cuttings cannot be cleared away from the bit fast enough and the ROP will not
be able to increase any further (the cuttings will in effect be re-drilled and risk balling up the bit).
• Plan the hydraulic regime for the hole carefully – if the nozzle sizes are inadequate or there is
turbulent flow around the BHA, there will be a corresponding drop in performance. Conversely,
the simulator will reward the engineer who chooses carefully.
• Use an adequate pump rate, as this will clear the cuttings away from the bit faster as well as
helping to lift the cuttings to the surface.
• Be prepared to circulate the hole clean if the drilling data screens show signs of the drill string
becoming stuck. This will save many hours of trying to break free and will also reduce the risks
of washouts in the drill string.
• Stick to the drilling plan (where possible).
• Watch for drilling breaks (if necessary, circulate bottoms up samples), this will not only enable
the student to pick the formation tops more easily but also give the mud engineer adequate
warning of any formation changes and make any changes necessary before problems arise.
Similarly, a positive drilling break (ROP increases) can indicate an overpressured formation
which may cause an influx into the well, recognising this phenomena early enough will limit the
amount of open hole in the overpressured formation and minimise the volume of any influx which
might occur.
• Maintain close watch on the data display for sudden losses or gains to the pits. It may be the
result of the mud engineer adding or removing material to / from the active pits without informing
you - this is considered to be very bad practice and may inadvertently be mistaken for a kick or
influx! Sudden losses may be the result of hitting a fracture or open fault, breaking down the
formation or simply drilling with the dump valve open.
• If you think there is any chance of becoming stuck in either a keyseat, a severe dogleg or
packing off then remember the golden rule – ALWAYS ADD JARS TO YOUR BHA!

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b) Leak off tests

It is often desirable to know the maximum pressure that the formation immediately below the casing
shoe (including the cement around the shoe) can safely withstand. This pressure is determined by a
leak-off test. For effective well control procedures to be carried out, it is also necessary to know the
maximum pressure which can be permitted inside the casing string, well control has many variables but
perhaps the most important of these is the casing rupture pressure. When the maximum allowable
casing pressure is exceeded a blowout may occur with gas migrating outside of the casing and therefore
uncontrollable.

This procedure is to close the well in and to raise the bit off bottom and then fill the hole. The BOP
should then be closed and ensure that the system is free of leaks. Pump in a small volume of mud (0.25
bbl) and then record the pressure. As the mud is pumped in, the surface pressure will rise and once the
value has settled, the value should be recorded as well as the cumulative volume of mud pumped in.
This procedure should be repeated until either the line being plotted ceases to be a straight line or a
decrease in pressure occurs. This point is known as the Leak-off point – pumping should be terminated
at this point to avoid damaging or fracturing the formation. The Pressure should then be bled off to allow
normal drilling operations to continue.

(A) Slack in the system

This final pressure, plus the pressure exerted by the weight of the mud column equals the total pressure
at which the formation would begin to break down.

The calculation is as follows:

PFRAC = MAASP + ((9.81 * Z S ) * d ) Where:

PFRAC = fracturing pressure (kPa)
MAASP = Pressure at start of injection point (kPa)
dFRAC = Fracture Density (kg/l)
Pfrac
d FRAC = d = mud density in the well during leak of test
(9.81 * Z S ) * d ZS = Depth of weak point or shoe (m)

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6. Mud Recipes
This section of the manual is designed to provide you with some basic recipes for a variety of standard
mud types. All the quantities listed are in oilfield units e.g. lbs per barrel & barrels unless stated.

Whilst it is important to choose the best mud available for the formations you will be drilling, it is also
important to work out the costs associated with each mud type, this is usually calculated as the cost per
barrel.

Example 1 - A simple Gel Gyp mud

Freshwater (400 bbls) @ $3 per barrel = $1200
Caustic = 1 drum @ $15.90 per drum = $15.90
Bentonite (10 ppb) = 4000lbs @ $286.65 per tonne = $520
Gypsum (2 ppb) = 14.5 sacks @ $3.50 per sack = $50.75

Total Cost = $1786.65

Cost per barrel = $1786.65 ÷ 400 = $4.46

Example 2 – XC Polymer Mud

Freshwater (400 bbls) @ $3 per barrel = $1200
Caustic = 1 drum @ $15.90 per drum = $15.90
XC Polymer (3 ppb) = 1200 lbs @ $160 per sack = $3490.91
Starch (2ppb) = 800 lbs @ $14 per sack = $203.64

Total cost = $4706.81

Cost per barrel = $4706.81 ÷ 400 = $12.28

a) Spud Mud & Sweeps

When spudding the well, it is common practice to use a combination of seawater and a thicker mud known
as a “sweep” to bring the cuttings up to surface. These sweeps should be pumped every stand to help
remove the cuttings from the annulus.

Basic Spud Mud

• Seawater

Gel & Gyp Mud Sweep

• Freshwater
• Caustic (1 drum per complete pit)
• Bentonite (10 ppb max) – prehydrated for 8 hours
• Gypsum (3 ppb max)

Thick Gel Sweep

• Freshwater
• Caustic (1 drum per complete pit)
• Bentonite (30ppb) – prehydrated for 8 to 12 hours

XC Polymer Sweep
• Freshwater
• 1 drum Caustic
• XC Polymer (1 to 3 ppb max)

b) Basic Gel Mud

This can be used as a base for all Gel mud systems. It should be built in a separate pit and then decanted to
other pits and then diluted to suit the requirements of the desired mud system. This is a simple & efficient
way of making a large volume of mud with little effort and minimising the number of pits set aside for
prehydrating Bentonite.
• Freshwater
• Caustic (pH 9)

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• Prehydrated Bentonite (30ppb max) – prehydrated for 8 hours

c) Gel & Gyp Mud

This mud can be used to drill through Chalk or Anhydrite formations with few problems, as the Gypsum will
inhibit Anhydrite reactivity. With this mud, it is important to keep the drilled solids low (under 10%) as
otherwise, stuck pipe problems may arise. If used to drill through a salt section, the Bentonite will react with
the dissolved salts and viscosify the mud rapidly.
Viscosity

Calcium Concentration

As the level of Calcium ions dissolved in the mud increases (produced from Limestone or gypsum
formations), the viscosity will increase and subsequently decrease in a manner described on the graph
above. If viscosity caused by calcium contamination becomes a problem with this mud system, either add
calcium to push the concentration higher and towards the right hand (descending) portion of the graph or to
remove the calcium from solution by adding Caustic Soda and towards the left hand (ascending) portion of
the graph.

• (Basic gel mud should be added to the freshwater so that the Bentonite has a max value of 10ppb
overall)
• Freshwater
• Gypsum (1 to 3 ppb)
• Barite (as required)

d) Gel & CMC Mud

With this mud, it is important to keep the drilled solids low (under 10%) as otherwise, stuck pipe problems
may arise. If used to drill through a salt section, the Bentonite will react with the dissolved salts and viscosify
the mud rapidly.

• (Basic gel mud should be added to the seawater so that the Bentonite has a max value of 10ppb
overall)
• Seawater
• CMC High (5 ppb max)
• CMC Low (5ppb max)
• Barite (as required)

e) Gyp Lig Mud

This mud can be used to drill through Chalk or Anhydrite formations with very few problems, as the Gypsum
will inhibit Anhydrite reactivity. With this mud, it is important to keep the drilled solids low (under 10%) as
otherwise, stuck pipe problems may arise. If used to drill through a salt section, the Bentonite will react with
the dissolved salts and viscosify the mud rapidly. If there is dissolved calcium in the mud, then at small
concentrations, it will cause the mud to viscosify whereas at greater concentrations, the viscosity will
decrease (to treat this problem, either add Caustic Soda which will force the Ca++ ions out of solution or add
Soda Ash or Bicarbonate to treat out the calcium). Lignosulphonate can be added to thin out the mud,
however the effect of the Lignosulphonate will diminish as the concentration rises.

• (Basic gel mud should be added to the seawater so that the Bentonite has a max value of 10ppb
overall)
• Seawater
• Caustic (pH 9)
• CMC High (3 ppb max)

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• CMC Low (3 ppb max)

• Gypsum (1 to 3 ppb max)
• Lignosulphonate (can be used to extend the life of the mud but this will limit the effectiveness of later
additions – also remember that Ligno has to be added in a ratio of 4:1 with Caustic Soda) 10 ppb
max.
• Barite (as required)

f) Salt Saturated
This mud is necessary for drilling any large salt section, as otherwise, the salt formation will be dissolved into
the drilling mud resulting in formation washouts, over-gauge hole and potential problems when running
casing and cementing. This mud system will viscosify rapidly if it encounters reactive shales, dispersive clays
or gumbo clays.

• NaCl brine
• Caustic (pH 9)
• XC Polymer (1 to 3 ppb max)
• Starch (1 to 2 ppb)
• Barite (as required)

g) KCL XC Polymer Mud

This mud system is the most effective at inhibiting reactive clays, it is however, very expensive. To maintain
the inhibitive properties of the mud, the Potassium to Chloride ration should be kept in the range of 1.0 to 1.1
as if the ratio falls to 0.8 the mud will behave as a Salt Saturated mud. This mud can also be built using NaCl
brine (add ½ NaCl brine) in which case, it will less inhibitive but far cheaper. If drilling through Gumbo clays,
then PHPA can be added.

• 1/5th pit volume KCL Brine

• 4/5ths pit volume Freshwater
• Caustic (pH 9)
• XC Polymer (1 to 2 ppb)
• Starch (1 to 3 ppb)
• Barite (as required)
• PHPA (if required)

h) KCL PAC Mud

This mud is a cheaper alternative to the KCL XC Polymer mud listed above but which still retains many of the
inhibitive properties. To maintain the inhibitive properties of the mud, the Potassium to Chloride ration should
be kept in the range of 1.0 to 1.1 as if the ratio falls to 0.8 the mud will behave as a Salt Saturated mud. If
drilling through Gumbo clays, then PHPA can be added to increase the inhibition.

• 1/5th pit volume KCL Brine

• 4/5ths pit volume Freshwater
• Caustic (pH 9)
• PACR (1 to 3 ppb)
• PACL (1 to3 ppb)
• Barite (as required)
• PHPA (if required)

i) NACL CMC Polymer Mud

This mud system is less effective at inhibiting reactive clays than a similar KCL mud system; it is however a
great deal less expensive than a KCL mud system yet still retains good inhibitive properties.

• 1/5th pit volume NACL Brine

• 4/5ths pit volume Freshwater
• Caustic (pH 9)
• CMC High (5 ppb max)
• CMC Low (5 ppb max)
• Barite (as required)

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j) NACL PAC Mud

This mud is a cheaper alternative to the KCL PAC Polymer mud listed above but which still retains many of
the inhibitive properties. This mud is far cheaper than the equivalent KCL mud system but does not have the
same degree of inhibitive properties as the KCL system.

• 1/5th pit volume NACL Brine

• 4/5ths pit volume Freshwater
• 1 drum Caustic
• PACR (1 to 3 ppb)
• PACL (1 to 3 ppb)
• Barite (as required)

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7. Chemical Addition Tables

These tables are provided to assist you during the exercise.

Number of 55lb (25kg) sacks required to build a given concentration in a set volume.

Imperial
Pit Volume
Desired 50 bbls 440 bbls
200 bbls 400 bbls
Concentration (Slug Pit) (Full Pit)
1 lb/bbl 0.909 3.636 7.272 8
2 lb/bbl 1.818 7.272 14.545 16
3 lb/bbl 2.727 10.909 21.818 24
5 lb/bbl 4.545 18.181 36.363 40
10 lb/bbl 9.090 36.363 72.727 80
30 lb/bbl 27.27 109.089 218.181 240

Metric
Pit Volume
Desired 7.95 m3 3 69.95 m3
30 m 60 m3
Concentration (Slug Pit) (Full Pit)
1 lb/bbl (equivalent) 0.909 3.430 6.861 8
2 lb/bbl (equivalent) 1.818 6.861 13.723 16
3 lb/bbl (equivalent) 2.727 10.29 20.58 24
5 lb/bbl (equivalent) 4.545 17.154 34.308 40
10 lb/bbl (equivalent) 9.090 34.308 68.617 80
30 lb/bbl (equivalent) 27.27 102.924 205.851 240

Amount of chemical (measured in pounds or kilograms) to add to a volume to make a concentration

in lbs/bbl (e.g. Bentonite addition)

Imperial
Pit Volume
Desired 50 bbls 440 bbls
200 bbls 400 bbls
Concentration (Slug Pit) (Full Pit)
1 lb/bbl 50 200 400 440
2 lb/bbl 100 400 800 880
3 lb/bbl 150 600 1200 1320
5 lb/bbl 250 1000 2000 2200
10 lb/bbl 500 2000 4000 4400
20 lb/bbl 1000 4000 8000 8800
30 lb/bbl 1500 6000 12000 13200

Metric
Pit Volume
3
Desired 7.95 m 69.95 m3
30 m3 60 m3
Concentration (Slug Pit) (Full Pit)
1 lb/bbl (equivalent) 22.679 90.719 181.438 199.582
2 lb/bbl (equivalent) 45.358 181.438 362.876 399.164
3 lb/bbl (equivalent) 69.039 272.158 544.316 598.748
5 lb/bbl (equivalent) 113.399 453.597 907.194 997.910
10 lb/bbl (equivalent) 226.798 302.398 1814.388 1994.820
20 lb/bbl (equivalent) 453.597 907.194 3628.776 3991.640
30 lb/bbl (equivalent) 680.395 2721.582 5443.164 5987.460

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8. Mud Treatments & Troubleshooting

This section is designed to help the student should any problems arise with their mud program and provide
some solutions for many common problems experienced during the training exercises.

Problem Symptom Solution

Too Low • Add Caustic
pH
Too High • Dilute with Freshwater
• Add Bentonite (Primary)
• Add Polymers (Primary)
Too Low
• Add Gypsum, Salt, Cement or Drilled Solids
(Secondary)
Viscosity
• Dilute
• Add Lignosulphonate
Too High
• Add Preventative / Inhibitive chemicals e.g.
Gypsum, salt, PHPA etc
Too Low • Saturate
Salt
Too High • Dilute
Too Low • Add Gypsum
Anhydrite
Too High • Dilute
• Add Lime
Too Low • Add Gypsum
• Add Caustic
Calcium
• Add Caustic
Too High • Add Soda Ash
• Add Bicarbonate
• Add Barite
Too Low
• Change Solids Control set-up
Drilled
Solids • Change Solids Control set-up
Too High • Inhibition
• Dilute

Problem – The Simulator says that I cannot mix different mud types in the annulus. I have
displaced the previous mud system and am now ready to drill ahead.
Solution – Check that all the settling tanks have been emptied and that all of the surface equipment has
been cleaned. If you still cannot proceed, your hole may be significantly over gauge so continue displace
the original mud.

Problem – I want to add a particular chemical to a pit and the simulator will not let me do so – it
brings up a message which says “You should not be using this chemical in this pit – please call
the instructor”.
Solution – The Simulator has detected that you are trying to combine an illogical or unwise combination
of chemicals. Please reconsider your choice using the chemical catalogue found in section 2 of this
manual. Alternatively, the simulator has determined that you are building the drilling mud in the wrong
order, i.e. trying to add Barite before the Yield Point can suspend it adequately.

Problem – I want to add a particular chemical to a pit but when I go to the “Add to Pit” menu, the
item has been disabled. Why is this?
Solution – This is because either there is none of that chemical onboard at this time or that the desired
chemical cannot be added to the chosen pit.

Problem – I want to add a particular chemical to a pit but a warning message appears which says,
“The chemical concentration would be outside the tested range, none of the chemical added”.
Solution – You are trying to add far too much of the chemical to the pit and you have reached the
absolute threshold of the simulator’s mathematical model. The simulator will not allow you to add this
amount of the chemical to the pit – please choose again or dilute the mud and try again.

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