DRILPLEXTM SYSTEM

FOR
CASING MILLING OPERATIONS
DRILPLEX is a Mixed Metal Oxide (MMO) bentonite extender and secondary shale stabilizer designed to give
improved carrying capacity and suspending ability in water base drilling fluids. It has particular application in
drilling of high-angle and horizontal wells, lost circulation zones, and also for casing milling operations where the
exceptional carrying capacity and shear thinning nature of the DRILPLEX System make it ideal for removing high
density steel swarf.
In Bingham plastic terms, the fluid exhibits a very low plastic viscosity and a high yield point. The high viscosity at
annular shear rates ensures excellent carrying capacity for the heavy steel cuttings which are easily transported to
surface even in high angle holes. At the same time, due to its high shear thinning nature, the fluid is capable of being
pumped at very high flow rates through fine shaker screens, with minimal losses. This is marked contrast to milling
fluid mixed from xanthan gum (XC Polymer) where surface losses are often high.
The DRILPLEX System enables maximum milling rates, reduced fluid costs and the elimination of lost time by
accumulation of steel cuttings in the annulus (birds nests).
The DRILPLEX system has been used successfully on many casing milling operations in the North Sea area, including
one record run, where 100ft (30.4m) of 9-5/8 casing was milled in just 6.75hrs. Instantaneous milling rates of up to
20ft/hr (6.1m/hr) have been achieved. Mud weights up to 13.4ppg (1.61sg) have been used.

9-5/8" Csg; 17,000ft; 68deg.

9-5/8" Csg; 3,670ft; 20deg.

9-5/8" Csg; 10,281ft; 57deg.

9-5/8" Csg; 10,281ft; 51deg.

7" Casing

Drill Collar at 943ft

10

Average Milling Rate (ft/hr)

TM

DRILPLEX is a trademark of M-I L.L.C.

rd

Rev 2: 23 Oct 2002

12

14

16

TYPICAL FORMULATIONS
GELPLEX
Freshwater
Seawater
DRILPLEX
Caustic Soda
Soda Ash

FRESHWATER
11.0 lbs (31.4 kg)
1.0 bbl (1m3)
--1.1 lbs (3.14kg)
0.5 lb (1.43 kg)
0.3 lb (0.86 kg)

TYPICAL PROPERTIES
Plastic Viscosity
Yield Point
Gels
6 rpm
3 rpm
pH

8 cps
60 lbs/100 sq.ft
35/40 lbs/100 sq.ft
35
33
10.5 11.0

SEAWATER
12.5 lbs (35.7 kg)
0.4 bbl (0.4m3)
0.6 bbl (0.6m3)
1.25 lbs (3.47 kg)
1.0 lb (2.86 kg)
1.0 lb (2.86 kg)

MIXING PROCEDURE
Treat drillwater with >0.5lb/bbl Soda Ash regardless of hardness. Prehydrate bentonite at 30 lb/bbl (86 kg/m3) for 24
hrs and check properties.

Freshwater systems:
Dilute with freshwater to achieve required bentonite final desired bentonite concentration and blend until
homogeneous. Add DRILPLEX; Soda Ash and caustic to pH 10.8 while mixing at maximum energy. When the
system has achieved maximum yield, add Barite to required density.

Seawater systems:
Treat dilution volume of seawater with 1 lb/bbl regardless of hardness. Dilute prehydrated bentonite slurry to
achieve required final bentonite concentration. Blend until homogeneous. Add DRILPLEX; Caustic Soda to pH
10.8 and continue mixing under maximum energy until yield is apparent.
It is possible to obtain higher rheological properties, if required, by increasing the concentration of DRILPLEX and
bentonite. Pilot testing should always be performed prior to deviating from the programmed formulation. Refer to
DRILPLEX Engineering Guidelines for more details.
DEMONSTRATIONS
SUSPENSION PROPERTIES
The suspension properties of DRILPLEX fluids was demonstrated in a test carried out at Robert Gordons Institute of
Technology in Aberdeen. The fluid was mixed from 12 lb/bbl (34.3kg/m3) bentonite and 1.2 lb/bbl DRILPLEX in
freswater. The fluid was pumped into a Perspex column and samples of milled casing were introduced and pumped
to the top of the column. The pumps were then shut off and settlement monitored over a 67 hr period.
RESULTS
Rheology:

Plastic Viscosity 4cps

Yield Point 111 lbs/100sq.ft
Maximum Settlement of steel cuttings in 67hrs was 1 (2.5cm)
SCREENING PROPERTIES
The ability of DRILPLEX fluids to pass through a shaker screens was demonstrated in a trial with a Thule VSM 100
shaker dressed with 80 mesh screens.
RESULTS
No mud losses were seen on 80mesh screens at 800 gpm (3,028 L/min)

Rev 1: 22

nd

Oct 2002

Case History #1

Case History #2

OPERATOR:

Phillips Petroleum

OPERATOR:

Phillips Petroleum

LOCATION:

North Sea

LOCATION:

North Sea

WELL:

48/29-B9

WELL:

16/29a-A1

OBJECTIVE: To cut a 60ft windown in the 9-5/8 x

40ppf casing from 3,670ft.
SYSTEM FORMULATION:
Bentonite:
12.5 lb/bbl
DRILPLEX
1.25 lb/bbl
NaOH
1.25 lb/bbl
Soda Ash
0.30 lb/bbl
TYPICAL PROPERTIES
Density:
8.5 ppg
Plastic Viscosity
13 cps
Yield Point
54 lb/100 sq.ft
Gels
24/27 lb/100 sq.ft
6 rpm reading
22
3 rpm reading
21
pH
12.0
GENERAL COMMENTS
One hundred feet of 9-5/8 casing was milled in 18
hours with an ROP of 8.68ft/hr. DRILPLEX passed
through 105 and 145 mesh screens with ease. There
were no difficulties in keeping the system within
specification and was found to be easy to engineer. It
was concluded by both the operator and milling
company that the fluid had significantly aided the
successful completion of this milling operation.

Rev 1: 22

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Oct 2002

OBJECTIVE: The milling of a bottom hole assembly

left in the hole at a depth of 9,939ft during previous
workover operations.
SYSTEM FORMULATION:
Bentonite:
13 lb/bbl
DRILPLEX
1.3 lb/bbl
NaOH
1.25 lb/bbl
Soda Ash
0.30 lb/bbl
TYPICAL PROPERTIES
Density:
12.4 ppg
Plastic Viscosity
4 cps
Yield Point
80 lb/100 sq.ft
Gels
27/28 lb/100 sq.ft
6 rpm reading
47
3 rpm reading
42
pH
11.0
GENERAL COMMENTS
The DRILPLEX milling system used on this well
performed well and was able to transport high density
steel cuttings to the surface. A few heavy and light
spots were encountered but overcome by adding the
barite before DRILPLEX. It was found to be easily
engineered with minimal chemical treatments needed
to keep the mud properties in specification.

Case History #3

Case History #4

OPERATOR:

Amoco Exploration Company

OPERATOR:

Philips Petroleum

LOCATION:

North Sea

LOCATION:

North Sea

WELL:

211/27-A46

WELL:

16/29a-A1 WO

OBJECTIVE: To mill a window 60 ft minimum, 100

ft maximum for kick off out of 9 5/8 casing at
10,300 ft.

OBJECTIVE: Milling of the 9-5/8 and 7 packers

after failing to pull the 3.688 AFH plug set below the
7 Lindsey Arrow DB Packer.

SYSTEM FORMULATION:
Bentonite:
12.5 lb/bbl
DRILPLEX
1.25 lb/bbl
NaOH
1.0 lb/bbl
Soda Ash
0.30 lb/bbl

SYSTEM FORMULATION:
Bentonite:
12 - 15 lb/bbl
DRILPLEX
1.2 1.5 lb/bbl
NaOH
0.75 lb/bbl
Barite
269 lb/bbl

TYPICAL PROPERTIES
Density:
11.3 ppg
Plastic Viscosity
9 cps
Yield Point
80 lb/100 sq.ft
Gels
27/28 lb/100 sq.ft
6 rpm reading
45
3 rpm reading
36
pH
11.5

TYPICAL PROPERTIES
Density:
12.1 ppg
Plastic Viscosity
10 cps
Yield Point
62 lb/100 sq.ft
Gels
25/26 lb/100 sq.ft
6 rpm reading
46
3 rpm reading
40
pH
12

GENERAL COMMENTS
One hundred feet of 9-5/8 casing was milled in 9
hours. Swarf was seen on the shakers immediately
after bottoms up when the initial cut was made during
the milling operation. No problems were incurred
during the milling operation. On completion of the
cut, bottoms up were again circulated, the shakers
clearing up almost immediately. Representatives from
Amoco and Red Baron both concluded that DRILPLEX
fluid contributed to time saving and cost effectiveness.

GENERAL COMMENTS
There were no problems encountered on this milling
operation. The DRILPLEX milling fluid performed its
function well, transporting the high-density steel swarf
to surface. The pipe was slugged prior to tripping with
weighted bentonite. Though many trips were made the
fluid remained in good condition throughout.

Rev 1: 22

nd

Oct 2002

Case History #5
OPERATOR:

Philips Petroleum

LOCATION:

North Sea

WELL:

2/4-B17A

OBJECTIVE: Milling of the 9-5/8 casing string.

SYSTEM FORMULATION:
Bentonite:
12.5 lb/bbl
DRILPLEX
1.25 lb/bbl
NaOH
0.75 lb/bbl
Soda Ash
0.30 lb/bbl
TYPICAL PROPERTIES
Density:
10.8 ppg
Plastic Viscosity
4 cps
Yield Point
107 lb/100 sq.ft
Gels
21/22 lb/100 sq.ft
6 rpm reading
44
3 rpm reading
39
GENERAL COMMENTS
Once the system had been mixed, it remained stable
with no chemical treatments needed. 113ft of casing
was milled and the cuttings were transported to the
surface with little difficulty.

Rev 1: 22

nd

Oct 2002