Method for Drilling and Completion Operations with Settable Resin Compositions

Abstract

A method for completing boreholes penetrating narrow gradient zones in a subterranean formation after drilling with an oil based drilling fluid for recovery of hydrocarbons. The method employs an epoxy-based resin composition with controllable density and rheology that provides a low equivalent circulating density and is compatible with the oil based drilling fluid. The composition acts as a substitute for cement in cementing operations including adhering casing to the borehole, zonal isolation, and consolidation.

1 . A method for conducting drilling and completion operations in a borehole for the recovery of hydrocarbons in a subterranean formation,
 wherein the subterranean formation has one or more narrow fracture gradient zones, and the method comprises the steps of:   drilling the borehole in the subterranean formation using an oil based drilling fluid having a known rheology and density, at least in drilling through one or more of the narrow fracture gradient zones of the formation;   providing a resin composition having a rheology and a density approximating that of the an oil-based drilling fluid;   using the resin composition instead of cement in the completion operation without fracturing the narrow gradient zones; and   allowing the resin composition to harden in place in the borehole.   
     
     
         2 . The method of  claim 1  wherein the completion operation is cementing the borehole. 
     
     
         3 . The method of  claim 1  wherein the completion operation is casing the borehole. 
     
     
         4 . The method of  claim 1  wherein the completion operation comprises isolating or consolidating a narrow gradient zone in the formation. 
     
     
         5 . The method of  claim 1  wherein the resin composition is formulated with a density approximating that of the oil based drilling fluid by adding solid particles to the composition. 
     
     
         6 . The method of  claim 5  wherein the solid particles comprise a balance of particles that effect said density. 
     
     
         7 . The method of  claim 6  wherein the solid particles comprise particles of large and small size to effect said density. 
     
     
         8 . The method of  claim 5  wherein the resin composition comprises a suspension agent for suspending said particles. 
     
     
         9 . The method of  claim 1  wherein the resin composition comprises an epoxy resin, a hardener, and an accelerator. 
     
     
         10 . The method of  claim 9  wherein the hardener and accelerator are amines. 
     
     
         11 . The method of  claim 9  wherein the composition further comprises a suspension agent. 
     
     
         12 . The method of  claim 11  wherein the suspension agent is a polyamide resin. 
     
     
         13 . The method of  claim 9  wherein the resin composition comprises an epoxy resin, an amine hardener, an amine accelerator, a polyamide resin suspension agent, and solid particles that give the fluid a density approximating that of the oil based drilling fluid. 
     
     
         14 . The method of  claim 5  wherein the particles are selected from particles ranging in size from about 5 μm to about 100 μm. 
     
     
         15 . The method of  claim 5  wherein the particles comprise glass spheres and the density of the resin is less than about 8.9 lb/gal. 
     
     
         16 . The method of  claim 1  wherein the hardened resin composition has a compressive strength greater than about 500 psi. 
     
     
         17 . The method of  claim 1  wherein spacers are not needed in the borehole after drilling with the drilling fluid and before use of the resin composition in the borehole completion operation. 
     
     
         18 . The method of  claim 1  wherein the density of the resin composition and the density of the drilling fluid differ by less than 1.5 lb/gal. 
     
     
         19 . The method of  claim 1  wherein the equivalent circulating density of the resin composition and the equivalent circulating density of the drilling fluid differ by less than 1.5 lb/gal. 
     
     
         20 . The method of  claim 1  wherein the resin composition comprises an epoxide containing liquids selected from the group consisting of: diglycidyl ether of 1,4-butanediol; diglycidyl ether of neopentylglycol; diglycidyl ether of bisphenol A; and diglycidyl ether of cyclohexanedimethanol.