Experimental and modelling studies on static sag of solid weighting powders in Polysulfonate workover fluids at high temperature and high pressure

The solid weighting material in a high-density workover fluid is prone to static sag. Existing experimental methods cannot predict the parameters of the settling stability of workover fluids at high temperature and high pressure (HTHP). Therefore, in this study, static settlement experiments were carried out using a novel experimental setup. The experimental setup enables the measurement of the density profile of heavy workover fluids at HTHP. A multi-parameter correlation equation between the sag factor and particle diameter, particle density, base fluid density, workover fluid density and rheological parameters, aging time, temperature, and pressure was obtained using dimensional analysis and multivariate nonlinear regression methods. The results reveal that the settlement stability of the workover fluid decreases with the increase in temperature and pressure. Based on the multi-parameter correlation, the predicted and the measured values were compared and verified. The error between the predicted value and the measured value was within 5%. The average prediction error was 1.68%, and the maximum prediction error was 3.8%. These results reveal that the model proposed in this study can effectively predict the static sedimentation stability of the solid weighted Polysulfonate workover fluids. Furthermore, the proposed correlation can guide the properties adjustment of the workover fluids to achieve the required sag stability. This work provides a new approach to predict and control the sag stability of the solid weighted workover fluids. • A novel experimental setup was developed for testing the sag stability of workover fluids. • A correlation was constructed for predicting the sag stability of the workover fluid. • An approach was proposed for preparing the workover fluid with a good sag stability.