Global Research & Technology Centre/ GRTC Training Department

LOST CIRCULATION

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Lost Circulation
Partial or Total loss of whole drilling fluid to the formation Occurs at any depth Occurs in almost all types of formation One of the major problems in drilling for hydrocarbons Associated with high cost and high risk

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Undesirable Effects of Lost Circulation

Lowering of the mud level in the annulus Hydrostatic Pressure < Formation pressure Increase in costs Fighting Mud Losses Loss of Lithological information No drilled cutting return to surface Stuck Pipe Leads to expensive fishing jobs Reduced Well Productivity LCM entering potential pay zone Possibility of Sidetracking Possibility of losing the hole
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Types of Lost Circulation Zones

Four main formation types which losses occur
Unconsolidated or Highly Permeable (Matrix losses) Naturally Fractured Induced Fractured Cavernous

Four types of loss rate

Seepage losses Partial losses Severe losses Complete losses < 25 WBM or 10 OBM bbls/hour 25 100 WBM or 10 30 OBM bbls/hour > 100 WBM or > 30 OBM bbls/hour No returns to surface

Classification will vary by Operator

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Unconsolidated & High Permeability Formations

Horizontal beds at shallow depths Formations can be gravel beds, sand, sea shells or combination of these Typical losses are slight, but can worsen dramatically Keep hole full by filling from top Cures Reduce hydrostatic / Foam Drilling Apply proper of LCM types and sizes Cement Plugs

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Naturally Fractured Formations

Usually occur at greater depth Either Horizontal or Vertical fractures Horizontal fractures usually above 2500 ft Vertical fractures usually below 2500 ft Fractures more common in areas of tectonic activity Commonly associated with limestone, dolomite, chalk, hard sands, hard shale Initial losses are often slight Cures Reduce Hydrostatic / Foam Drilling LCM Pills Cement Plugs
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Induced Fractured Formation

Occur at any depth (Horizontal < 2500 ft, Vertical > 2500 ft) and any type of formation Usually associated with weak bedding planes Often results from sudden surges against the formation Running casing too quickly Pumping too quickly Gel Strengths too high Mud weight too high Losses are normally sudden and complete
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Cavernous Formations
Associated with Limestone and Dolomite Losses are usually sudden and complete Pressures are normally subnormal Lower than hydrostatic Most difficult loss zone to cure Cures Case-off zone Limited success with conventional tech niques

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Mechanics of Lost Circulation

Hydrostatic pressure exceeds formation pore pressure Mud is forced into the zone Mud is lost through the pore spaces in loose sand/gravel Unrestricted entry into formations Cavernous formations Loss rate will exceed pump rate Hydrostatic pressure exceeds formation fracture pressure Fracture will continue to extend until Pressure at fracture tip < Fracture propagation pressure The hydrostatic drops below formation fracture pressure

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Mechanics of Lost Circulation

Vertical Fractures Limited in height by boundaries LCM tends to settle on low side Horizontal Fractures Limited height due to overburden LCM more likely to succeed

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Preventing Lost Circulation

PREVENTION IS BETTER THAN CURE
Well planning and mud program preparation should consider all aspects of avoiding lost circulation: Offset well data did they have losses why - what LCM worked or did not work Casing setting depths for current well Which contingency LCM to have on rig and onshore as backup What pills to pump and how to spot them Should LCM pills be premixed necessary in some areas where losses pose serious well control issues Prepare LCM Decision Trees

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Preventing Lost Circulation

PREVENTION IS BETTER THAN CURE
Minimize the hydrostatic pressure to the lowest safe level Optimize the mud properties (minimise ECD) Viscosity Yield Point Gel Strengths Maximize BHA clearance Minimum number of reamers, stabilizers, etc. Avoid oversized stabilizers Drill-pipe rubbers must not swell

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Preventing Lost Circulation

Minimise Swab and Surge Pressures Reduce tripping speeds for casing or drill-pipe Break circulation cautiously Using the lowest pump rate necessary Maintaining optimum mud properties Control the Drilling Rate Drilled cuttings should not exceed 5% by volume Avoid mud rings and bit balling Solids Control Equipment Optimization Controls filter cake thickness

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Preventing Lost Circulation

Extra casing string or better choice of casing points Loss zones not subjected to high muds weights Air, Foam or Aerated Mud Drilling Hydrostatic pressure reduction Blind Drilling Drill loss zones prior to treatment Not possible if water is scarce Risk of sticking the drill string Well control problems

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Preventing Lost Circulation

Drilling not Spudding Bridges Increase in ECD Use of Inhibitive Muds Prevent clay formations hydration and squeezing

Pre-treat system with 5 - 10 ppb LCM Reduce changes of losses in known loss zones e.g. calcium carbonate as bridging agents Current Database with up to date records Assists in planning on future wells
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Location of Lost Circulation Zones

There are four main methods of depth determination TEMPERATURE SURVEY RADIOACTIVE TRACER SURVEY HOT WIRE SURVEY SPINNER SURVEY

These are rarely used zones normally determined by prior experience or best feel for what is happening downhole
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Conventional Lost Circulation Materials/LCM

Fibrous Materials Raw Cotton Wood Fibre Bark Fibre Textile Fibre Mineral Wool Straw Asbestos Leather Peat Moss Feathers Flax
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Flake Materials Mica Cellophane Cork Corn cobs Cotton seed Plastics

Granular Materials Nut Shells Nut hulls Rice hulls Wood Corn cobs Asphalt Ground Rubber Salt Bentonite Limestone/CaCO3 Perlite

Lost Circulating Materials/LCM

Scomi Oiltools continues to treat LC events casually and without much thought to selection of material or size. The most effective LCM have been identified as: API barite - excellent LCM up to opening size of 150-200 microns Calcium carbonate - ranges of sizes extending from 0.1 micron to 1 mm Synthetic graphite (Hydro-Seal) when used in barite weighted muds Fine grind synthetic graphite (Hydro-Seal F) with d50 of about 100 microns for special applications Ground nut hull (nut-plug) - fine grind material with d50 of 350 450 microns. Ground carbon (petroleum coke) - size ranges with d50 of about 100 microns and 300 microns

LCM larger than 1 mm is ineffective and increases circulating losses

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Lost Circulating Materials/LCM

Key engineering staff at Shell, Conoco-Phillips, Shell, BP and ExxonMobil helped established these guidelines. Fibers, flakes, rubber, mica should generally be avoided except in vuggy formations. The concept was taught in patents written by Conoco, BP, Halliburton (Superior Graphite), and in defined engineering practices of Shell, BP, ExxonMobil, ConocoPhillips, Halliburton, Miswaco, where this technology has been employed by Scomi (Pakistan, certain Malaysian jobs, Thailand) the results have been predictable and virtually always successful.

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Selecting the Bridging Particles

Bridge must to be sealed to prevent leakage of fluid into the fractures which could grow the fracture Estimate the fracture width Select strong particles such as marble, large enough to bridge the fracture mouth Largest pore throat of unsealed bridge is approximately 1/3 to the fracture aperture Use a smooth size distribution that range from < 1 micron to the fracture width Consider particle already in the base fluid
1 micron
Clay fine barite

50 microns

Frac width

BASE MUD
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BRIDGING SOLIDS

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Losses to High-Permeability Sands

A properly bridged reservoir composed of relatively high porosity sand cannot be fractured. To achieve this characteristic, selection of particle size is critical and depends upon the grind of barite or calcium carbonate selected to meet requirements for mud density and formation pore size distribution For bridging of barite weighted muds a calcium carbonate with d50 of 200 to 300 microns. Fine grind "nut plug" is also very useful if ground to international specs with range of about 75 - 1000 microns with d50 of about 400.

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Losses to Low-Permeability Sands and Shale

Same sort of bridging materials as previously described (losses to high permeability sand) in barite weighted muds. This range of calcium carbonate provides a bridge for barite and mud cake to build a seal. Fibrous material will not properly and will generally not stop fracture charging.

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Losses to fixed fractures

90% of fixed fractures to which barite weighted mud is lost can be best sealed with the same material as described previously (losses to high permeability sand). Un-weighted muds will require an expanded range of calcium carbonate size.

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Losses to Vuggy Zones

Vuggy limestones are a different issue. If deep, it is likely that the vugs have collapsed and LCM as described previously will be effective. If Vertical Stress is less than the unconfined compressive strength of the limestone, then vugs will remain open and can be of virtually any size. Shredded wood, fibers, flakes, mica, or anything else will probably help!

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Field Application
BY PASS Shakers? Reuse materials
Less materials Less works to add Less waste Can be premixed at plant

Screen-out of system? More control on size in the system Rheology more easily controlled Sand removed from system
Less wear on pump liners Less wear on LWD

Particle grinds down

High rheology

Sand stay in the system

Wear on pump liners Wear on LWD

Use more materials

More work to add More waste materials More inventory on deck

Must replace ground down particles RECOMMENDED FOR SHORT SCOMI OILTOOLS INTERVAL ONLY

Contamination of cutting with CaCO3 RECOMMENDED FOR LONG INTERVAL OF APPLICATION

Lost Circulation Response

This will vary from operator to operator and from field to field. Response may depend on various factors: Are there enough chemicals / mud stocks Can we continue to drill with the loss rate until we can set casing Does well control allow us to drill with losses or lower the mud weight Pre planned Lost Circulation Decision Trees will aid response based on experience on offset wells 2 examples follow
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Precautions During Losses

Keep the hole full at all times to avoid well control problems. The pipe should be moved continuously to avoid getting stuck. Order mud chemicals and LCM as soon as losses become evident. Ensure you are informed as soon as losses are detected. Keep a minimum contingency of LCM material to avoid delays.

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Lost Circulation Response

< 25 WBM or < 10 OBM BPH: Continue Drilling (can you live with the losses) Reduce pump rate Pump LCM pill 30 - 100 WBM or > 10 OBM BPH : Reduce pump rate immediately Pump LCM pill Continue with LCM pills till cured > 100 WBM or > 30 OBM BPH (and complete losses) Stop drilling Spot LCM pill, observe well Keep annulus full of water or base oil if well control considerations allow
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Severe and Complete Loss Circulation Cures

Cement Cheap Composition can vary Weight Setting Time Filter Loss High Filter Loss Slurries Mixture of Attapulgite, Lime and various bridging agents Only Pump Acid or Water Soluble Materials in the Reservoir
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Severe and Complete Loss Circulation Cures

Gunk Plugs Diesel Oil Bentonite (DOB) Diesel Oil Bentonite and Cement (DOBC) Set on contact with water Bridging agents can be added if required
DOB 50 BBL diesel / base oil 300 ppb bentonite Barite if required Procedure Squeeze 50 - 100 psi Hold for 1 hour Wait further hour before drilling out.
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DOBC 50 BBL diesel / base oil 200 ppb bentonite 94 ppb cement Barite if required Procedure Squeeze 50 - 100 psi Hold for 1/2 hour WOC 4 - 8 hours before drilling out. Mixing sub for DOB/C Plugs

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Selection of Bridging Particle Size Summary

No more Fine, Medium and Coarse In most cases the primary bridging and lost circulation material is API Barite API Barite will plug large pores and fractures up to 150 microns or about 6/1000 inch Total loss of returns can occur to a fracture of only 250 750 microns When drilling with a barite weighted mud, the optimum size range for an additional bridging material is close to : 10% less than 100 microns 50% less than 300 microns 90% less than 600 microns
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Selection of Bridging Particle Size Summary

The optimum distribution can close and seal fracture and vugs off up to 2 milimeters Sealing studies have shown that requirement for concentration of bridging material varies with the square of the increase in fracture width. If 10 lb/bbls is required fro 250 micron fracture, then 40 lb/bbls is required for a 0.5 millimeter fracture, and 160 lb/bbl may be required for a 1 millimeter fracture. Fractured of less than 1.5 to 2.0 mm may be controlled by bridging material carried in the mud system. For large fracture width, high solids pills may be necessary.

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Selection of Bridging Particle Size Summary

Bridging material greatly exceeding the fracture width is ineffective and will interfere with development of a seal and closure Bridging material similar in size to the barite already used in the mud system is generally useless. Discontinue recommendation for calcium carbonate of less than50 microns for sealing fractures. For bridging, sealing, closure of induced and natural fractures less than 2 mm rely on standard sized resilient graphite, ground calcium carbonate, properly sized clean hard nut hull, or ground petroleum coke.

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Selection of Bridging Particle Size Summary

Never use platy, fibrous or roundly spherical materials. Soft resilient material such as rubber and plastics are much less effective than hard materials. When massive losses are not expected to induced fracture, fine grind synthetic graphite may also be useful. HYDROSEAL G Fine ia a sized material which will largely pass 60 mesh shaker screens for more economical less demanding applications.

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Selection of Bridging Particle Size Summary

Filtration control is important when drilling relatively impermeable clastics for wellbore strengthening to occur. HTHP values of less than 2 ml are typically specified. An HTHP of less than 1 ml would be better ifit can be achieved when drilling impermeable clastics.

Filtration control is less important when drilling highly permeable rock

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Selection of Bridging Particle Size Summary

If losses are expected to induced fractures when drilling reservoir rock, supplemented bridging agent material must be in place before losses occur, especially when drilling with oil or synthetic based mud. Damage to formation may be eliminated Damage to production screens on flow back will be prevented A few pounds of graphitic bridging material is likely much less damaging than 100 barrel of whole mud loss to reservoir rock. 100 barrels of whole mud flowing back with produced sand can plug and collapse an entire screen section.
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EZ Squeeze

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Description and Specifications

Description : E Z Squeeze is a high fluid loss, high solids slurry and its performance is unique to other type of LCM. Solid plug is formed within the loss zone when liquid phase is squeezed from slurry Applications : Open hole remedial lost circulation squeeze Open hole preventative lost circulation squeeze Cased hole squeeze for sealing perforations or casing leaks. 38
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Benefits
Benefits : Solves lost circulation problems Eliminates risk of side-tracking hole (as can occur with cement) Does not contaminate drilling fluids Less costly than mixing and pumping pill after pill of conventional LCM Compatible with all water-base, oil-base and syntheticbase muds. Can be pumped through MWDs and LWDs.

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E Z SQUEEZE

The type of filter cake deposited by an E Z Squeeze and conventional drilling slurry. This is indicative of the type of plug that will form in the lost circulation zone.
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Key Factors
There are two key factors to obtaining a successful E Z Squeeze: 1. a slurry with an extremely high solids content and high fluid loss must be prepared. 2. the slurry must be placed at the proper location in the wellbore.

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How does EZ SQUEEZE Work

1) Squeezing the EZ Squeeze from drill string into the loss circulation zone 2) As the mud is pumped behind the EZ Squeeze, the fluids is squeezed out creating a bed of solids in the loss zone 3) The Solids Bed begins to build - The fluids continues to flow through the solids without forcing them into the loss zone 4) The mud begins to build a wall cake against the solids bed. Continued squeeze pressure causes the mud filter cake to compress the solids bed tightening the seal 5) Once the squeeze pressure is obtained, the EZ Squeeze hardens in place, forming a near permanent seal

EZ SQUEEZE SCOMI OILTOOLS MUD

FLUID

SOLID BED

MUD CAKE

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How does EZ SQUEEZE Work

Squeezing the EZ Squeeze from drill string into the loss circulation zone

As the mud is pumped behind the EZ Squeeze, the fluids is squeezed out creating a bed of solids in the loss zone
FLUIDS

The Solids Bed begins to build. The fluids continues to flow through the solids without forcing them into the loss zone
MUD CAKE

EZ SQUEEZE
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MUD

SOLIDS BED

How does EZ SQUEEZE Work

The mud begins to build a wall cake against the solids bed. Continued squeeze pressure causes the mud filter cake to compress the solids bed tightening the seal
EZ SQUEEZE
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Once the squeeze pressure is obtained, the EZ Squeeze hardens in place, forming a near permanent seal

MUD

FLUIDS

SOLIDS BED

MUD CAKE

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