Downhole losses

With the potentially high overbalance and the risk of ECD exceeding the Leak-off pressure
of the formation there is a risk of fracture propagation and subsequent lost circulation.
Where the ECD is a contributing factor to a loss situation, experience has shown that drill
string rotation can cause the ECD to increase, thereby exacerbating the situation. On a
round trip it is advisable during running in (say half-way) to circulate in order to establish
whether a (theoretical) ECD can be achieved. For the same reason, this exercise should be
repeated at the shoe. Being at the shoe is seen as the best compromise in case losses are
actually induced; the drill string is not in open hole, and the bit should be close enough to
bottom for the placement of cement.
The Addition of G-Seal at 20 kg/m3 has proved effective in the past at sealing off such
zones and would be recommended for seepage loss treatment. Higher loss-rates could
require the pumping of LCM pills. In the unlikely scenario that total losses would be
encountered, the hole should be filled and a level established a.s.a.p. It is recommended to
utilise water rather than base-oil to establish level and corresponding formation strength.
While mud weights are designed to overbalance expected (virgin) formation, if losses have
occurred the formation may be supercharged and as such could give back fluid. If, in the
process of giving back fluid, hydrocarbons are also flushed out of the formation, the
wellbore will have taken an influx without it being recognisably induced.

Due to the high cost associated with VERSAVERT system, high loss-rates cannot be
tolerated. The methodology adopted in the event of lost circulation will therefore have a
strong bias towards economics.

LOST CIRCULATION CONTINGENCY PROCEDURES

Graded Calcium Carbonate (Safe-Carb) will be the primary Lost Circulation Material used
as a contingency on the rig because of their dual functionality as a Lost Circulation
Material and Bridging Agent in the reservoir.

3.1 Procedures By Severity

Minor Seepage Losses: (0.2-1.6-m3/ hour)

Minor losses are considered seepage losses. Reducing or stopping the pump rate and
allowing the formation to heal and become sealed off by the development of a filter cake
frequently can control these losses. The pump rate can be gradually increased after the
losses have stopped.
Hourly treatments, over and above any existing maintenance treatment, direct to the
Moderate Seepage Losses: (1.6 - 8.0 m3/ hour)
In the event losses become more severe the situation will usually require treatment.
However, as a first action the bit should be pulled off-bottom, the pumps turned off and
the formation given the chance to heal by itself. If losses stop, drilling can be resumed,
with reduced drilling fluid weight and/or pump rate, if these two actions are possible. If
losses do not heal by themselves, add LCM materials directly to the active system on an
hourly basis (over and above any existing maintenance treatment)
Also, a pill can be built and swept through hole at a reduced pump rate to allow for
increased contact time.

Moderate to Severe Losses: (>8m3/hour)

If continuing losses become impractical, and more radical remedial measures are required,
then pulling the drilling assembly may be necessary. Run open-ended pipe to the thief
zone and spot a pill of 10-15 m3 active mud with 220 kg/m3 LCM material
An alternative treatment may be to spot some sort of reinforcing plug e.g. a Gunk squeeze
or Form-a-Squeeze

Complete Losses
The priority here usually is well control, so the annulus must be filled from the top with
drilling fluid, water or other lightweight liquid. Unless the fracture is induced, losses can
normally not be stopped by pumping conventional LCM pills. The alternative then is a
reinforcing plug or cement. However, a pill of LCM is often the first choice since it gives
quick response if it works and it is easy to do. Recommended pill to pump should contain
as much LCM as possible.

Lost Circulation Decision Tree

Below are 2 example lost circulation decision trees taken from M-I SWACO “Prevention &
Control of Lost Circulation” manual. These are included for reference only, as some of the
products mentioned may not be available at the rig.
In any circumstance where lost circulation is expected a plan of action should be
formulated and agreed on at the rig site before beginning drilling out of the casing.