Mi-Lost Circulation Manual

TECHNICAL REPORT
TITLE: LOST CIRCULATION MANUAL
REPORT FOR: Operations Norway

AUTHOR: Knut Taugbøl
APPROVED BY: Charlie Svoboda
REPORT NO: TR2000-02 LOST CIRCULATION MANUAL
DATE: March 22, 2000
SUMMARY This report covers all aspects around prevention and curing of lost
circulation of mud during drilling operations. The report is mainly focusing
on drilling offshore Norway, but the recommendations will also be applicable
elsewhere
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European Technical Center
Stavanger, Norway
Gamle Forusvei 43, N-4033 Forus, Norway, Phone No. 47-51 57 73 00, Fax No. 47-51 57 0605
1. INTRODUCTION...................................................................................................................................3
2. CAUSES OF LOST CIRCULATION....................................................................................................4

2.1 NATURAL LOSSES............................................................................................................................. 4
2.2 INDUCED LOSSES.............................................................................................................................. 4
2.3 TYPICAL LOSS ZONES OFFSHORE NORWAY..........................................................................................5
3. PREVENTION OF LOST CIRCULATION.............................................................................................7
3.1 WELL DESIGN................................................................................................................................... 7
3.2 DRILLING FLUID SELECTION.............................................................................................................. 8
3.3 DRILLING PROCEDURES..................................................................................................................... 8
4. QUANTIFICATION AND ANALYSIS OF LOSSES.............................................................................11
5. CURING LOST CIRCULATION PROBLEMS....................................................................................13

5.1 THE THEORY BEHIND BRIDGING AND SEALING OF FRACTURES AND PORE OPENINGS...........................13
5.2 THE USE OF REINFORCING PLUGS..................................................................................................... 15
6. CURING LOSSES WHEN DRILLING WITH WATER BASED MUD.............................................16
6.1 SEEPAGE LOSSES............................................................................................................................. 16
6.2 PARTIAL LOSSES............................................................................................................................. 16
6.3 TOTAL LOSS OF RETURNS................................................................................................................ 17
6.4 REINFORCING PLUG......................................................................................................................... 17
6.5 LOSSES IN PAY ZONE....................................................................................................................... 17
6.6 LCM COMPATABILITY WITH DRILLING EQUIPMENT...........................................................................17
7. CURING LOSSES WHEN DRILLING WITH OIL-/SYNTHETIC BASED MUD.........................19
7.1 SEEPAGE LOSSES............................................................................................................................. 19
7.2 PARTIAL LOSSES............................................................................................................................. 19
7.3 TOTAL LOSSES OF RETURNS............................................................................................................. 20
7.4 REINFORCING PLUG......................................................................................................................... 20
7.5 LOSSES IN PAY ZONE....................................................................................................................... 20
7.6 LCM COMPATABILITY WITH DRILLING EQUIPMENT...........................................................................21
8. REINFORCING PLUGS..........................................................................................................................22
8.1 FORM-A-PLUG................................................................................................................................ 22
8.2 REVERSE GUNK SQUEEZE................................................................................................................. 24
8.3 VERSAPAC...................................................................................................................................... 25
8.4 GUNK SQUEEZE............................................................................................................................... 26
9. FLOW CHART.........................................................................................................................................28
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1. INTRODUCTION
The term Lost Circulation describes the partial, or complete loss of whole drilling fluid
from the hole into the formation.
Lost circulation occurs when the openings in the formation are large enough to permit the
entry of whole mud. The hydrostatic pressure in the drilling fluid column must also be
greater than the formation pressure strength. In practice, if the formation openings are
greater than about 200 microns, there is a potential for losses of whole mud to occur The
openings can occur naturally in the formation or they can be induced by the drilling
process. The size of these openings can be increased mechanically by a number of drilling
practices that can cause losses.
In this report methods for prevention and curing of lost circulation will be described. Lost
circulation can cause dramatic well control situations, as well as it can be very costly, both
due to the high cost of the lost drilling fluid and due to the high cost related to non
productive time for the drilling rig.
Lost circulation is a bigger problem when drilling with invert muds than with water based
muds for several reasons. One is the higher cost of inverts, another is the fact that curing of
lost circulation in invert traditionally is more problematic than curing losses when drilling
with water based mud. New LCM pills specially designed for invert emulsion fluids based
on material selection and bridging theory will be introduced. The report is mainly focusing
on drilling offshore Norway, but the recommendations will also be applicable elsewhere.
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2. Causes of Lost Circulation

Loss zones can broadly be categorized into two types: natural or drilling induced causes.
The occurrence of each type varies around the world and is dependent on the drilling
operation and the geology. Within the North Sea most losses are due to induced fractures.
However there are areas where drilling into fractured chalk formations is a problem.
2.1 Natural Losses

(a) Losses Through Pores/Matrixes
For whole mud to be lost, formation openings must be about three times larger than the
particle size found in the mud. Thus, a formation must typically have a permeability in
excess of 10 to 25 darcy or a pore size of 200 microns for a well formulated mud to be
lost. Therefore this type of loss is confined to coarse sands and gravels.
(b) Formations Containing Permeable Natural Fractures

These losses can occur at high rates, even at overbalances as low as 3-4 bar (50psi).
Permeable natural fractures can be found in most types of formations and cause some of
the most troublesome lost circulation incidents. Within the North Sea fracture apertures as
wide as 3mm have been recorded for instance in the Tor formation.
(c) Cavernous Formations

Over geological periods of time, limestones, dolomites and salts are easily dissolvable by
groundwater. This can lead to the creation of fractures and caverns ranging from pin size
to tunnel size. These formations are not normally found in the North Sea.
2.2 Induced losses

Losses to induced fractures occur when the wellbore pressure exceeds the fracture
gradient, causing the formation to break down. These losses may occur due to excessive
ECD or during pressure surges. Fracture gradients cannot be extrapolated linearly with
depth, but alter with change in rock type. Thus certain formations are more susceptible to
induced fractures than others.
Drilling into pressure depleted reservoir zones have shown to be specially troublesome in
many Norwegian fields. The pore pressure depletion from producing the reservoir will
cause a reduction in the formation strength. In some formations the fracture gradient can
be reduced to a value below the initial pore pressure for the reservoir. Thus, the well must
be drilled with mud weight below the initial pore pressure which can cause dramatic well
control incidents if reservoir zones with virgin pressure is encountered.
Induced fractures are also often a result of poor drilling practice. Inadequate hole cleaning
will cause an increase in mud density and ECD which can cause the formation to break
down. The hole being packed off with cuttings during drilling or reaming can give
extremely high pressures to act on the formation. Pack off is a frequently seen cause for
lost circulation. Surge pressures from running in with drill pipe or casing too fast can also
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break down the formation as well as pump surge from increasing the pump speed too
rapidly.
2.3 Typical loss zones offshore Norway

Lost circulation can be a problem anywhere caused by poor drilling practice. However,
there are areas and formations where lost circulation is more likely to happen and where it
can be very difficult to prevent it from happening. The nature of losses can also differ from
one formation to another and thereby also the way it should be resolved. An investigation
among the different operators in Norway has shown that there are differences in the way
losses should be approached in different areas. Drilling into natural fractures will often
require different treatment resolving circulation than from induced fractures. In Norway
induced fractures are the most common cause, but there are areas in the southern part of
the North Sea were natural fractures occur. In this section some typical loss zones offshore
Norway will be discussed.
In the Tampen area where some of the biggest oilfields offshore Norway like Snorre,
Gullfaks and Statfjord are located, the major problem is drilling into pressure depleted
reservoirs. Pressure depletion will cause a reduction in fracture pressure. In a layered
reservoir like the Snorre the pressure depletion is difficult to predict for the different zones
and there is often big variations in pressure which makes it difficult to drill the whole
reservoir section without either losing circulation or taking an influx. The reservoir consists
of sand and shale layers and the losses often occur at the shift in lithology. The fractures
are caused by to high ECD and the way to prevent it from happening in this field has been
by focusing on well design in order to limit ECD and to split the reservoir into different
hole sections which then can be drilled with different mud weights. However, losses still
occur due to the big uncertainties in the pore- and fracture pressure predictions. The best
way to cure losses has shown to be by pumping the Form-a-Plug. Conventional LCM
mixtures containing blends of mica, nutplug, fyber, kwickseal etc. has shown not to be
effective in the synthetic mud used at this field. However, very recently a pill containing G-
seal and calcium carbonate together with , Mica, nutplug and fyber was able to heal losses.
Thus, by changing the pill contents a better effect of particular LCM can be achieved.
In the Statfjord field there are some coal layers in the Brent group that often causes losses,
in addition to the problems seen in the Statfjord group caused by pressure depletion as in
the Snorre field. Also on Statfjord, pumping of conventional LCM pills have shown little
success. In a recently drilled well at this field addition of bridging particles to the mud, G-
seal and calcium carbonate, proved to be effective in preventing losses to occur and
actually increasing the strength of the formation by plugging of micro fractures. Thus,
adding bridging particles like G-seal to the mud before drilling into zones were fractures
are likely to be induced, can be a good preventive method.
Fluid invasion over time is thought to be the reason for sloughing shale, causing pack off
and lost circulation in the shales at the Valhall field. Analysis of the shale has shown that it
contains natural micro fractures which are believed to be the cause of the problems. A
blend of G-seal and calcium carbonate added to the mud during drilling of these sections
has given successful results, blocking the micro fractures and thereby preventing this from
happening.
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In the southern part of the North Sea, such as the Ekofisk, Eldfisk and Valhall fields, where
we have the chalk reservoirs, there are problems with natural fractures. These fractured
areas are often located in the cap rock just above the chalk reservoir. These fractures cause
a sudden total loss of circulation when drilled into it and can normally not be cured by
LCM pills. In this type of losses a plug which sets up immediately is the preferred choice.
The best solution in this area has proven to be the reverse gunk squeeze. If high possibility
for encountering such a zone, the gunk is often made up in forehand ready to be pumped
as soon as losses start. Another approach used at Valhall has been to drill through the
fractured formation with a drill-in liner without returns to surface.
Drilling through faults is another area were problems are suspected to occur. Faults can
often be difficult to detect on the seismic and is therefore often difficult to omit. A study
conducted by Saga for the Snorre field however, showed that there were no increased
probability of loosing circulation when drilling through faults unless the formation were
pressure depleted after producing from the reservoir. In such a case the faults seemed to
increase the probability of losses.
Many fields are not mentioned in this discussion. However, most of the field in the North
Sea will have some similarities to one of the above mentioned areas. When finding the best
cure for lost circulation in a specific field, the cause of losses should be analyzed and the
way to treat the problem chosen thereafter. More discussion on treatments is given in the
coming sections.
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3. PREVENTION OF LOST CIRCULATION

For all drilling operations, lost circulation contingencies and prevention procedures should
be considered. Remedy of lost circulation will be most effective when it is planned before
the well is spudded.
3.1 Well design

Clearly the casing plan exerts the single greatest influence in avoiding lost circulation. In
many cases induced fractures occur because the intermediate casing string was set too high
and the mud weight needed to control deeper, high-pressure zones fractured an exposed
low-pressure formation. As a general rule, there should be a minimum of open hole
between the casing shoe and the expected loss zone. Good casing design using all available
tools and information to identify potential problem zones is critical as is knowledge of
fracture gradients and the existence of depleted zones. The fracture gradient of depleted
zones is often unknown. Plans may also be needed for contingency casing strings. If the
loss zone is hydrocarbon bearing, consideration needs to be given to possible bullheading
operations.
Casing design can also be used to reduce the ECD increment. For instance drilling a 12 ¼”
hole with a certain mud weight gives lower ECD than drilling an 8 ½” hole with the same
mud weight, since the annular clearance is greater between the drill pipe and the bore hole
wall in a bigger hole, giving lower frictional pressure loss. Installing of liner instead of
casing can reduce the ECD increment when drilling the subsequent hole section. For
instance installing a 9 5/8” liner from 13 3/8” casing shoe instead of running it all the way
up to seabed have shown to give a reduction in ECD increment of approximately 50 %
when drilling on the Snorre field. The 9 5/8” liner can be tied back to seafloor after the 8
½” section has been sealed off by a cemented liner if 9 5/8” casing is needed as production
casing.
Also the drill string configuration will have an effect on the ECD increment. For instance
replacing 5 ½” drill pipe with 5” when drilling a 8 ½” hole can have great effect in
reducing the ECD. Drilling with rotary stearable systems (such as Autotrack) can also be
an important tool in reducing the possibilities for lost circulation since it improves hole
cleaning and thereby the changes for pack-off etc.
By using the software Virtual Hydraulics, which calulate ECD, hole cleaning performance
etc. during drilling operations, in the planing of wells, the casing design and drill string
configuration can be optimized to give minimum ECD during drilling of the problem zones.
Virtual Hyrdaulics can also be used to optimize the drilling fluid rheology and pump rate to
ensure minimum ECD’s at acceptable hole cleaning.
3.2 Drilling fluid selection
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Drilling fluid selection is very important. If lost circulation is likely, then preference should
normally be given to water based fluids as opposed to oil- or synthetic-based fluids. This is
not only for cost reasons; the logistics of supply are usually easier for water-based muds
and they can be mixed more quickly. Lost circulation has also historically been easier to
cure when drilling with water based fluid.
For all drilling fluids it is important to optimize the rheology to ensure maximum hole
cleaning at minimum ECD.
When drilling through weak formation with high potential for losses, addition of LCM to
the drilling fluid can be recommended. The size distribution of these LCMs should be
tailord to match the expected fractures or pore sizes. Recent experience from the Statfjord
field showed that addition of G-Seal and calcium carbonate to the mud system during
drilling seemed to strengthen the formation and nearly eliminating losses. Experiences from
former wells have been large problems with losses during drilling through the same
formations. The theory is that the G-Seal is sealing off the fractures created due to elevated
ECD before the fracture have time to grow and propagate.
LCM can also be used to help prevent losses before running and cementing casing.
A tight fluid loss will help to maintain maximum annular clearances and minimize ECD,
swab and surge pressures.
3.3 Drilling procedures

Drilling procedures have an important part to play in avoiding lost circulation. The drilling
program should address the following points:
Mud weight and ECD

The lowest safe mud weight should be used to minimize hydrostatic pressures. Efficient
solids control and clear dilution guidelines will help to minimize mud weight and ECD.
Rheology should be optimized to minimize the equivalent circulating density (ECD).
Increased ECD will increase the pressure on the formation and aggravate the lost
circulation problem. The rheology should not be decreased to the point where barite sag
might occur. If the mud density cannot be reduced without endangering the well or de-
stabilizing the hole, it may be possible to reduce the ECD by altering the rheological
properties, or by reducing the circulation rate while the potential loss zone is being drilled.
"Seepage" type losses can frequently be cured by the simple action of reducing the pump
rate and allowing the formation to heal and become sealed off by the development of a
filter cake. Sometimes the pump rate can gradually be increased after the losses have
stopped.
Hole cleaning
Drilling rates and hole cleaning capabilities should be consistent with the need to avoid
overloading the annulus with cuttings. An increase in annular mud weight due to drilled
cuttings can result in formation breakdown, particularly in surface holes. The effective
increase in annular mud weight must be taken into account. In extreme cases the cuttings
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will build up and bridge off the annulus, this results in an induced fracture in the formation
and the total loss of returns.
Calculation of effective mud weight

(contribution from drilled solids only, not included ECD):
First calculate "Circulation rate" of cuttings (m3/hr):

Qc = ROP • (D • 0.0127)2 • 
Where : ROP = Rate of penetration (m/hr)
D = Hole diameter (inches)
 = 3.14
Then calculate effective mud density (s.g.):

SGE = SGM •(Q – Qc) + SGc•Qc
Q
Where : SGM = Mud density (s.g.)

SGC = Cuttings density (s.g.)
Q = Circulation rate (pump output) (note: m3/hr)
NOTE: This formula assumes a steady penetration and that all the drilled cuttings are being
removed. If hole cleaning is inadequate, the mud density increase can be substantially
higher. Specially under oriented drilling (sliding) when the pipe is not rotating the hole
cleaning efficiency can be drastically reduced.
Good hole cleaning is the number one criteria for avoiding lost circulation problems. If
hole cleaning is inadequate the well bore will be overloaded with cuttings which will
increase the ECD and subsequently increase the probability of pack-off, especially during
tripping.
Drilling practices
Drilling practices should be designed to reduce transient pressure fluctuations, in particular
surge pressures generated while running into the hole, or break-circulation pressures. Such
pressures cause a temporary increase in bottom-hole pressure, increasing the risk of lost
circulation. Swab and surge computer simulators (Virtual Hydraulics) should be used to
help predict problem situations, especially while tripping or running casing.
Staging into the hole and rotation of the drill string to help break gel strength should be
considered before restarting circulation after a trip. When restarting circulation, the pump
rate should always be increased slowly.
The BHA should be designed for maximum annular clearance and minimum sticking
potential consistent with other requirements. Use wiper trips if appropriate to check hole
condition. Larger bit nozzles should be considered if lost circulation is expected. The
internal diameters of downhole tools and motors should be checked.
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Consider conditioning trips midway through long logging programs. Increased gelation
may occur if the fluid is left static in the hole for extended periods.
Take necessary precautions to avoid barite sag. Monitor the mud weight of returns after a
trip to ensure that these are effective.
Ensure that no unnecessary mud transfers or additions/dilutions are made when drilling
into a potential loss zone. Ensure that the driller and mud loggers are informed prior to
making any transfers or treatments that will affect pit volume. Review pit volume
measurements and crew alertness of same.
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4. QUANTIFICATION AND ANALYSIS OF LOSSES

Knowing why a loss is occurring helps in selecting the best LCM solution, the probable
position of the loss zone and whether any changes to mud weight, mud properties or
drilling practices are necessary. By discussing the loss with the mud logger, rig geologist
and mud engineer, the cause of the loss can be determined. The mudloggers’ data chart can
provide an accurate record of how and when the loss initiated. The rig geologist often has
offset log data of the formation from adjacent wells, which can help identify the cause and
potential location of the loss. The mud engineer can help in deciding how to alter any of
the mud properties.
It is important to confirm that losses are to the formation and not at surface.
Before trying to cure the loss, carry out the following procedure:
(1) Establish loss rate.

(2) Check all solids control equipment to ensure no increase in background loss rate or
that any equipment has just been switched on.
(3) Check with mudlogger/mud engineer/pit room/driller that no mud has been dumped
or transferred.
Check riser slip joint for leaks.
Characteristics of different types of loss zones
(a) Losses Through Pores

Occur in unconsolidated or high matrix permeability formations.
Occur when solids content of mud is low.
Loss starts gradually, building up to maximum rate with additional penetration.
Loss rate not appreciably higher whilst tripping out.
Loss rate not particularly sensitive to pump rate.
Mud weight substantially below fracture gradient.
(b) Losses Through Induced Fractures

Mud weight approximately equal to fracture gradient.
Formation may be impermeable and is not of high matrix permeability.
Likely to occur on change in lithology from shale to sandstone.
Loss starts suddenly, initial rate is maximum rate.
Loss rate is considerably higher when tripping etc.
Loss rate is very sensitive to pump rate.
Loss rate not associated with drill break.
Fluid is often produced back when pumps are switched off.
(c) Losses Through Natural Fractures and Caverns.

Mud weight can be substantially below expected fracture gradient.
Formation is not of high matrix permeability.
Loss starts suddenly.
Loss rate may decline exponentially.
Loss rate whilst tripping is of similar magnitude to when circulating.
Loss rate moderately sensitive to pump rate.
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With additional penetration, loss rate is highly variable at constant overbalance.

Loss may be associated with drill break.
Identifying the loss zone

The on site geologist should ensure that the drilling team are kept aware of the location of
potential loss zones.
If a loss occurs while drilling, it is likely that the losses are on bottom. However, it should
not be automatically assumed that the thief zone is on bottom. A poor cement bond
around the casing shoe may have broken down, or a fracture could have been induced into
a weak formation anywhere in the open hole. If losses are due to natural fractures or
caverns the losses are likely to be at bottom. If losses occurs whilst tripping, wiping or
increasing mud weight, the losses can be off bottom. Losses off bottom are often caused by
induced fractures.
There are several methods of locating the loss zone. The geologist should be able to
identify the most likely formations. A temperature survey or other logging run can also be
used to locate the zone.
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5. CURING LOST CIRCULATION PROBLEMS

In order to cure or prevent lost circulation most effectively, proper planning must be done.
If drilling through a certain formation is likely to give losses, treating the mud with LCM
before entering the potential loss zone can be recommended. If total losses are expected
when drilling into a naturally fracture zone (like the Tor formation on Ekofisk) or a
pressure depleted zone (like the reservoir on Snorre) a reinforcing pill should be mixed
ready prior to entering this zone and pumped immediately when the losses occur.
However, in many cases, losses are not expected and the situation must be analyzed before
treatment starts. The result of the quantification and analysis of losses will decide the type
of curing method to be used. In addition the type of drilling fluid will decide which type of
material to use in the plugs to be pumped. The first LCM to be pumped is often a pill
containing different types of particles to bridge off the fracture. These materials are mixed
directly into the mud, pumped down and will work immediately if successful.
For severe losses the LCM pill will not always be able to seal off the fracture and the
solution will be a reinforcing plug such as Form A-Plug or Gunk, or Cement. When drilling
into known formations with natural fractures, the solution can be to go directly to a
reinforcing plug if experience have shown that LCMs do not work in sealing the fracture.
5.1 The theory behind bridging and sealing of fractures and pore openings
Selection of bridging material
For a bridge to be effective it is very important that the bridging particles enters into the
fracture. Bridging on the fracture opening will normally only be temporary and disrupted
when the bit and drill string is passing the bridge. For the bridge to enter and seal inside the
fracture it is important that the LCM pill contain the correct particle size distribution and
that the particles are designed correctly for the drilling fluid used. Water based and
oil/synthetic based drilling fluids will require different types of particles. In a water base
mud the surface of the particles should be preferably hydrophilic whereas in an oil/synthetic
based mud the particle surface should be lipophilic. Some type of material such as G-Seal
have a neutral surface and can work in both types of fluid.
The reason for the importance of the surface conditions of the particles is that if the
wettability is not correct, the particles will not be transported effectively into the fracture
opening and seal the fracture inside the fracture. In stead the particles will typically screen
out of the solution and form a bridge on the outer surface of the fracture. The use of a
cellulosic fiber product like KwickSeal in an oil/synthetic based mud is a typical example of
this, where a temporary seal can be formed from screening out the material on the fracture
surface, but where the seal very often is broken when drilling operation is resumed
Fracture sealing in water versus oil/synthetic based systems.

Although there should be no difference between water-and oil base muds in the pressure
needed to initiate a hydraulic fracturing of the formation, there is a significant difference
once the fractures are formed. Water based fluids typically have a higher “spurt” fluid loss
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causing an almost instantaneous filter cake to form that aids in formation sealing in
permeable formations. When drilling with water based mud the cuttings are often partly
dispersed giving particles of all different sizes in the system. These particles also act in
building the filter cake. It is also often seen that the fracture heals by itself if the mud in the
hole is left static for a period of time probably because of some swelling of shale surfaces.
Oil base fluids do not display the same characteristics. Once the fracture is initiated the
pressure necessary to propagate the fracture is much smaller by comparison. This is
compounded by lack of a significant pressure drop across the filter cake of most oil base
muds. This allows changes in wellbore pressures to be transmitted to the formation more
readily and further propagate the fracture. When using oil base fluid, almost no cuttings
dispersion take place and the filter cake is built mainly by the emulsion droplets in the mud,
giving a very thin impermeable filter cake. To get an effective heal of the fractures then,
particles of certain size must be added to act as the bridging agent within the fracture,
giving the spurt loss to build an effective filter cake which can prevent the fracture from
propagating. The size of the particles must be tailord in size so they give an effective seal,
thus it need to contain both large particles to bridge off the fracture and smaller particles to
seal off in between the bigger ones.
Particle size and shape distribution

In addition to have the right type of particles the particle size distribution is very important.
To get a good strong sealing of the fracture big particles are needed for the initial sealing
and smaller particles are needed for sealing in between the big ones. When drilling with
water based mud the main part is to have big particles for the initial bridge since the drill
solids often will have sizes to bridge off in between the big ones. The exception might be
silicate mud which is so inhibitive that the cuttings stay almost intact not forming smaller
drill solids.
When using oil base fluid the particle size distribution must be more properly designed. In
all pills the base should be almost the same but with addition of larger particles for larger
fractures. Dynamic flow experiments, where fractures of 3000  size were sealed, also
showed that there should be a blend of granular, flakes and fybers to make an effective
seal. For smaller fractures and pore throats only granular particles will do the job. A typical
formulation for curing seepage losses will then contain a blend of the granulars Calcium
Carbonate and G-Seal. For larger losses, Ven Fyber and Mica may need to be added as
well.
5.2 The use of reinforcing plugs

The use of a reinforcing plug such as Form-a-Plug, gunk or reverse gunk is normally
considered as the next option for curing losses when the LCM pills have not been
successful. The plug will set up down hole and thereby regain strength to the formation.
The plug can in some cases be the only necessary treatment to allow continued drilling of
the section. However, often it is also necessary to reduce mud weight and/or pump rate to
reduce ECD when drilling further since the plug will not give any additional strength to the
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formation. In many cases it can be the necessary base to be able to run and cement casing
before drilling ahead a new section with reduced mud weight.
A reinforcing plug needs to be spotted in the right place to be effective, i.e. across the loss
zone. Location of the loss zone can sometimes be difficult. Pumping of LCM pills ahead
can in such cases give some indications of where the losses are if some partial
improvement is seen when pumping these pills.
Pumping of reinforcing pills always imply some danger of plugging pipes or flow lines if
the pumping is not done by following the specific procedures. This often results in some
hesitation on the rig to start mixing and pumping these systems. The result is then often
that they continue pumping the standard LCM even if it has not given any effect and the
result is that valuable time is lost. Especially when drilling with oil-/synthetic based muds
there are seldom any improvements over time. Thus, if the LCM pill did not work in the
first place the next step should be a reinforcing plug.
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6. CURING LOSSES WHEN DRILLING WITH WATER BASED MUD
6.1 Seepage losses

Losses up to approximately 3 m3/hr (20 bbls/hr) are normally considered as seepage losses.
Seepage type losses are frequently cured by the simple action of reducing or stopping the
pump rate and allowing the formation to heal and become sealed off by the development of
a filter cake. The pump rate can be gradually increased after the losses have stopped.
If losses do not heal by themselves and the amount of loss can not be tolerated by
economical or other reasons LCM pill for curing the loss must be pumped.
Recommended pill to be used:
Mix II Fine 20 kg/m3

Calcium Carbonate (C) 20 kg/m3
G-seal 40 kg/m3
If seepage losses are expected during drilling through a certain formation, treating the
whole mud system with LCM before entering the loss zone can be recommended. Such a
treatment will depend on pore/fracture size distribution in the actual formation but a
general recommendation will be to treat the system with:
Mix II Fine 15 kg/m3

Calcium Carbonate (M) 15 kg/m3
6.2 Partial losses

Losses from 3 m3/hr up to total loss of all returning fluid are often referred to as partial
losses. The situation will usually require treatment. However, as a first action the bit should
be pulled off bottom, the pumped turned off and the formation given the chance to heal by
itself. If losses stop, drilling can be resumed, if possible with reduced mud weight and/or
pump rate. If losses do not heal by it self the following LCM pill is recommended:
Mica M: 25 kg/m3
Mix II Med 25 kg/m3
Nut plug M 25 kg/m3
G-seal 50 kg/m3
If this pill does not heal the losses, the pill described below for curing total losses should be
pumped.
6.3 Total loss of returns

The priority will usually be well control so the annulus must be filled from the top with
either drilling fluid, water or other lightweight liquid. Unless the fracture is induced, losses
can normally not be stopped by pumping conventional LCM pills and the alternative then is
425446178.doc Page 16
Stavanger, Norway
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. A standard formulation would be:
Mica M: 40 kg/m3
Mix II Med 30 kg/m3
Mix II Coarse 30 kg/m3
Nut plug F 50 kg/m3
G-seal 50 kg/m3
If this pill does not heal the fracture a reinforcing plug or cement should be set across the
loss zone.
6.4 Reinforcing plug

If the above mentioned pills are not able to stop the losses, a reinforcing pill should be
pumped. If total losses are expected, always have a pill ready mixed prior to entering the
zone. When using a pill like this, it is essential to know where the loss zone is located since
the pill need to be spotted across the loss zone to be effective.
For water based mud Form-a-Plug is the recommended plug to set. Form-a-plug need to
be static when it is setting up, thus if there is large static losses this pill will not likely cure
the losses. In such a case a gunk, which set up immediately when in contact with the mud
down hole should be pumped. Formulations and procedures for these pills are given in
section 8.
6.5 Losses in pay zone

Formation damage from the LCM is normally considered as a problem only in wells that
are open hole completed, since for wells that are completed with cemented and perforated
liners the perforations will go through the possible damaged zone. However, also in wells
with open hole completions curing the losses are most often the primary goal and the LCM
is chosen from that perspective using the most effective LCM. If there are a desire of
removing the LCM after completion the particles of the pills should mainly be calcium
carbonate which can be acidized. As a choice for reinforcing plug the Form-a-Plug should
be used since it also can be removed by acid.
6.6 LCM compatability with drilling equipment

Before an LCM pill is pumped it should be clarified by the operator that the particles
chosen can pass the BHA without plugging the tools. For most tools used in the North Sea
in normal drilling operations, the above-mentioned pills will pass the MWD, motors and
bits used. Coarse particles like Nutplug M/C will cause the biggest problems. These coarse
materials can be replaced by finer material if plugging problems are suspected.
Particular LCM can also cause problems for the slurryfication units used for cuttings
reinjection. It is therefore advisable to take out the LCM when it hit the shakers and send it
to share as special waste material in such occasions.
425446178.doc Page 17
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7. CURING LOSSES WHEN DRILLING WITH OIL-/SYNTHETIC

BASED MUD
7.1 Seepage losses

Losses up to approximately 3 m3/hr (20 bbls/hr) are normally considered as seepage losses.
Seepage type losses are frequently cured by the simple action of reducing or stopping the
pump and/or reducing the mud weight.
If losses do not heal by themselves and the amount of loss can not be tolerated by
economical or other reasons LCM pill for curing the loss must be pumped.
Recommended pill to be used:
Ven Fyber: 20 kg/m3

G-Seal: 40 kg/m3
Calcium carbonate (C) 20 kg/m3
If seepage losses are expected during drilling through a certain formation, treating the
whole mud system with LCM before entering the loss zone can be recommended. Such a
treatment will depend on pore/fracture size distribution in the actual formation but a
general recommendation will be to treat the system with:
G-Seal 10 kg/m3
Calcium Carbonate (M) 10 kg/m3
7.2 Partial losses

Losses from 3 m3/hr up to total loss of all returning fluid are often referred to as partial
losses. The situation will usually require treatment. However, as a first action the bit should
be pulled off bottom, the pumped turned off and the formation given the change to heal by
itself. If losses stop, drilling can be resumed, if possible with reduced mud weight and/or
pump rate. If losses do not heal by it self the following LCM pill is recommended:
Mica M: 30 kg/m3
Ven Fyber 40 kg/m3
G-Seal 50 kg/m3
If this pill does not heal the losses a pill with some coarser particles is recommended and
the pill given below for curing total losses should be pumped. If that one also fails, one of
the reinforcing plugs or cement is recommended.
425446178.doc Page 18
Stavanger, Norway
7.3 Total losses of returns

The priority will usually be well control so the annulus must be filled from the top with
either drilling fluid, water or other lightweight liquid. Unless the fracture is induced losses
can normally not be stopped by pumping conventional LCM pills and 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. A standard formulation would be:
Mica M: 40 kg/m3
Ven Fyber 30 kg/m3
Mix II Coarse 30 kg/m3
G-Seal 50 kg/m3
Nut plug M 50 kg/m3
If this pill does not heal the fracture a reinforcing plug or cement should be set across the
loss zone.
7.4 Reinforcing plug

If the above mentioned pills are not able to stop the losses, a reinforcing pill should be
pumped. If total losses are expected, always have a pill ready mixed prior to entering the
zone. When using a pill like this, it is essential to know where the loss zone is located since
the pill need to be spotted across the loss zone to be effective.
For oil based mud Versapac oil based LCM plug is the recommended plug to set. Versapac
will be activated by a combination of shear and temperature and can be used for
temperatures of 60-100 oC. It can not be used in synthetic mud for environmental reasons.
For synthetic mud and as a secondary option for oil based mud, Form-a-plug should be
used. Form-a-plug need to be static when it is setting up, thus if there is large static losses
this pill will not likely cure the losses. In such a case a reverse gunk, which sets up
immediately when in contact with the mud down hole should be pumped. Formulations and
procedures for these pills are given in section 8.
7.5 Losses in pay zone

Formation damage from the LCM is normally considered as a problem only in wells that
are open hole completed, since for wells that are completed with cemented and perforated
liners the perforations will go through the possible damaged zone. However, also in wells
with open hole completions curing the losses are most often the primary goal and the LCM
is chosen from that perspective using the most effective LCM. If there are a desire of
removing the LCM after completion the particles of the pills should mainly be calcium
carbonate which can be acidized. As a choice for reinforcing plug the Form-a-Plug should
be used since it also can be removed by acid.
7.6 LCM compatability with drilling equipment

Before an LCM pill is pumped it should be clarified by the operator that the particles
chosen can pass the BHA without plugging the tools. For most tools used in the North Sea
in normal drilling operations, the above-mentioned pills will pass the MWD, motors and
425446178.doc Page 19
Stavanger, Norway
bits used. Coarse particles like Nutplug M/C will cause the biggest problems. These coarse
materials can be replaced by finer material if plugging problems are suspected.
Particular LCM can also cause problems for the slurryfication units used for cuttings
reinjection. It is therefore advisable to take out the LCM when it hit the shakers and send it
to share as special waste material in such occasions.
425446178.doc Page 20
Stavanger, Norway
8. REINFORCING PLUGS
This section gives the different options of reinforcing plugs with operational procedures to
be used in severe loss situations.
8.1 Form-A-Plug
Form-a-plug can be used to cure severe losses of both water- and oil/synthetic based mud.
The formulations below have shown to set up after approximately 2.5 hours when tested
in the lab. This should be sufficient for most operations. When pumped down there will
take some time before the plug heats up to the down hole temperature, thus the plug
should be left for 6 hrs to set up. The setting time at different temperatures will be
depended on the concentration of Form-a-plug and Form-a-plug accelerator in the water
and by the portion between the two chemicals. The desired weight of the plug can be
adjusted by adding barite. Barite will not affect the setting time. The amount of barite
needed can be calculated by the weight of the unweighted formulation.
The following amount of chemicals should be added to make 1 m3 of unweighted Form-a-

plug:
Temperature (oC) 4 38 55 65 70 80 85 95 110
Drill water (m3) 0.90 0.88 0.87 0.89 0.88 0.89 0.90 0.88 0.88
Form a plug (kg) 148 163 165 146 148 137 128 172 183
Form a plug acc. 50 82 83 73 74 69 64 43 41
(kg)
CaCl2 (kg) 25
Weight of 1.12 1.13 1.13 1.12 1.12 1.11 1.10 1.10 1.10
formulation (SG)
A retarder can also be added if the setting time needs to be prolonged.
Mixing instructions
The cross-linking mechanism is a chemical reaction. Therefore it is important to carefully
control the ingredients and mixing conditions in order to ensure that the reaction proceeds
as expected.
1. Ensure that the pit and mixing lines are flushed clean and free from salt, brine
and/or any materials which could affect the salinity or pH of the pill.
2. Add the appropriate volume of drill water to the pit; pH should be 6-8.
3. Add Retarder as fast as practicable via the mix hopper (If retarder is required).
4. Add the appropriate quantity of Form-a-Plug via the mix hopper at 3-4 minutes
per. 25 kg sx.
(Depending on the performance of the mixing equipment).
425446178.doc Page 21
Stavanger, Norway
5. Shear to yield the polymers.
6. Add barite to desired density.
7. Keep the fluid agitated but not mixing (generates heat).
8. Immediately before pumping add the appropriate quantity of accelerator. This

should be added through the hopper as quickly as possible, but only at a rate that
will allow even distribution throughout the mix.
9. Displace the FORM-A-PLUG to the well.
10. Pull above Form-a-Plug pill. Close annular preventor and squeeze down annulus
and drill pipe to ensure pill has entered the formation.
Viscous spacers (minimum 1,5 m3) are recommended ahead and behind the FORM-A-
PLUG if the drilling fluid has a high salinity. The spacer can either be water based, or oil
based (synthetic/mineral oil), but should not contain any salt. It should be weighted to the
same density as the drilling fluid and the FORM-A-PLUG.
Operational comments and guidelines

Once the accelerator has been added, the fluid should be regarded as cement. It will cross
link and set.
The final composition should be pumped immediately down hole.
Form-A-Plug can be pumped through BHA.
Any fluid left static in the string will set-up inside. The fluid should be adequately displaced
and spotted as required.
Similarly, if the mud pumps were to fail prematurely, an alternative means should be used
to pump the fluid into place i.e. have the cement unit on stand-by as contingency.
Once displaced, the string should be pulled clear above the estimated top of plug. Time
spent waiting on plug , circulating or squeezing, should be performed with the string out of
the plug. Avoid ballooning effect of the plug. Any movement of the pill will increase the
setting time.
It is recommended that the plug should be left in place for a minimum 6 hours before
drilling out/dressing the plug.
If possible a sample of the pill should be left static in a heating oven at the same
temperature as the lost circulation point. This will confirm the setting time.
425446178.doc Page 22
Stavanger, Norway
Surplus FORM-A-PLUG left in the pit should be dumped while it is still fluid. Pit, lines
and pumps should be thoroughly flushed with sea/drill water.
Treat the fluid with care

Addition of lime or calcium chloride to the system cause rapid setting.
Low pH will delay (or in extreme cases prevent) setting up the FORM-A-PLUG. Keep
acid out of the fluid.
High pH will cause rapid setting.
The set-up rate increases with temperature, therefore avoid situations such as prolonged
shearing of the fluid, which could cause heating.
8.2 Reverse gunk squeeze

Reverse gunk squeeze can be used in severe loss situation when drilling with oil or
synthetic based mud.
When drilling into a possible total loss formation, a Gunk pill should be prepared in
advance, to enable immediate response and minimize losses. The Gunk pill should be
prepared in a separate batch mixing tank, well away from the mud pits. Once mixed, the
Gunk should be continuously circulated.
Formulation for 6 m3 of gunk

4 m3 Drill water
25 kg Lime
50 kg Lignosulphonate
3200 kg Organophilic clay
Barite to reach the required mud weight
Spotting technique
1. RIH and place the bottom of the drill pipe +/- 1 joint above the thief zone. Pump 6
m3 gunk down with 1 m3 viscosified water ahead and behind as spacer.
2. Displace with mud until water ahead reaches bottom of drill pipe.
3. Close annular preventer.
4. Squeeze gunk by using both pumps on the cement unit.

No. 1; Pump down DP at 300 l/min.
No. 2; Pump down annulus at 80 l/min.
5. Squeeze total 6 m3 (until all water is cleared from the drill pipe).
425446178.doc Page 23
Stavanger, Norway
6. Pull drill pipe well above gunk.
7. Wait on gunk (2-4 hrs).
Additional comments
 Barite can normally be excluded from the formulation since in events of total losses the
hydrostatic column imparted from the barite addition is not required. Additions of barite
to the formulation take time and can be difficult to achieve.
 Base oil may be applied to the annulus in the event of total losses, where a temporary
reduction in hydrostatic can be tolerated until the gunk is in place.
 Occasionally a second gunk may be required, should the first not work. Be aware that a
deposit of gunk may form inside the drill pipe when pumping the gunk. Subsequent
attempts, or gunking frequently, results in overdisplacement into the annulus.
 Be sure of spotting techniques to squeeze the gunk, and minimise any gunk coming up
into the annulus. This can result in higher ECD when re-attempting circulation, and or
uncomfortable quantity of clay to segregate at the surface when returns are achieved at
the shakers. Gunk at the shakers needs to be by-passed as excessive blinding will occur
otherwise.
 No attempts should be made to reverse circulate the gunk as it will plug the string.
 The Gunk should ideally be prepared by use of a batch mixer or cementing tanks,
isolated from the surface mud system. Plugging of mud lines is a serious potential
hazard.
 The gunk can be pumped through most BHAs.
8.3 Versapac
Versapac is an oil based LCM plug to be used when severe losses occur when drilling with
oil based mud. The formulation of the plug is very simple. It is made from the mud with
addition of three products and it can be pumped down without the use of spacers.
A standard VersaPac formulation consist of:

Oil based mud 1 m3
Versapac 60 kg
MI-X II 15 kg
Ecotrol 15 kg
Versapac is activated by a combination of shear and temperature. Versapac is a thermally

activated gelling agent which will generate viscosity and develop gel structure as soon as
425446178.doc Page 24
Stavanger, Norway
the temperature exceeds 60 oC. the melting point of Versapac is 120 oC, thus the
temperature range for this plug is between 60-110 oC.
Operational guidlines
A typical volume to pump will be 3-4 m3. The chemicals should be added to the mud in a
separate pit. This pill should then be pumped downhole, displaced by mud. It can be
pumped through the BHA.
Any fluid left in the string will set-up inside. The fluid should be adequately displaced and
spotted as required.
Similarly, if the mud pumps were to fail prematurely, an alternative means should be used
to pump the fluid into place i.e. have the cement unit on stand-by as contingency.
Once displaced, the string should be pulled clear above the estimated top of plug. Time
spent waiting on plug , circulating or squeezing, should be performed with the string out of
the plug.
It is recommended that the plug should be left in place for a minimum 6 hours before
drilling out/dressing the plug. If possible a sample of the pill should be left static in a
heating oven at the same temperature as the lost circulation point. This will confirm the
setting time.
Contamination of the mud with the plug will not cause any dramatic effect to the mud.
Only slight increase in the viscosity can be expected when drilling out the plug.
8.4 Gunk squeeze

Gunk squeeze can be used in severe loss situation when drilling with water based mud.
Since oil is used in the gunk it can only be used in zero discharge situations.
Formulation for 10 m3 of gunk

8 m3 Base oil
4000 kg Bentonite
The bentonite will not yield in the oil, but it will hydrate and swell into the formation when
in contact with water based mud.
Spotting technique
1. RIH and place the bottom of the drill pipe +/- 1 joint above the thief zone. Pump
the gunk down with 2 m3 oil ahead and 1 m3 behind as spacer.
2. Displace with mud until oil ahead reaches bottom of drill pipe.
3. Close annular preventer.
425446178.doc Page 25
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4. Squeeze gunk by using both pumps on the cement unit.

No. 1; Pump down DP at 300 l/min.
No. 2; Pump down annulus at 80 l/min.
5. Squeeze total 10 m3 (until all oil is cleared from the drill pipe).
6. Pull drill pipe well above gunk.
7. Wait on gunk (2-4 hrs).
 Occasionally a second gunk may be required, should the first not work. Be aware that a
deposit of gunk may form inside the drill pipe when pumping the gunk. Subsequent
attempts, or gunking frequently results in overdisplacement into the annulus.
 Be sure of spotting techniques to squeeze the gunk, and minimise any gunk coming up
into the annulus. This can result in higher ECD when re-attempting circulation, and or
uncomfortable quantity of clay to segregate at the surface when returns are achieved at
the shakers.
 No attempts should be made to reverse circulate the gunk as it will plug the string.
 The Gunk should ideally be prepared by use of a batch mixer or cementing tanks,
isolated from the surface mud system. Plugging of mud lines is a serious potential
hazard.
 The gunk can be pumped through most BHAs.
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9. FLOW CHART
Loosing fluid while drilling
Stop drilling and observe levels
Losses on surface
Yes
No
Locate and stop losses
Well flowing?
Yes
No
Record shut in pressure.

Kill the well Measure rate of loss
Seepage losses, < 3m 3/hr Partial losses, > 3 m3/hr Total loss of returns
Oil/synthetic Waterbased Oil/synthetic Waterbased Oil/synthetic Waterbased

mud mud mud mud mud mud
Spot pill: Spot pill: Spot pill: Spot pill:

Ven Fyber 20 kg/m3 Mix II Fine 20 kg/m3 Mica M 30 kg/m3 Mica M 25 kg/m3
G-Seal 40 kg/m3 Calc.Carb.(M) 20 kg/m3 Ven Fyber 40 kg/m3 Mix II Med. 25 kg/m3
CalcCarb (C) 20 kg/m3 G-Seal 40 kg/m3 G-Seal 50 kg/m3 Calc.Carb (C) 25 kg/m3
CalcCarb (C) 30 kg/m3 G-seal 50 kg/m3
Nut Plug M 25 kg/m3
No success
No success
Spot pill:
Mica M 40 kg/m3 Spot pill:
Spot plug: No success Ven Fyber 30 kg/m3 Mica M 40 kg/m3
VersaPac or Mix II Coarse 30 kg/m3 Mix II Med. 30 kg/m3
Form-a-plug or G-Seal 50 kg/m3 Mix II Coarse 30 kg/m3 Spot plug:
Reverse Gunk or Nut Plug M 50 kg/m3 G-Seal 50 kg/m3 Form-a-plug or
Cement Nut Plug M 50 kg/m3 Gunk or
No success
Cement
425446178.doc Page 27

Mi-Lost Circulation Manual

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TECHNICAL REPORT

TITLE: LOST CIRCULATION MANUAL

REPORT FOR: Operations Norway

2. CAUSES OF LOST CIRCULATION....................................................................................................4

5. CURING LOST CIRCULATION PROBLEMS....................................................................................13

2. Causes of Lost Circulation

2.1 Natural Losses

(b) Formations Containing Permeable Natural Fractures

(c) Cavernous Formations

2.2 Induced losses

2.3 Typical loss zones offshore Norway

3. PREVENTION OF LOST CIRCULATION

3.1 Well design

3.2 Drilling fluid selection

3.3 Drilling procedures

Mud weight and ECD

Calculation of effective mud weight

First calculate "Circulation rate" of cuttings (m3/hr):

Then calculate effective mud density (s.g.):

Where : SGM = Mud density (s.g.)

4. QUANTIFICATION AND ANALYSIS OF LOSSES

(1) Establish loss rate.

Characteristics of different types of loss zones

(a) Losses Through Pores

(b) Losses Through Induced Fractures

(c) Losses Through Natural Fractures and Caverns.

With additional penetration, loss rate is highly variable at constant overbalance.

Identifying the loss zone

5. CURING LOST CIRCULATION PROBLEMS

Fracture sealing in water versus oil/synthetic based systems.

Particle size and shape distribution

5.2 The use of reinforcing plugs

6. CURING LOSSES WHEN DRILLING WITH WATER BASED MUD

6.1 Seepage losses

Recommended pill to be used:

Mix II Fine 20 kg/m3

Mix II Fine 15 kg/m3

6.2 Partial losses

6.3 Total loss of returns

6.4 Reinforcing plug

6.5 Losses in pay zone

6.6 LCM compatability with drilling equipment

7. CURING LOSSES WHEN DRILLING WITH OIL-/SYNTHETIC

7.1 Seepage losses

Recommended pill to be used:

Ven Fyber: 20 kg/m3

7.2 Partial losses

7.3 Total losses of returns

7.4 Reinforcing plug

7.5 Losses in pay zone

7.6 LCM compatability with drilling equipment

The following amount of chemicals should be added to make 1 m3 of unweighted Form-a-

Temperature (oC) 4 38 55 65 70 80 85 95 110

A retarder can also be added if the setting time needs to be prolonged.

5. Shear to yield the polymers.

6. Add barite to desired density.

7. Keep the fluid agitated but not mixing (generates heat).

8. Immediately before pumping add the appropriate quantity of accelerator. This

9. Displace the FORM-A-PLUG to the well.

Operational comments and guidelines

The final composition should be pumped immediately down hole.

Form-A-Plug can be pumped through BHA.

Treat the fluid with care