Lost Circulation

Baroid Fluids Handbook Lost Circulation

Lost Circulation Table of Contents 1.

Lost Circulation....................................................................................................................................... 3 1.1.

1.2.

1.3.

1.4.

1.5.

Overview ..................................................................................................................................... 3 Fluid Selection ............................................................................................................... 3 Lost Circulation Indicators............................................................................................ 3 Surface Losses ................................................................................................................ 3 Risks and Hazards.......................................................................................................... 3 Causes of Lost Circulation ........................................................................................... 4 Economic Impact ........................................................................................................... 5 Formation Types Associated with Lost Circulation ....................................................... 5 Classification of Losses ................................................................................................ 5 Treatment Options ....................................................................................................................... 6 Pretreatment .................................................................................................................. 6 Lost Circulation Remediation ........................................................................................ 7 Seepage .......................................................................................................................... 8 Partial Losses................................................................................................................. 8 Severe Losses ................................................................................................................. 9 Complete Losses............................................................................................................. 10 General Recommendations ............................................................................................ 10 LCM Classifications ..................................................................................................... 11 Engineered Approach to Lost Circulation ................................................................................. 12 Casing Point Selection ................................................................................................... 12 Planning ......................................................................................................................... 12 Geomechanical Modeling .............................................................................................. 13 DFG Hydraulics Modeling and ECD ............................................................................. 13 Wellbore Stress Management ...................................................................................................... 13 Prevention of Lost Circulation ...................................................................................... 13 Hydraulics and ECD Modeling ..................................................................................... 14 Fracture Modeling ......................................................................................................... 14 Rheology Prediction for Invert Emulsion Fluids after the Addition of LCM ................ 18 Treatment Guideline Reference Tables ....................................................................................... 20 Less than 10 bph ............................................................................................................ 20 10-50 bph ....................................................................................................................... 21 50-100 bph ..................................................................................................................... 22 100-200 bph ................................................................................................................... 23 Greater than 200 bph..................................................................................................... 23 Underground Blowout ................................................................................................... 23

Tables Table 1 Formation Types Associated with Lost Circulation ...................................................................................... 5 Table 2 Example Loss Rates....................................................................................................................................... 6 Table 3 Lost Circulation Treatment Guidelines ....................................................................................................... 11

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Baroid Fluids Handbook Lost Circulation

Table 4 LCM Types and Classifications................................................................................................................... 12 Table 5 Wellbore Strengthening Example Data Set ................................................................................................. 15 Table 6 Specialty Particulate Materials .................................................................................................................... 16

Figures Figure 1 Lost Circulation / Kick Scenario .................................................................................................................. 4 Figure 2 Differential Sticking At or Near Loss Zone ................................................................................................. 4 Figure 3 Wellbore Strengthening Dynamics ............................................................................................................ 14 Figure 4 Screen Shot of WellSET Treatment Design Module ................................................................................. 15 Figure 5 Example Material Selection and Particle Size Distribution Solution ......................................................... 16 Figure 6 Pretreatment Option for Entire Drilling Fluid System ............................................................................... 16 Figure 7 Sweep Option for Drilling Fluid System .................................................................................................... 17 Figure 8 Open Hole FIT Option– WellSET Treatment ............................................................................................ 17 Figure 9 Rheology Prediction Model Screen Shot ................................................................................................... 18 Figure 10 Effect of LCM Addition on Rheology ..................................................................................................... 18

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Baroid Fluids Handbook Lost Circulation

1.

Lost Circulation

1.1.

Overview

Fluid Selection Drilling fluids with low non-progressive gels help lower the risk of lost circulation. The ACCOLADE and ENCORE synthetic-based systems and HYDRO-GUARD or BOREMAX water-based systems are examples of fluids formulated with low colloidal content that exhibit desirable gel characteristics. Baroid offers other systems with similar performance characteristics. Selection depends on conditions such as temperature, shale reactivity, environmental concerns, and solids control efficiencies.

Lost Circulation Indicators Lost circulation is defined as complete or partial loss of whole mud to the formation that typically occurs when hydrostatic pressure in the annulus exceeds the fracture gradient of the exposed formation or natural fractures are encountered. When lost circulation occurs, less fluid returns to surface than is pumped downhole. In the event of total loss of circulation, no fluid returns to the surface even though pumping continues. Lost circulation can be detected by monitoring return flow and pit levels with sensors and pit volume indicators. Most sensors are equipped with an alarm set point to alert crews to losses and gains in flow and pit volume.

Surface Losses Prior to assuming that mud loss to the formation has taken place, all surface equipment should be examined for leaks or breaks (i.e.. mud pits, solids control equipment, mud mixing system, riser slip joints, and/or incorrectly lined up pumps or circulating lines). Losses may also occur during a fluid transfer.

Risks and Hazards Depending on the severity of the rate of mud loss, drilling operations may be significantly impaired. Losses can significantly increase the overall well cost, both in time and in drilling fluid requirements. If the annulus does not remain full when pumping ceases, the hydrostatic pressure decreases until the differential pressure between the mud column and the loss zone is zero. This may cause formation fluids from other zones, previously controlled by the hydrostatic pressure of the mud column, to flow into the wellbore, resulting in a kick, blowout, or underground blowout (Figure 1).

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Baroid Fluids Handbook Lost Circulation

Figure 1 Lost Circulation / Kick Scenario

Loss of hydrostatic pressure may also cause previously stable formations to collapse into the wellbore. Loss of circulation may lead to differential sticking of the drillstring (Figure 2).

Figure 2 Differential Sticking At or Near Loss Zone

Causes of Lost Circulation Loss of circulation occurs when the hydrostatic pressure exceeds the fracture gradient (FG) of an intact formation and/or the pore pressure of a formation with open fractures. The most common causes of excessive hydrostatic pressure are as follows: • • • • •

Excessive overbalanced mud weight Cuttings loading in the annulus due to poor hole cleaning Elevated viscosity and rheological properties Restricted annular space Excessive surge pressure while running the drillstring or casing in the hole

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Baroid Fluids Handbook Lost Circulation

•

Combination of the above factors

To help ensure the most appropriate lost circulation treatment(s) are applied in each case, the mud engineer should evaluate not only the characteristics of the loss zone, but all the parameters that may be affecting hydrostatic pressures in the wellbore.

Economic Impact The economic impact of lost circulation is significant. When unacceptable losses are encountered, normal drilling operations may be delayed indefinitely while attempts are made to regain full returns. Under certain conditions, the operator may decide to “drill blind” (i.e., without returns) in an effort to allow cuttings to seal off the loss zone. In a well with exposed gas- or water-bearing formations, this practice may induce a kick or blowout if the hydrostatic pressure becomes less than the formation pressure. Lost circulation is a major contributor to non-productive time (NPT) and flat time. Once well construction begins, a primary goal is the reduction of NPT (i.e., intervals where drilling ceases due to hole problems). Likewise, flat time related to formation evaluation (logging) and setting casing should be minimized by ensuring that hole conditions are at their best for the particular operation. The cost of a lost circulation incident includes the value of the lost mud, the rig time required to address the problem, the materials added to the mud system to reduce or stop the loss rate, and under very severe circumstances, the abandonment or sidetracking of the well. Offset well data may indicate where losses may be expected and under what conditions.

Formation Types Associated with Lost Circulation The following formation types are most commonly associated with lost circulation events: Table 1 Formation Types Associated with Lost Circulation Formation Type

Characteristics

Loss Severity

Sandstone

Permeable

Seepage to partial

Sandstone

Highly permeable and/or fractured

Partial to complete

Vugular and/or cavernous

Partial to complete

Impermeable

Partial to complete

Unconsolidated sand Sub-salt rubble Limestone reef Dolomite bed Chalk Shale

Classification of Losses The correct treatment of lost circulation depends on the rate of mud loss and the type of loss zone encountered. Historically we have classified losses based on percentage of fluid pumped. The actual values varied between operators and service companies, but examples include the following: • •

Seepage losses 100 - 200 bph

Thermatek LC**

BDF 562 plus 1 ppb BDF-456

BDF 562

60-80 ppb treatment

N-SQUEEZE

or

or

or

Thermatek LC

Thermatek LC

K-MAX + DUO-SQUEEZE R plus 1 ppb BDF-456

FlexPlug OBM

FlexPlug OBM

or

or

FUSE-IT

FUSE-IT

ThermTek LC

ThermaTek LC

ThermaTek LC

or

or

or

Low Fluid Loss Acid Soluble Cement

High Fluid Loss Cement

Thixotropic Cement

>200 bph

*HYDRO-PLUG NS for PARCOM regulated countries. ** Check temperature limitations.

LCM Classifications Types of LCM typically include the following: • • • •

• •

Non-reactive moderate particle size (NRMPSD) material combinations that can be premixed for stand-by service Non-reactive large particle size (NRLPSD) material combinations that can supplement the (NRMPSD) Reactive Components (RC) used to supplement other combinations Reactive swelling material plus large aspect ratio (20-30) fibers (RSMF) to supplement the NRLPSD material combinations. These combinations will generally be applied open ended or through a treating sub such as a PBL sub. Chemical sealants that react with the drilling fluid (CSDF). Chemical sealants that are stand alone without drilling fluid interaction (CS).

Current Halliburton products that meet these criteria are shown in the following table.

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Baroid Fluids Handbook Lost Circulation

Table 4 LCM Types and Classifications

RMPSD NRLPSD NRLPSD RC CSDF CSDF CSDF CS CS CS

HYDRO-PLUG BDF-551 BDF-562 BDF-tbd FUSE-IT FlexPlug OBM ThermaTek RSP N-SQUEEZE/N-PLEX TermaTek Shear Sensitive Cement

Contains a swelling polymer Bimodal PSD without STEELSEAL combinations Bimodal Large PSD with STEELSEAL combinations swelling polymer plus large aspect ration fiber swelling polymer in non-aqueous carrier(NAC) latex base reacts with OBM ThermaTek materials in NAC. Cross linked polymer metal oxide/salt produces set acid solid plug High gel strength thixotropic cement

1.3.

Engineered Approach to Lost Circulation

Treating the active system with lost circulation material (LCM) is just one step in the process of reducing or eliminating losses.

Casing Point Selection Whenever possible, casing should be set in non-porous formations with high fracture gradients. By setting casing as deep as possible, some formations with higher pore pressures may be drilled safely. A formation of high matrix strength is recognized by one or more of the following: • • •

Reduction in penetration rates Mud logging data MWD logging data

Planning In situations where offset well information indicates a likely encounter with a weak and/or depleted zone, the use of an engineered approach to drilling the zone(s) can help minimize losses, and at times prevent their occurrence completely. This approach incorporates a number of planning tools: • • • • • • •

Borehole stability analysis Equivalent circulating density (ECD) modeling Drilling fluid selection WellSET™ modeling and lost circulation material (LCM) selection Downhole pressure measurement tools Connection flow monitoring Timing of LCM applications

Borehole stability analysis, hydraulics and WellSET modeling are conducted in advance of the actual drilling operations. The results of these investigations influence drilling fluid selection and help identify the most effective types of LCM for each case. Analysis continues as the well is drilled.

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Baroid Fluids Handbook Lost Circulation

Geomechanical Modeling The use of geomechanical modeling in well planning can provide the “safe mud weight window” boundaries for ECD. The static mud weights needed to mechanically stabilize the wellbore are influenced by parameters such as in-situ stress, pore pressure gradients, wellbore orientation, and formation material and strength. Exposure to drilling fluid alters near-wellbore pore pressure, inter-granular stresses and rock strength and can cause progressive wellbore instability. Baroid uses a wellbore stability simulator to evaluate time- dependent mechanical, thermal, and chemical effects. Hydraulic simulations using Baroid’s proprietary DFG hydraulics modeling software can determine projected ECD levels after the mud weight operating windows are identified in the wellbore stability modeling process. Baroid Technical Professionals and Senior Service Leaders typically perform DFG hydraulics modeling.

DFG Hydraulics Modeling and ECD The DFG program accounts for existing fluid properties and drilling parameters such as rate of penetration (ROP), pump rate, pipe rotation speed, wellbore geometries, and hole cleaning efficiency. The user can determine cuttings loading in the wellbore for a given set of conditions and the potential impact on ECD. Pressure-while-drilling (PWD) values transmitted by the downhole pressure measurement tool help verify the ECD modeling done in the planning stage. During drilling operations, DFG modeling can continue to allow the user to optimize fluid properties and hydraulics. The introduction of the DFG RT (real time) drilling simulator in 2004 provided onshore and wellsite personnel with “ahead of the bit” visualizations related to ECD and hole cleaning efficiency. Controlling the ECD as fluid properties and wellbore geometries change is a critical factor in preventing lost circulation.

1.4.

Wellbore Stress Management

Wellbore Stress Management™ service is Halliburton’s engineered solutions which are designed to improve wellbore strength and help reduce drilling non-productive time due to lost circulation. This fully engineered approach requires both unique planning software and unique materials. Planning must include means to prevent lost circulation as well as stop losses.

Prevention of Lost Circulation Conventional loss prevention entails pre-treating the whole system prior to and while drilling permeable formations, or where seepage losses are expected. Sweeps may also be pumped to prevent fracture propagation or reduce risk of wellbore breathing ballooning. In the last decade, prevention of lost circulation by improving wellbore strength has achieved a successful track record. This is accomplished by designing and applying WellSet treatments that increase the hoop stress around the wellbore. The goal of all the WellSet treatments is to increase the “hoop stress” (and thus the wellbore pressure containment ability) in the near wellbore region. While drilling, plugging the pores in a permeable sand and plugging microfractures that create wellbore breathing accomplishes this dynamically.

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Baroid Fluids Handbook Lost Circulation

Once an interval has been drilled, a more robust treatment may be applied to more significantly increase the wellbore strength. Though an over simplification, these treatments may be described as placing a designed particle size distribution particulate treating pill across an interval, and then performing an open hole formation integrity test up to the maximum ECD expected while drilling, casing and cementing that interval. A short fracture (or fractures) is initiated but is plugged immediately by the specially designed particulate treatment (Figure 3) that prevents further pressure and fluid transmission to the fracture tip, while at the same time mechanically propping the fracture to prevent closure. This action increases the hoop stresses around the wellbore, resulting in a strengthened wellbore that can contain a higher fluid pressure (ECD). Figure 3 Wellbore Strengthening Dynamics

This generally is done by using correctly sized resilient graphitic carbon (e.g., STEELSEAL lost circulation material) and ground marble (e.g., BARACARB 600 bridging agent). Chemical lost circulation treatments that form a deformable, viscous and cohesive material (e.g., FlexPlug sealant) may also have the ability to improve the wellbore pressure containment as long as they can increase compressive stress at the fracture face.

Hydraulics and ECD Modeling Hydraulic design simulations can be initiated using the DFG hydraulics module to help determine projected ECD levels when the mud weight operating windows have been identified in the wellbore stability modeling process. The principal factors in wellbore hydraulic predictions include: • • • • •

Pump rate Hole and drill pipe geometry Hole cleaning efficiency Rate of penetration Drill pipe rotation speed

To help obtain ECD predictions within a window of acceptability, operating ranges of each of these major factors should be determined. Hence, the simulation process can be quite lengthy. However, with fine-tuning, the iterative process can produce ECD predictions that can be used with some confidence.

Fracture Modeling Once the ECDs have been predicted over intervals of interest, another module within DFG can be used to predict a fracture geometry that may be initiated during the well construction process. To do this modeling, the rock elastic properties of Poisson’s Ratio (PR) and Young’s Modulus (YM) must be known, or at least estimated. Other input parameters for the model are borehole diameter (BD), mud weight (MW), depth, stresses, and a short fracture length. The fracture width calculated will be dependent on fracture length. Fracture length is possibly determined by fracture toughness based on fracture mechanics theories, as discussed in a previous paper. Rock mechanics theory

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Baroid Fluids Handbook Lost Circulation

also predicts that near wellbore stresses dissipate past a few wellbore radii, so fracture lengths can be selected as the borehole diameter. A general length of 6 inches is a good default value. An example data set is shown in Table 5. Table 5 Wellbore Strengthening Example Data Set Model Parameters

Drilling Fluid Properties

Hole Diameter = 12.25

Mud Weight = 1.74 SG

Fracture length = 6 inches

OWR = 80/20

Mud Weight =1.74 SG

IO base oil

Depth = 3050m TVD

Average specific gravity of solids = 4.0

Horizontal Stress = 476 bar

Water phase salinity of calcium chloride = 200g/l

Poisson’s Ratio = 0.33

Rheology

Young’s Modulus = 102040 bar

600 rpm = 83 300 rpm = 53 200 rpm = 42 100 rpm = 30 6 rpm = 12 3 rpm = 11

Solids Control

API 120 Shaker Screens

These data are input into the module and a fracture width is calculated (Figure 4). Figure 4 Screen Shot of WellSET Treatment Design Module

Based on this fracture width, the model can select the proper types and sizes of materials to plug the initiated fracture. These materials generally are selected from a full range of specialized resilient graphitic carbon and ground marble products (Table 6), with d50s ranging between 5 and 1300 microns.

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Baroid Fluids Handbook Lost Circulation

Table 6 Specialty Particulate Materials Material

D10 microns

D50 microns

D90 microns

BARACARB 1200

300

1200

1489

STEELSEAL 1000

604

1000

1539

BARACARB 600

515

600

1125

STEELSEAL 400

270

400

744

BARACARB 150

70

150

325

BAROFIBRE O

19

90

298

STEELSEAL 100

12

100

182

STEELSEAL 50

12

50

108

BARACARB 50

3

50

125

BARACARB 25

1

25

63

BARACARB 5

1

5

18

An example model solution output is shown in Figure 5. The d10, d50 and d90 of the solution is given, along with a composite curve showing the particle size distribution (PSD) of the mixture of materials as well as the PSD curves for the individual components. In addition, a cumulative curve is shown from which you can determine the volume of materials in the mixture that lies below that micron size by simply placing a cursor at any point along the curve. Figure 5 Example Material Selection and Particle Size Distribution Solution

BARACARB 150 BARACARB 600 STEELSEAL

3

35 kg/m 3 35 kg/m 3 70 kg/m

A number of engineering scenarios can be evaluated during the planning phase for implementation during the well construction phase. These may be a pretreatment of the entire system (Figure 6) to manage seepage and wellbore breathing issues. Figure 6 Pretreatment Option for Entire Drilling Fluid System

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Baroid Fluids Handbook Lost Circulation

A sweep treatment using larger particles or potential fracture initiation in problem zones (Figure 7). Figure 7 Sweep Option for Drilling Fluid System

A treating pill can be placed across the problem interval for a borehole stress treatment and/or prior to running casing and cementing (Figure 8). Figure 8 Open Hole FIT Option– WellSET Treatment

Also shown in these examples is the consideration that is given to what amount of material will be lost from the active system based on solids control screen size.

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Baroid Fluids Handbook Lost Circulation

Rheology Prediction for Invert Emulsion Fluids after the Addition of LCM A hydraulically valid model with the resultant viscosity predicting algorithms has been developed for lost circulation material (LCM) addition to invert emulsion drilling fluids (Figure 9). Figure 9 Rheology Prediction Model Screen Shot

Though it does not mimic perfectly the measured performance of all product additions at all concentrations, there is adequate data to support the model. Thus, rheology predictions can be made for LCM additions to invert emulsion drilling fluids with sufficient accuracy that minimize error on ECD predictions (Figure 10). Figure 10 Effect of LCM Addition on Rheology

Mixed Products Viscosity Prediction vs Measured Data

Dial Reading

100 90

Predicted Rheology after LCM addition 12.0 ppg Base SBM,

80

Measured Rheology after 16 LCM addition 20 lb/bbl BAROCARB, BDF 398, 10 BAROFIBRE

70

Predicted 20 lb/bblofBAROCARB, 16SBM BDF 398, 10 BAROFIBRE Measured Rheology 1.45 SG Base

60 50 40 30

3

BARACARB® 50 GM – 57kg/m 3 BDF-398 RGC – 45 kg/m 3 BAROFIBRE SF fiber – 28 kg/m

20 10 0 0

100

200

300

400

500

600

RPM The measurement of drilling fluid rheology for fluids that contain LCM is difficult, and sometimes impossible, with a standard bob and sleeve rheometer due to the interference of the particles with the rotation of the sleeve in

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Baroid Fluids Handbook Lost Circulation

the narrow annular gap. The use of a different bob and sleeve with a larger annular gap is likewise problematic since the fundamental assumption of a constant shear rate across the gap is no longer valid. Consequently, the development of a predictive model would not only make the rheology determination easier and more efficient, but it also is likely to be more accurate.

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Baroid Fluids Handbook Lost Circulation

1.5.

Treatment Guideline Reference Tables

Less than 10 bph Preventive or 200 bph or total Within reservoir Permeable Requires cement pumping equipment

Formulation

Not applicable

ThermaTek RSP or LC; Low fluid loss “acid soluble” cement

Underground Blowout Formulation

Total concentration

Underground blowout FUSE-IT or FlexPlug + Thixotropic cement

Requires cement pumping equipment

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