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This paper was prepared for presentation at the AADE 2002 Technology Conference “Drilling & Completion Fluids and Waste Management”, held at the Radisson Astrodome, Houston, Texas, April 2 - 3,
2002 in Houston, Texas. This conference was hosted by the Houston Chapter of the American Association of Drilling Engineers. The information presented in this paper does not reflect any position,
claim or endorsement made or implied by the American Association of Drilling Engineers, their officers or members. Questions concerning the content of this paper should be directed to the individuals
listed as author/s of this work.
Performance improvement was the target of this subsequently lead to total loss of returns. Severity of the
proposal to the operator, with the performance losses varies from block to block due to the variation in
improvements being directed not at the drilling fluid, but formation integrity common to the HMD field and the
the large gap existing between conventional LCM and mechanical forces applied while drilling each section.
cement squeezes for severe loss of circulation. The The above scenario was encountered numerous
CACP proposed to the operator had the following times in the HMD field while drilling the troublesome
properties. sections. It must be stated that changing the casing
1. A simple fluid that can be pumped through the design is not an option. If the 7-in. casing is set higher,
bit and bottomhole assembly (BHA). the situation becomes worse due to the resulting
2. Adjustable particle-size distribution to fit reservoir depletion which leads to a greater pressure
formation specific requirements (squeezable into transition problem. Establishing a link between the TAG
micro-size fractures). and Cambrian (reservoir section) formations is not an
3. Forms a semi-ridged gel structure as a filling appropriate completion strategy for the wells.
material for the loss zone. Numerous attempts had been made to attack the
A time breakdown was conducted on a number of sub-salt thief zone using different solutions suggested by
offset wells in the HMD field. The results of this analysis cement and drilling fluids companies. Results varied
suggested that if the sub-salt lost circulation problems from total failure to partial success The most common
could be eliminated, a drastic enhancement of the practice to cure the massive losses on the offset wells
drilling performance was possible. The following was to spot and squeeze cement into the induced
example illustrates the time and cost benefits available fractures. The aim of the cement squeeze was to
through eliminating the non-productive time (NPT) reconsolidate the formation to allow drilling to continue
associated with the sub-salt losses. without further losses. Depending on the severity of the
If HMD field developed with an average of 25 wells losses, this process often had to be repeated several
per year, the following savings would be realized. times on some wells. Prior to application of the CACP,
• Average 49 days per well no other remedy was able to satisfactorily solve the fluid
• Average 3 cement plugs per well loss problem.
• 2.0 days lost per plug
• Total NPT = 150 days Sub-Salt Lost Circulation
• 3.06 additional wells could be drilled Drilling through salt formations can be troublesome
• Over all performance could be improved by, for a number of reasons. Typically, the formations
3.06 / 25 = 12.2 % immediately below the salt are either mechanically
• 12.2 % possible additional production. weaker or fractured, introducing a greater risk for loss of
The CACP technique was proposed as a lost returns. The lost time treating severe sub-salt losses can
circulation solution in the TAG formation with the specific be up to several weeks, with obvious cost implications,
requirements to cure losses with maximum possible especially for deepwater drilling operations. Though not
sealing efficiency and increase formation integrity across the case in the extensively developed HMD field, often
the weak sections. Additionally, the process of applying on exploration wells, little information regarding pore
the CACP was to involve less time than that currently pressure and fracture gradient is available. Gulf of
associated with applying the cement squeezes. The new Mexico sub-salt wells often encounter higher pore
technique was applied successfully, sealing the TAG pressures below the salt, creating challenging well
formation without any lost tripping time, and allowing control issues. In this instance, the higher mud weights
drilling to continue with no further losses. required to balance the pore pressure place even
2
greater stress on the weakened sub-salt formations. In
Problem Overview the case of the HMD field, the pore pressure, and
The following section describes the typical formation subsequent required mud weight, was significantly lower
properties and drilling conditions for a HMD well. The than that required in the actual salt formation. As such,
sub-salt sections are typically drilled with 1.98 – 2.1 sg the formations directly below the salt are drilled in a high
(16.5 to 17.5 lb/gal) salt-saturated mud system. The over-balance environment.
higher mud density is required for the Jurassic Dogger, Losses in the formations directly below the thick salt
3
LIAS, and Trias-Salifere, which require typical pressures zones are typically severe, ranging from 16 m /hr (100
of 10,000 psi to maintain over-balance (Fig. 1). Once the bbl/hr) up to total loss of returns and the inability to
Trias Argileux has been penetrated, a pressure maintain a full annulus. A wide variety of lost circulation
reduction is encountered. This interval contains weak materials (LCM) have been applied in sub-salt thief
formations, highlighted in Fig. 1 and Fig. 2, which are zones, in an effort to control losses. Pills containing
readily broken down by the high hydrostatic pressure in sized solids, gunk squeezes, conventional cement
the annulus. The mechanically induced fractures squeezes, and foamed cement have all been proposed
as solutions to sub-salt lost circulation. While the cement
AADE-02-DFWM-HO-30 LOST CIRCULATION SOLUTIONS FOR SEVERE SUB-SALT THIEF ZONES 3
squeezes were able to reduce losses in the HMD field, rapidly and become effective as soon as possible. The
the associated non-productive time remained a costly CACP involved minimal downtime between the onset of
factor. the losses and placement of the pill across the loss
zone.
Chemically Activated Crosslinking Pill In order to minimize the potential for stuck pipe, the
The CACP proposed for the sub-salt lost circulation safest practice after pumping the pill required pulling the
problem in the HMD field is a blend of crosslinking drillstring above the high-pressure formation (TS#2)
polymers and fibrous material. The material was immediately after placing the pill across the loss zone. If
designed to plug deep fractures, faults and vugular the borehole did collapse due to reduced annular
1
formations. The material can be blended with a pressure being insufficient to support the borehole, any
biopolymer to enhance the viscosity of the material to potential for stuck pipe would be reduced. Typically,
suspend barite while pumping. The crosslinking process 9000-psi equivalent fluid density is required to stabilize
is chemically activated. After setting, the material forms the formation. Once the string is located above the loss
a firm, rubbery, ductile plug in the fractures and voids zone, the CACP is squeezed into the induced fractures
that it has been squeezed into, preventing further loss of to reconsolidate the section and allow drilling to
fluid. continue. The operation can be repeated to seal
The CACP can be mixed in freshwater, seawater additional weak zones that may be encountered drilling
and saltwater and applied in wells drilled with water- to interval TD.
based, oil-based and synthetic-based mud systems. One
major advantage of the CACP is that it can be pre-mixed Pill Design and Planning
ahead of time. This allowed for significant time savings The well that was selected to apply the first CACP
on the HMD field. The anticipated volume of CACP lost circulation pill was located in one of the most
required was pre-mixed and kept on standby. When challenging blocks in HMD field. This scenario provided
drilling below the salt formation, once severe losses an opportunity to aggressively test the approach against
were encountered, the crosslinking agent was added to severe loss conditions and a high level of borehole
the pill and the CACP was immediately pumped into the instability.
thief zone. Though not necessary, the CACP can be The section to be drilled would require a 2.02 sg
used to cure losses and at the same time shut off zones (16.9 lb/gal) salt-saturated mud system. It would be
producing water or gas. This would suggest that the necessary for the CACP to be designed with
CACP might be an ideal material for attacking Gulf of consideration for the following surface and downhole
Mexico sub-salt thief zones. conditions;
Variations of the CACP are available that can be • The effect of high concentrations of barite on
tailored to specific applications. Depending on the both the slurry rheology and thickening time
formation properties and the characteristics of the loss • The compatibility of the CACP with the mud
zone, higher polymer loadings can be selected, higher system when drilling through the plug
fiber loading, or a CACP with coarse calcium carbonate • The effect of formation salt contamination while
can be used. The CACP is not recommended for pumping and squeezing the pill
producing zones as the material does not degrade and is • Mixing time and temperature effects
not acid soluble. The slurry design was based on 90 minutes
pumping time and a total of 5 hours setting time, which
Risk Assessment would be sufficient to allow for mixing, pumping,
The proposal developed to counter the chronic lost squeezing and pulling the drillstring above the pill to
circulation problems in the HMD field had not previously 3000-meters (9834-ft) measured depth. Fig. 3 illustrates
been proven in this type of situation. As such, the the rapid increase in the viscosity of the material 90
potential risks were identified and reviewed in the minutes after crosslinking has been initiated.
context of applying the CACP once losses occurred.
Since the pressure profile for the open-hole section Spotting Procedure
is very complicated with a large pressure reduction and Based on the potential risks and the pill design
weak formations, there is always potential for wellbore criteria, a spotting and squeeze procedure was designed
instability to develop once formation losses occur. The that would minimize any operational risks. For the initial
massive losses that occur can reduce the annular 3
trial, 8 m (50 bbl) of the CACP was mixed prior to
hydrostatic pressure to levels that cannot support the drilling into the trouble zone. Once the thief zone had
upper sections of the wellbore, introducing the potential been drilled into and only if losses occurred, the
for borehole collapse. Once loss of returns has occurred, following procedure was utilized. Fig. 4 provides an
any delay in curing the losses introduces the risk of illustration of the stages involved with spotting and
losing the well. For this reason, it was imperative to squeezing the CACP.
develop a lost circulation solution that could be deployed
4 M. FERRAS, M. GALAL, and D. POWER AADE-02-DFWM-HO-30
Argileux
JURASSIQUE
Dogger
Lagunaire
L.D.1
L.D.2 Dolomite, Marl Pressurized formation.
LIAS
High volume water influx.
S#1
S#2 Salt, Very high-pressure zone.
Anhydride
Potential risk of stuck pipe
Shale
Salifere intercalation if mud level (pressure)
drops in the annulus.
TRIAS
fine sand
Gres d’EL Atchane
Argile D’El Gassi
RI
CAMBRIAN
Ra
R2 Set 7-in. casing shoe 3-4
R3 to meters into Cambrian
SALIFERE
L L L Massive
TRIAS
L Salt
Salt
G1 Reddish Bowen
0 L L L Shale
L SALIFERE
G20
L L L Shale (colored)
TRIAS ARGILEUX
Upper
L SALIFERE
G30
Anhydride,
Dolomitic
G35 Shale
G40 Sandstone
Dolomitic
Medium
Shale, Marl
G50
BRUN Shale
GRESEUX
VF SandStone
G60
TRIAS
Black Shale
G70 Lime Stone
Lower
(Colored)
B A A - Cambrian
B - Andesite
CAMBRO
G10 = Top of Trias Argileux
G20 = Seismic marker
G35 = Last salt marker
G40 = first sand marker
40
3 r pm
35
6 r pm
10 se c G el
Fa nn 35 D ial R e ading (lb /10 0 f t
30
10 m in G el
25
20
15
10
0
0 1 2 3
T im e sin c e C r os s lin ke r a d de d (h r )
Fig. 3 - Comparative rheology profile for CACP after crosslinker has been added and while hot
rolling at 86°C. After 3 hr, the samples were too thick to be measured.
Fig 4 - Spotting and Squeezing Procedure for CACP in TAG formation. When the bit is below the salt and in
the TAG formation, if and only if there is a loss of returns, the bit is picked up to a position above the thief zone
(above the TAG and TS2 formations), the CACP is displaced from the drill string and squeezed into the loss zone
with the annular preventers closed. At this point, pressure is held on the pill for several hours. After the pill has set,
the plug can be drilled/reamed through and drilling can recommence.