SPE/lADC

SP31ADC 16082

Lwt Circulation: A Solution I?ased on the Problem

by J.F. Gockel, C.E. Gockel,’ and M. Brinemann, Agri-Systems of Texas Inc.
— ‘ SPE Member

COW+! 1S67 7PEAAOC w67 D@mq c.antemnca

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q Cc.nwscws and are auojact 10 cwmcwn oy ma auawst T* mareriti aa pmaantsd 00ss not necessamq retwd any psmcm 01 ths IAOC oi
SPE Its otbcars w MSMOW$ twain weznnled s! SPEMfZC msalmes we sub+acl 10 0UM*811WI by EOIWJUI Cammt!ws cd I* IAOC ●nd SPE P&.
mtssnm !0 * ,s reslri$teO 10 an eosoacl ot no! more nun ZCOwords Illustmtmv may W W mwd The abslmcl SROuklCOM*,. CO*@us SC
WOW+SOOman! of We and DV- UIUO&WIa wa$erm.j Wrte PulxIcatwIs ManaQw SPE P O do%SZZS?& RICMIKZSOII1 X 750S3 2S3S Telex
7SOkWS~PE OAL

AaelltAcT this method can be effect ive. it has inherent weak

neaaea.
Lost circu]atlon requiring positive treatment ran
be.$t be solved by using aaterlal$ similar in strur Where the materials used for control 1 ing lost cir-
tura to tbe forntlon involved . Use of a vltrl - culation have less structural integrity than is
fled. ●ineral -based granular ■aterl:l 1s best $ul - common to a co-pet ent format ion. the LW=SI produced
ted to thig purpose beraua? of lts wide range of wi ii aiways be potentially brearhabie TO create

arplicabillty and the unique features which this an effect Ive and permanent seal. the uae of n sat -
type of processing produces. erlal with sisilar structural strength is desira -
bie.

IfdTRoeucTIow A group of mateTiala kn6Wn coilertively sri expan

tted aggregates are capable of providing bridges of
Lost circulation is estimated by so-e nuthoritles the reqnjred strength Artditlonaily. the other in-
to affect up to 75% of all wells drilled Al- h-rent charac+erist Irs of theqe ●arerlal$ add use.
thowgh It ia a problem which has existed since the fui tools to the armory of the drilling rnglneer
inception of rotary drill lng. solutions have hp-n and thove wnrking wl~h lost circulation problemq
few. and pal 1 Itrt .ves barely adequst e The deslr on slto
able solution to lost circulation IS to prevent it.
or falling that. to stop it pei fianent Iy when lt
doPs occur. LOST CIRCULATION - AN OYERYISW OQ T4fNtITIORAL
~.
A common ●lsconcept ion concerning the prnbabl 1 it y
of the occurrence of lost circulation is baspd in Lost cirruiat ion is the result of drilllng through
the idea that if the mud wt=lght doea not exceed the a foraat ion with less Intrinalc pressure than is
fracture presqure of a given zone. no loss is llk*- being created in the wellbore: ss elsewhere in na-
lY to occur Thjs is not thp case if a subnormal IY t ure. the pressure dlfferpnt ials attempt to equal-
presqured zone is encount erwl. Sub normal pressure ize. With the exception of the piastic forma tjnns
zones can oecwr net ural lY, or cm be the reaitlt Of encountered In off-shore drill lng. all lost circu -
product Ion deplet ion of a zon~ In either caae. I at lon occurs in competent format lona These inc -
the fracture gradient can be nor -nal . but the pore Iude sand and grave I zones. fractured rock ranging
pressure is not capable of withstanding the dynamic from 1 imeatone through granite. and vugwlar forma.
pressure generated by the cl rculat ing mud. t ions.

Once Ioat circulat ion has occurred. the prevalent In tlw early days of rotory dr “lng. the relat:’/e-
methods use fJexible and/or frangible materials in ly shallow wells encounterefl lost circulation pro-
combination with drilling fluid, other speciaity blems which could be brouf’ t under cent rol by the
fluids, or ce=ent aiurriea: the concept being that uae of simple organic rtai’t products. such aa cot -
t heae product a wi 11 conform to the porous forsa - ton gin trash. straw. ‘td ot~ @r, similar ●aterials.
t ion’s interat ices, and eventwal lY build up a dense Although theee waate8 .Fere rather in? fflcient. they
barrier adequate to stop the fluld loss Whlie had the advantage of beii.g avaj lable in large quan-
tities. at sinimal cost olven time and care,

.
 WE140824
-, ---- -—
of the hole simply create plaques which will alwst
they worked wel 1 enough to be cono Idered solut Ions.
certainly be jarred loose when rot at ion is resu~d.
*he pressure different lals were usual 1 y minor.

The sost desirable ●ffect to be obtained from a

As is the case with many terhnologles. lost clrcu -
lost cJrculat Ion addlt ive is a shallow. permanent
JaI ion arhtltives developed along the llnes indica-
bridge. which will atop fluid losses. yet respond
ted by the early experiences with the probl*m
to perforating should production need to be at-
Other organic lost circulation ●aterials were de-
tempted In the zone ai a later tlw
veloped which were ● ore .?ffec: Ive. faster. and less
detrimental to :he ●ud ayatem Organic ●aterials
The types of lost circulat ion under d~acusslo. take
are Clexible to varying degr~es. and are subject to
place in porous formations In ●atrices of hard ●at-
degradnt ion from abvaaion. rotting, or h!gh t?mpe--
eria)s A basic principle of bridging jn moot en-
ature% Since these saterlals both ab- and adso.”b
gltv-::!ng di$clpllnes recognizes the Importance of
tb- llqu16 portion of the drill ini fluid. :rtey ra?
Wsi;,g structural ly zl~l]ar ●ateria]s to achieve the
make si~nifirant chang~s in t h? rht=o Io.qy of t h.=
br 1 dge Reinforcing concrete in a dza with corn-
mud: t ‘,ey can alao createa chemical inccmpat ibll 1-
cobs would not be ronaldered pract Ical or desira-
t]**
ble Vi,. tually all products used for lo$t circu-
lat ion have less at ructural strength than the form-
I n this same develcwent al phase. varlova lnorganlr
ation In which they are to be uted The rea80n
materials were tegted, and found to have soae ut 11-
this has been the case is that appropriate bridging
lty in lost rircu]at ion problems These product a
●aterials have not been considered. except for
also had negative characteristics: ●lnerai products
often have a chemical makeup rthich conflicts with
tho8e who could all- sollds to build up in the ●ud
systea, particularly tthen the potential problem is
the rheologlcal properties of th~ drilllng fluid.
seep loaa.
Others are fragile, breaking und?r prpsaire. and
threatening the integrity of the any seal created
In modern drilling. where wells are being developed
In Increasingly harsh environments. at greater
Over the hlatory of rotary drll 1 lng, nrarly every
depths, higher temperatures, in areaa with unknown
pnsslble waste aate?ial encountered was given *ome
potential. the so=et Ime$ haphazard prac: icc ? coa -
consideratjun aa n lost circulation additive. some
● on to the paat wi 1 I no longer be adeou~te.
of the experlment$ are not suitable for general
pwb] Ir dlacuaaion; the nature of the ●aterials used
Due In great part to the booa createt by high pet-
shows considerable rreat Ive effort . bt. t reportedly
roleua prices, and the rush to produce to aeet de-
created shortages rlatrisental to thr general we) -
aand , the teedit lanai praet ices ttera beoagttt for-
fare of the local area
ward wjth little modification. Now that the drtll -
Ing environment haa changed again. ef f iclent and
The days of the simple on-81te experlsent have
econo-teal ●ethods srhlch save time on locat jon,
given way to high technology. polyaers are coming
onto the srene in various form, and the burgeoning
●aterials used. and prowote trouble-free drl lling
are ●uch needed.
industry which finds new uses for varioua types of
lndnstrial waste brlnga a new product into being
These j a another considerate Ion which makes a sim-
every few wePka There la no lack of hopvt ii ven-
ple. effective procedure *or lost circulation desi-
dors. seeking markets for yet another 10! t clrru.
rable: no ●atter how sophisticated the well plan
lation ●aterial.
nay be. the actual operation 1s often handled on-

so far, very few of the commercial or experimental

slte on an esergency basis. using whatever ●ater -

produc*q available for lost circulation havp ad-

ials and ●ethods are at hand. Further, the differ-

dressed the funrlament~l nature of the problem

ence In the ●et hod planned and the method used may
be considerable. as anyone with even minimal ?xper -
It-nce can testify.
Almost anything can he uspd to arhieve a plug in a
porous furmat ion, given enough pressure. and proper
part lrl P sizes or propert Iea WhethPr the plug
wII 1 remain in plarr under the stresses nf resumed EXPAWOEO AGGREGATES

rotation. v]hrat ion. and pressure. is another mat-

ter The general deaignat ion “expanded aggregates’ . des -
cclbes a group of materiala produced by a similar
technique for various purposes Aggregate are
One coamon effect of lost circulation treatment is
to puqh great volumes of LCM Into the foraat ion ●ade from several types of clay-bearing aoile. or
from shale or slate.
The inatanrea where LCM and replacement ●ud pro-
durts ate re-supplied to a well experiencing lost
The clay-bearing soils are mined while at field ca-
cjrcu]at ion In nultjp]e truckloads are leglrm:
pacit y (wit h conate water present ), crushed. and
these
euasion
stories
that
are
takea
the
place
core of
emtrerning
every informal
lost cirewJa-
dia -
put t hr&gh rot&Y ki lna 8$ tempa~atures r~lw —
froa 800 F (427 C) to 1800 F ($02 C). They are
tion These cat ast rophea occur when t h? ●ateria 1s
then screened into the appropriate size categories
being used do no pos.sesa adeqoat e structural
for the intended uae, and atockpl led. The process-
strength to create a competent bridge, and are de-
so that they are ●oved fur- ing and grading can produce part Icles ranging In
formed or broken down,
size froa one lnrb in diaaeter. to those passing a
ther and further into the format ion by -1 lbore
$400 screen. For the purpose of usual lost CI rcu-
pressure. This effect guarantees that should there
te potential production capability from the for*a -
Iat Ion pract ice, all ■aterial passes a ●IO screen.

tion in question, it will be virtually impossible

What la created by this proceo$ Ia a porous. vitri-
to tap It. Materials which plate off on the wall
fled Inorganic aaterial which is a product of the
—- --- —
—
 SPE16082~
basic
erlals
structure
have a pla.
of these
--llke
soils
structure
All
in
of
their
these
Ilative
●at-
CASE

1.
STUDIES

Stuck pjpe was experienced after lost circu-

I
state When they .we fired, the :onate water @X- lation wkiie3drilllng tit 6500 ft (19$1 s)with 10
ploci.os the particle rather 1 Ike ptpcorn: the heat PPg (li92 k/= ) mud wejknt. Drilling waa “~tt@*Pt “d
vitrlt lea the expanded part .cle w:th some of th+? with 9 B ppg (1174 k/Q3) ●vd after successful
result ing pores be~ng sealed. a.ld some left opm; f lshing operat i on-; I?st circulat ion recurred
mny of these !atter Interconnect All particles Varioua ]oat circu]at 10IJ product ~were pumped with-
pt educed by tJ . protest, of whatever S1 ZP. have out success A 50 N.] (7.9 R ) p~l of expanded
the same charhcter}$t Ic$. agZregate ●ixed at ]5 ppb (42. 75 kg/m ) was spotted
and the hole was al lowed to heal for 2 bouq$.
The vitrification pioduces an Interesting anomaly: Drilling was reeumrd with 10 ppg mud (28.5 kg/B” }
while the part IcI-s surface-wet both Inside and withou- incident to tht. next casing seat
out . no fluid la abaorbed. In the real sense
There Is drilling fluid. rot ●erely filtrate. with - 2. Lost circulation was experienced in an air/mist
In and outside of the part jclv; only a minor degree ueil Ail attempts to regain returns failed, in-
of adaorpt ion takes place Tbla effect re$ults In cltfding mudding up nnd ●ixin3! ~mwktifjnltl fl~r
the material’a having only the moat limited reac ano flake ●aterial A 100 barrel (i5.13 ● ) Pill of
tlon with the fluid It sugpenda in ●ost medium- exp~nded aggregate was ■ixed In 8 .5 ppg (ioi8 s
to lightweight fluids. having neutral buoyancy in k/m ) fl~,ld and spotted at total depth. Circula-
such ●nvi ronment $ Addltlonaliy. :he proceaa im - t ion waa regained, the aystes converted back to
parta a compreaaive strength which rangea up to air/siat and the hole continued to total depth.
3000 pal (206s2 kPa): providing virtual Iaaunity t~
t herma degradat ion at temperatures exceeding 1000 3 Loat circulat Ion occurred while drilling O\t
i
F (53s c). below the casi.~g shoe with ii .0 ppg (131f! kh )
mud. An attempt to squeeze the casing shoe P I): ?d,
Expand?d aggregate are both hydrophi i ic and 01 Io - filled repeatedly wi$h 9.3 ppg
philic; they w1l! uptake whichever fluid they ftrst ~~i~h~/#~&n? A 200 barrel f15.8 ● ) pill of
encounter, and are approximately equa] ly effect ive expanded aggregate was epot ted at the shoe and the
In oil- or water-baaed f iuida Additionally. they hoJe allowed to h?al The shoe was swcresaful IY
are largely chemically !mrt . making few chang~s in re-ceaented and dri 11 ing was resuzed
rheology Aggregates may be removed fros the sud
ayat e, wit h the at andard shaker acrs-ena and hydro 4. Lost ret urns and subsequent parker teat ing in-
cyc lonea present on t ha rig. They present no env i - dicated a bole in tkte casing at 1000 ft (304.8 a).
ronaent al or personal hazard. Cemmt ~tt.ezes were not ef feet lve A 10 barrel
(31 8 ● ) pijl of expanded aggregate nixed at 15
There is a sub-cat-gory of aggregate. ■ade from ppb (42 ‘f kim ) waa diuplared into the hole at 1000
Fuller’s earth, whirh known as calcined clay, and ft (305 ●)and the zone allowed to heal After
1s faailiar aa the product used to absorb splll~d staging in thr hole and regaining full returns. the
oil. or as a cat box fiJler This particular clasa hole In the casing was squeezed successfully and
of aggregates has potential utility in drliiing. as dri J ling cent inued to the next casing depth.
it has good character iatica as a lost cIrculat inn
addit ive. and builds wail cake. It is not the pri 5 Normal drilling through a wctlon of the Hi9-
nary material under conaiderat Ion, however, and slsstppian foraat ion in Gat#ield Co. . Oklaho*a re-
will not be ●ent ioned further In this discussion quired 18 pph (S1 3 kja ) of convent ional l~t
circulation saterial ●ixed in 8 3 ppg (99S k/a )
The only ne+gat ive chararterist ics demonst ratewt by drilling fluld One operator repot$ed dri 11 ing
the aggregates are functions of rh-ir strmrgths, in through the sert ion with 6 prb \17. i k/m’ ) -xpanded
the literal sense While the material is graded. aggregate and io Ppb 128 ~ ki~ ) eott On seed hulls
it createa exceptionally strong hridge$. With this ●ixed in 9 1 ppg 11G91 k,m ) rlrllling fluid without
bridging capacity, it la prudent to use the aggre losing returns.
gate in ten to flft Pen pounds per barrel COiICeIItrd -
tlons, or leas Becauae the material is so effi 6. In south Louiaiann the ““lfe t”’ line was penetra-
cient . this concentration la adequate to stop the ted using expanded aggregat~ as the lost clrcuia -
10ss In any case; hlght=r concent rat ions are not t ion treatment Drl 11 ing progreaaed withont inci-
useful, and wi 1 i ●erely be reclaimed on the shaker dent 200 ft {61 s) into the zone using the 250
screens. The aggregat ea have the potential to plug sacks of expanded aggregate on Iocat ion ttlth no
the bit if too ●any part iclea reach the sane addit ional aggregat * available. the balance Of
orifice simultaneously. For this rt=aaon. the total drilling was hampered by lost circulation problems
quantity of ■aterial to be used should b- mnni and the use of convent Ional ●aterial wa$ marginal iy
tore.d. and the aggregatea should be mixed into the anccessful A “gunk squeeze” and controlled drill-
drilling fluid prior to application, in order to ing with partial returna permitted the well to
avoid this type of problem reach the next eaaing point.

in the cases to be cited. one $peclflc clay aggre- Calculation of the quantities of material used in
gate was used, and Ita characteristics will be de- the above exa-pica is instructive in noting the
tailed for the purposes of this discussion The efficiency of the material tested.
material should not be asattaed to be typical . nor
to
eirculatjon
be the =ost
addit!ve
desirable
It
choice
la cited
for
as
uae
the
as
original
a lost
I COf4CLUSILMt8
I
test and trial ●odel Expanded aggregate, used aa a lozt circulation ad-
dit ive, posseaaes aigni f i cant advantages over t ra-

291
COllCLUSIti,

Expanded aggreget e. used as a lost circulation ad-

ditive, possesses slgnlflcant adwntcges over tra-
ditional materials The factors of high compres-
sive str?ngth. superior efficiency, lark of theo-
logical than, e, t ,Iermal tolerance and the rapid re-
solution o? “Iuid 10 SSI?S ■ake the ●aterial desira-
ble for use in all dri IIing operat ions where lost
circulation is experienced

-NcLATURS

Expirrw ed aggregate a thermal lY treated, porous,

ainerll mater it’ with applications in lost
circulation crwrtr. i