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Prior Art
US 2010/0230164 A1 Sep. 16, 2010
COMPOSITIONS AND METHODS FOR based drilling fluids can be comprised entirely of oil, or more
INHIBITING LOST CIRCULATION DURING commonly, may contain water ranging in concentration from
WELL OPERATION 10% up to 50%. In such a mixed oil and water system, water
becomes the internal phase and is emulsified into the oil such
RELATED APPLICATION that the oil becomes the external phase.
0001. This application is a continuation-in-part of U.S. 0008 Drilling fluids can have a number of functions
patent application Ser. No. 12/402,993 filed Mar. 12, 2009. including lubricating the drilling tool and drill pipe which
carries the tool, providing a medium for removing formation
FIELD OF THE INVENTION cuttings from the well, counterbalancing formation pressures
to prevent the inflow of gas, oil or water from permeable or
0002 Drilling fluid additive compositions are provided porous formations which may be encountered at various lev
for use with synthetic, oil based, or water based drilling fluids. els as drilling continues, preventing the loss of drilling fluids
The combined additive and drilling fluid are effective for into permeable or porous formations, and holding the drill
reducing lost circulation, seepage loss as well as wellbore cuttings in Suspension in the event of a shutdown in the
strengthening and/or wellbore lining. The method includes drilling and pumping of the drilling mud. Drilling fluid addi
injecting the drilling fluid and 0.01 or more pounds per barrel tives can also form thin, low permeability filter cakes that can
of a loss control additive including ground and sized pumice, seal openings in the formation penetrated by the bit and/or act
barite, dolomite or anthracite coal dust. In addition, sized to reduce the unwanted influx of fluids and/or the loss of the
additives are effective as proppants in various formations. drilling fluids to a permeable formation. A filter cake forms
when the drilling fluid contains particles that are approxi
BACKGROUND OF THE INVENTION mately the same size as the pore openings in the formation
0003 Boreholes created in the earth for extraction of min being drilled. A filter cake is an integral component of well
eral deposits such as oil and gas pass through numerous and bore strengthening.
varied geologic formations. These geologic formations have 0009 For a drilling fluid to perform the desired functions
varied properties including numerous chemical and mechani and allow drilling activities to continue, the drilling fluid must
cal properties such as permeability, porosity, pore fluids, remain in the borehole. Frequently, undesirable formation
internal pore pressures, etc. Each of these properties are con conditions are encountered in which substantial amounts, or
sidered to some degree in the design and implementation of a in Some cases, practically all of the drilling fluid may be lost
drilling program. For example, material properties of the to the formation. Drilling fluid can leave the borehole through
formation that affect well design include compressive large or Small fissures, or fractures in the formation orthrough
strength, tensile strength, fracture initiation and propagation a highly porous rock matrix Surrounding the borehole.
limits, porosity, Young's elastic modulus, Poisson ratio and 0010. Because fluid loss is a common occurrence in drill
bulk modulus. ing operations, drilling fluids are typically formulated to
0004 Significant variations in formation pressures and intentionally seal porous formations during drilling in order
their material properties, and formation fluids often require to stabilize the borehole and control fluid loss. However,
isolation and specific treatment. Such treatments include but formations are frequently encountered that are so porous Such
are not limited to methods to increase fracture initiation pres that the loss of drilling fluids is increased beyond an accept
Sure, the consolidation of fractured materials, sealing up thief able limit despite the use of traditional lost circulation addi
or lost circulation Zones, reducing permeability and porosity tives. In extreme situations, when the borehole penetrates a
that is causing the loss and/or shutting off undesirable water fracture in the formation through which most of the drilling
or nuisance gas. fluid may be lost, drilling operations may be stopped until the
0005 Such treatments include the use of steel casing or loss circulation Zone is sealed and fluid loss to the fracture is
cement. When Steel casing is used to isolate particular strata, reduced. Typically these Zones are isolated with steel casings
these structures are expensive and will result in the overall or through the use of cement.
reduction of the diameter of any lower sections of the exca 0011. In some cases, fluid losses can be induced from
Vation. This reduction can significantly affect potential pro increases in fluid density resulting in excessive hydrostatic
duction of gas and/or fluids from the well. In addition, the cost pressure and Subsequently induced fractures and the resulting
of these steel structures can significantly affect the economic loss of fluid into these fracture, or as a result of underground
justification for the well. blowouts.
0006 Drilling fluids, or drilling muds as they are often 0012 Underground blowouts are characterized as uncon
known, are generally slurries of clay solids, polymers and trolled increases in wellbore pressures associated with the
other fluid materials. Typically, a drilling mud is circulated entry of pressurized fluids from adjacent formations that may
down through the drill pipe, out the drill bit, and back to the cause fractures in the formations during well control opera
surface through the annulus between the drill pipe and the tions or as the uncontrolled flow of reservoir fluids from one
borehole wall. Drilling fluids generally include one or more reservoir into the wellbore, along the wellbore, and into
of viscosifiers or Suspending agents, weighting agents, cor another reservoir.
rosion inhibitors, Soluble salts, seepage loss control additives, 0013 During an underground blowout, this crossflow
bridging agents, emulsifiers, lubricants as well as other addi from one Zone to another can occur when a high-pressure
tives selected to impart desired properties to the drilling fluid. Zone is encountered, with the result being that the well flows,
0007 Oil-based drilling fluids are comprised of oils, and the drilling crew reacts properly and closes the blowout
including for example, diesel, polyalpha olefins, mineral oils, preventers (BOPs). Pressure in the annulus then builds up to
propylene glycol, methyl glycoside, modified esters and the point at which a weak Zone fractures. Depending on the
ethers, and the like and mixtures thereof, and invert emulsions pressure at which the fracturing occurs, the flowing formation
ofoil in which water is dispersed in an oil-based medium. Oil can continue to flow and losses continue to occur in the
US 2010/0230164 A1 Sep. 16, 2010
fractured Zone. Underground blowouts are historically one of include nut and seed shells or hulls, such as, for example,
the most expensive problems in the drilling arena, eclipsing pecan, almond, walnut, peach, brazil, coconut, peanut, Sun
the costs of even Surface blowouts. In some cases, it may flower, flax, cocoa bean, cottonseed, rice, linseed, oat, and the
become necessary to drill a second kill well in order to rem like. See for example, U.S. Pat. No. 5,004,553 (House, et al.);
edy an underground blowout. U.S. Pat. No. 2,799,647 (Borchardt); and U.S. Pat. Nos.
0014. A review of the prior art indicates that many tech 4,460,052 and 4,498,995 (Gockel).
nical Solutions have been proposed for dealing with the chal 0021. Further still, there has been a need for a new class of
lenges facing a drilling engineering program and particularly compounds that can be used as effective proppants in fractur
to improve seepage loss and well strengthening. ing operations.
0015. However, there continues to be a need for improved
additives and compositions of drilling fluids which can pro SUMMARY OF THE INVENTION
vide an in-situ method for dealing with many of the foregoing 0022. In accordance with the invention, drilling fluid addi
challenges of seepage loss control, wellbore strengthening tives, drilling fluid compositions and methods for reducing
and/or minimizing the risk and/or effects of underground lost circulation, seepage loss of drilling fluids and under
blowouts with a cost effective and readily deployed method ground blowouts in drilling operations are provided.
ology. 0023. In a first embodiment, a drilling fluid additive for
0016. A review of the prior art shows various composi reducing circulation loss during drilling operations is pro
tions and strategies have been employed in the past. For vided comprising ground pumice, barium, dolomite or
example, U.S. Patent Publication No. 20060276348 discloses anthracite having an average particle size between 100 and
the use of a method for creating a geosynthetic composite 4000 microns.
in-situ, which includes a reactive ester having at least one 0024. In a second embodiment, a drilling fluid composi
carbon-carbon double bond, preferably a vinyl ester of a C to tion comprising a liquid carrier and a drilling fluid additive is
C versatic acid or vinyl ester of a long chain fatty acid, or a provided including any one of or a combination of ground
combination thereof, at least one unsaturated thermoplastic pumice, barium, dolomite or anthracite having an average
elastomer soluble in the reactive ester, at least one di- or particle size between 100 and 4000 microns.
tri-functional acrylate or methacrylate monomer. 0025. In further embodiments, the drilling fluid composi
0017 U.S. Pat. No. 3,701,384 discloses a method of seal tion is characterized by one or more of the following proper
ing permeable areas in a formation by plugging the pores with ties:
a solid material. A slurry of finely divided inorganic solids is 0026 the additive is mixed with the liquid carrier such
injected into the formation together with an aqueous colloidal that the concentration of additive in the liquid carrier is
dispersion of a water-insoluble metal hydroxide in dilute greater then 0.01 pounds per barrel (ppb) of liquid car
aqueous solution of an organic polymeric polyelectrolyte, r1er:
preferably containing a high molecular weight polyacryla 0027 the additive is barite and the concentration is
mide or hydrolyzed polyacrylamide. At low concentrations, 0.01-700 ppb.
between 0.01 and 0.2 percent by weight, the dissolved poly 0028 the additive is pumice and the concentration is
mer causes the suspended solids to flocculate, thereby block 0.01-300 ppb.
ing pores in the formation. The tested inorganic solids 0029 the additive is dolomite and the concentration is
included finely ground asbestos fibers and magnesium oxide. 0.01-300 ppb.
As is known, due to its carcinogenic nature, asbestos is unde 0030 the additive is anthracite and the concentration is
sirable for widespread commercial use. 0.01-300 ppb.
0018 U.S. Pat. Nos. 4,683,949 and 4,744,419 disclose a 0.031 the concentration is less than 48% by volume
method for sealing permeable areas informations using poly additive in liquid carrier;
mers cross-linked in-situ. Both patents note that effective 0.032 the additive has an average particle size between
polymer/cross-linking agents must be supplied sequentially 100 and 4000 microns;
with great care to prevent the cross-linked polymer from 0033 the ground pumice has a particle size distribution
setting up too early. of 600 to 2000 microns;
0019. In addition, various formation agents and additives 0034 the ground pumice has a particle size distribution
are known in the art to form formation seals and/or filter cakes of 250 to 1400 microns;
on the wall of a well bore. These include sugarcane fibers or 0035 the ground pumice has a particle size distribution
bagasse, flax, Straw, ground hemp, cellophane strips, ground of 180 to 425 microns;
plastics, ground rubber, mica flakes, expanded perlite, silica 0.036 the anthracite has a particle size 100-4000
slag, ground fir bark, ground redwood bark and fibers, grape microns.
extraction residue, cottonseed hulls, cotton balls, ginned cot 0037. In further embodiments, the drilling fluid includes a
ton fibers, cotton linters, waxes, gilsonite, asphaltine, calcite, secondary additive selected from any one of or a combination
dolomite, and the like. of hydrophobic synthetic fibrous particles, comminuted par
0020. However, the use of cellulose fibers has generally ticles of plant and mineral materials, weighting materials, and
been for control of seepage loss or lost circulation and differ gelling agents.
ential sticking, rather than for the stabilization of shale for 0038. The hydrophobic synthetic fibrous particles may be
mations. To prevent further seepage loss, a number of differ selected from any one of or a combination of nylon, rayon,
ent cellulose materials have been added to prior art drilling polyolefin fibers.
fluids in an effort to reduce the permeability of the formation 0039. The comminuted particles of plant and mineral
being drilled. Such prior known cellulose fiber materials can materials may be selected from particles derived from nut and
include fibrous, flake, and granular ground forms, and com seed shells or hulls including peanut, almond, brazil, cocoa
binations thereof. Representative of such cellulose fibers bean, coconut, cotton, flax, grass, linseed, maize, millet, oat,
US 2010/0230164 A1 Sep. 16, 2010
peach, peanut, rice, rye, soybean, Sunflower, walnut, wheat; 100-4000 microns and wherein step b) is repeated with
rice fractions including rice tips, rice Straw and rice bran; an additive having a smaller average particle size than
crude pectate pulp; peat moss fibers; flax, cotton; cotton lint the upper quartile.
ers; wool; Sugar cane; paper, shredded paper; ground hemp., 0054. In another embodiment, the invention provides a
paper pulp; cellophane Strips; ground bark; bagasse; bamboo: method of recognizing and controlling an underground blow
corn Stalks; tree fractions including sawdust, wood or bark; out in a Subterranean formation comprising the steps of:
Straw; cork, dehydrated vegetable matter, whole or ground
corncobs; corncob fractions including light density pith core, 0.055 a. monitoring surface pressure within a well to
corn cob ground woody ring portion, corn cob coarse or fine detect a pressure increase indicating fluid influx into the
chaff portion; cotton seed stems; flax stems; wheat stems; well;
Sunflower seed stems; soybean stems; maize stems; ryegrass 0056 b. closing in the well in response to the pressure
stems; millet stem; gilsonite; asphaltine; waxes; and calcium increase;
carbonate. 0057 c. monitoring surface pressure and detecting an
0040. The weighting materials may be selected from any underground blowout if well pressure drops and fluid
one of or a combination of barite, barium Sulfate, calcium loss increases above threshold values:
carbonate, galena, hematite, magnetite, iron oxides, ilmenite,
siderite, celestite, dolomite, calcite, manganese oxides, Zinc 0.058 d. circulating a drilling fluid composition com
oxide, and Zirconium oxides. prising a liquid carrier and a drilling fluid additive
0041. The gelling agents may be selected from any one of including any one of oracombination of ground pumice,
or a combination of starch or derivatized starches and chemi barium, dolomite or anthracite having an average par
cally modified Starches including carboxymethyl starch, ticle size between 100 and 4000 microns; and,
hydroxyethyl starch, hydroxypropyl Starch, acetate starch, 0059 e. monitoring the fluid loss and adjusting the size
Sulfamate starch, phosphate starch, nitrogen modified Starch, and/or concentration of drilling fluid additive in
starch cross-linked with aldehydes, epichlorohydrin, borates, response to changes or lack of changes in the fluid loss.
and phosphates. 0060. In accordance with a further embodiment, novel
0042. In a further embodiment, the invention provides a proppant materials are described. In particular, proppants for
method for ameliorating seepage loss while drilling a subter use in downhole fracturing are described comprising any one
ranean well comprising the steps of: ofora combination of ground pumice, barium, anthracite and
0043 a. monitoring seepage loss while drilling; dolomite. In preferred embodiments, the proppant is anthra
0044) b. circulating a synthetic oil, oil, or water based cite or pumice.
drilling mud into the drill string wherein the drilling
fluid comprises a liquid carrier and an additive of ground BRIEF DESCRIPTION OF THE DRAWINGS
pumice, barite, dolomite or anthracite or a combination
thereof and wherein the liquid carrier is a synthetic, oil, 0061. The invention is described with reference to the
or water based drilling mud and the additive is added to drawings in which:
the liquid carrier at a concentration of greater then 0.01 0062 FIG. 1 is a graph showing required barite particle
pounds per barrel of liquid carrier.
0045. In further embodiments, the additive is barite and size distribution for use in drilling fluid in accordance with
the concentration is 0.01-700 ppb; the additive is pumice and American Petroleum Institute (API) standard API 13 A.
the concentration is 0.01-300 ppb; the additive is
0046. In another embodiment, the concentration is less DETAILED DESCRIPTION OF THE INVENTION
than 48% by volume additive in liquid carrier.
0047. In a further embodiment of the method, the additive 0063. In accordance with the invention, improved seepage
has an average particle size between 100 and 4000 microns. control drilling fluid additives, drilling fluid compositions
0.048. In a still further embodiment, the concentration of and methods of use are described. The additives, composi
additive is increased during circulation. tions and methods are designed to decrease or eliminate seep
0049. In yet further embodiments of the method: age loss and lost circulation of oil, synthetic, water and mixed
0050 step b) is initiated with an additive having an oil/water drilling fluids in a drilling operation. The invention
average particle size in the lower half of the range of can be supplied as an additive for drilling fluid, or may form
100-4000 microns and wherein step b) is repeated with part of a drilling fluid composition. That is, the additive may
an additive having a larger average particle size than the be added to a drilling fluid as needed when excessive seepage
lower half or circulation loss problems are encountered during drilling
0051 step b) is initiated with an additive having an or form part of an initial drilling fluid.
average particle size in the upper half of the range of 0064. The general method of the invention generally
100-4000 microns and wherein step b) is repeated with includes injecting a drilling fluid with a loss control additive
an additive having a smaller average particle size than together wherein the loss control additive has mechanical
the upper half: properties enabling the effective creation of a high tensile
0.052 step b) is initiated with an additive having an strength barrier within a lost circulation Zone to reduce fluid
average particle size in the lower quartile of the range of loss.
100-4000 microns and wherein step b) is repeated with 0065. The loss prevention additives may be used with
an additive having a larger average particle size than the oil-based, water-based or synthetic drilling fluid systems,
lower quartile; or, including various mineral oil and diesel based drilling fluids.
0053 step b) is initiated with an additive having an As will be described in greater detail below, preferred loss
average particle size in the upper quartile of the range of prevention additives include ground pumice, barium Sulfate
US 2010/0230164 A1 Sep. 16, 2010
(hereinafter “barite'), dolomite and anthracite and other addi stems, millet stem gilsonite, Asphaltine, waxes, calcium
tives having desired mechanical properties based on size and carbonate, dolomite, and the like, and various mixtures
hardness. of these materials.
0072. 3. Known weighting materials, including barite,
Applications barium Sulfate, calcium carbonate, galena, hematite,
magnetite, iron oxides, ilmenite, siderite, celestite, dolo
0066. The additives and compositions in accordance with mite, calcite, manganese oxides, Zinc oxide, Zirconium
the invention provide superior results in terms of improved oxides, and the like. As known, weighting materials
loss circulation, wellbore strengthening and filter cake devel generally function to increase the density of the drilling
opment in a wider variety of formations. For example, the fluid. Generally, a drilling fluid should have a sufficient
compositions can be effectively used in the sealing of low density to provide a hydrostatic pressure that is greater
pressure sands, sealing fractures, the stabilization of shale than formation fluid pressures to prevent blowout and/or
sections, and the reduction of differential Sticking tendencies the uncontrolled flow of fluids from the formation into
in low pressure sands. the well. However, the density must not be too high to
0067 Further still, the additives of the present invention cause further seepage loss.
can also be used in coring fluids and oil-based workover and 0.073 4. Gelling agents, such as starch or derivatized
completion. The additives of the present invention can be starches. Any suitable granular starch or mixture of
utilized with drilling fluids at both low concentrations for starches may be used in the present invention. Accord
routine use during normal drilling operations and then ingly, as used herein, the term "starch is understood to
include one or more natural starches, one or more chemi
adjusted to higher concentrations when necessary for appli cally modified Starches, and mixtures of one or more
cations (such as pill applications) to prevent further circula natural or/and/or chemically modified starches. Natural
tion loss or seepage if the drill bit hits a formation causing a starches that may be employed in the invention include,
drop in pressure and loss of drilling fluid. but are not limited to those of potato, wheat, tapioca,
rice, corn, roots having a high starch content, and the
Additives and Compositions like. Waxy starches, such as for example, waxy corn
0068 Generally, the additives of the present invention are starch, is often preferred as a gelling agent. Chemically
modified starches can be those derived from natural
characterized in terms of their particle size and mechanical
strength. Compositions of the present invention are charac starches by chemical reaction of the natural starch with
terized in terms of the concentration of an additive within a Suitable organic reactant. Chemically modified
known drilling fluids. For example, an additive may be mixed starches which may be used in the invention can include,
with synthetic and oil based drilling fluids in concentrations but are not limited to, carboxymethyl starch, hydroxy
from 0.01 or greater pounds per barrel (ppb) of drilling fluid, ethyl starch, hydroxypropyl Starch, acetate starch, Sulfa
depending on the formation conditions so as to create agen mate starch, phosphate starch, nitrogen modified Starch,
eral use drilling fluid composition. In other embodiments, starch cross-linked with aldehydes, epichlorohydrin,
when required in spot or pill applications during drilling, borates, and phosphates, and mixtures thereof. Various
concentrations of between 10 and 50 ppb can be employed to starches are disclosed in U.S. Pat. Nos. 4,652.384;
prevent further loss due to unexpected seepage, or in an effort 4,822,500; 4,422,947; 4,123,366; 5,804,535; 5,851,959
to seal micro-fractured formations. and 5,948,733.
0069. In further embodiments, the additives of the present Particle Size
invention can be used alone (within a drilling fluid) or in 0074 As is known, in a typical drilling operation, weight
combination with a variety of other materials that may pro ing agents are utilized Such that the particle size of the weight
vide secondary sealing and/or drilling fluid weight including ing agent effectively contributes to the density of the fluid by
but not limited to: i) remaining Suspended in the Solution without rapid settling
0070) 1. Hydrophobic synthetic fibrous particles suit and ii) so as to not adversely interfere with normal solids
able to prevent seepage and circulation loss including separation of drill cuttings from drilling fluid at Surface. As
nylon, rayon, polyolefin fibers and combinations Such, and in accordance with American Petroleum Institute
thereof. (API) standards, the API 13A specification requires barite
0071 2. Comminuted particles of plant and mineral particle size for use in drilling fluid to be as shown in FIG. 1.
materials including particles derived from nut and seed That is, for use as a weighting agent, the API specifies that the
shells or hulls such as those of peanut, almond, brazil, particle size distribution of barite is smaller than 100 microns
cocoa bean, coconut, cotton, flax, grass, linseed, maize, with roughly 60% of barite particle between 20-80 microns.
millet, oat, peach, peanut, rice, rye, soybean, Sunflower, In addition, U.S. Pat. No. 6,180,573 specifies that barite par
walnut, wheat; various portions of rice including the rice ticles are at least 85% by weight particles less than 75 microns
tips, rice Straw and rice bran; crude pectate pulp; peat and greater than 6 microns in equivalent spherical diameter.
moss fibers; flax, cotton; cotton linters; wool; Sugar Other industry known API specifications dating back to 1981
cane; paper; shredded paper, ground hemp, paper pulp; specify 95%-45 microns (325 mesh).
cellophane strips; ground bark; bagasse; bamboo; corn 0075. In accordance with the invention, additives such as
stalks; various tree portions including sawdust, wood or pumice, barite or dolomite have an increased particle size that
bark; straw; cork; dehydrated vegetable matter; whole is added to a drilling fluid alone or in combination with other
ground corn cobs; or various plant portions of the corn sized materials in the drilling fluid.
cob light density pith core, the corn cob ground woody (0076 Table 1 shows effective particle size distributions of
ring portion, the corn cob coarse or fine chaff portion, a pumice additive of the present invention for different com
cotton seed stem, flax stems, wheat stems, Sunflower mercial pumice products designated A-E. As shown, particle
seed stems, soybean stems, maize stems, rye grass sizes range from 180-2000 microns plus.
US 2010/0230164 A1 Sep. 16, 2010
TABLE 2
Comparison of Measured Hardness of Various Substrates by Various
Hardness Test
Hardness
Test Name Pumice Dolomite Barite Cal-Carb Mica Gilsonite Graphite
Moh Mineral Hardness 5.5 3.5-4 3 2.5 2.5 2 1.5
HB (3000) Brinell 10 mm >> 217-299 150 97 97 <-3 -3-3
Standard 3000 kgf
HB (500) Brinell 10 mm >> 189- 136 90 90 <-3 -3-3
Standard 500 kgf
HB Brinell 10 mm 629 217-299 150 97 97 <-3 -3-3
(Tungsten Tungsten 3000 kgf
3000)
HB Brinell 2.44 4.1-3.5 4.90 -3-3 -3-3 <-3 -3-3
(Indentation) Indentation (mm)
HK Knoop 705 239-327 169 117 117 <-3 -3-3
HRA Rockwell A-Scale 81 60-66 <-3 -3-3 -3-3 <-3 -3-3
HRB Rockwell B-Scale >> 97- 81 57 57 <-3 -3-3
HRC Rockwell C-Scale 59 19-32 <-3 -3-3 -3-3 <-3 -3-3
HRD Rockwell D-Scale 70 39-49 <-3 -3-3 -3-3 <-3 -3-3
HRF Rockwell F-Scale >> >> 98 89 89 <-3 -3-3
HR-1SN Rockwell Superficial 90 69-76 <-3 -3-3 -3-3 <-3 -3-3
SN
HR-1ST Rockwell Superficial >> 92+ 87 79 79 <-3 -3-3
5T
HR-3ON Rockwell Superficial 76 40-52 <-3 -3-3 -3-3 <-3 -3-3
3ON
HR-3OT Rockwell Superficial >> 82+ 71 S4 S4 <-3 -3-3
3OT
HR-45N Rockwell Superficial 65 18-33 <-3 -3-3 -3-3 <-3 -3-3
4SN
HR-45T Rockwell Superficial >> 71+ 55 29 29 <-3 -3-3
45T
HS Shore Scleroscope 79 33-44 23 16 16 <-3 -3-3
Approx. TS Tensile Strength 2387 724–998 510 338 338 <-3 -3-3
MPa (Approx.)
HV Vickers 669 229-315 157 102 102 61 37
US 2010/0230164 A1 Sep. 16, 2010
0082. Thus, the operator will seek to increase the concen pressure conditions, embed themselves in the cracks and fis
tration of the seepage loss agent in the drilling fluid Such that Sures in a multi-layer matrix that reduces the channels for
the seepage loss is effectively minimized. As known to those drilling fluid escape while simultaneously providing a layer
skilled in the art, drilling fluid viscosity, hydrostatic pressure, of strength to the well bore wall.
circulation rate and well pressure are control parameters that I0089. That is, in order to effectively provide loss circula
an operator will choose to adjust so as to effectively control tion control and well bore strengthening an additive particle
seepage loss. As well, for certain formations, an operator may must wedge and lock in the mouth of the fracture. Assuming
choose to add an additive of a larger or Smaller particle size that a fracture is generally wedge-shaped with a wider mouth
depending on the recognized effect. adjacent the borehole, the initial width of the fracture mouth
0083. More specifically, the operator can utilize larger loosely defines the particle size which in turn can be used to
particle size additives preferably in the range of 100 and 4000 determine a concentration of additive.
microns and adjust the concentration of additive during cir 0090. As such, the concentration of the additive is directly
culation in response to observed data from the well. Quanti proportional to the volume and density of the additive having
tatively, circulation may be initiated with an additive having a particle size equal to the average fracture width and
an average particle size in the lower half of the range of inversely proportional to the average fracture Volume and the
100-4000 microns wherein, in response to observed data, proportion of the additive having a particle greater than the
circulation is repeated with an additive having a larger aver average fracture width.
age particle size than the lower half particle size. 0091 Advantageously, by introducing high tensile
0084. In another embodiment, circulation may be initiated strength agents, the shear strength of the well bore wall is
with an additive having an average particle size in the upper increased such that an increased mud weight can be employed
half of the range of 100-4000 microns wherein, in response to without inducing fluid losses into the formation(s) exposed.
observed data, step b) is repeated with an additive having a 0092 Subsequent to or simultaneously with, a plastering
Smaller average particle size than the upper half particle size. agent may be introduced into the drilling fluid to provide
0085. Further still, circulation may initiated with an addi secondary sealing of the microchannels within the primary
tive having an average particle size in the lower quartile of the matrix or those channels not affected by the additive.
range of 100-4000 microns wherein, in response to observed 0093 Suitable plastering agents may be Montan wax,
data, circulation is repeated with an additive having a larger mica, graphite, gilsonite and/or other agents identified above.
average particle size than the lower quartile particle size. 0094 Pumice is a preferred loss circulation additive.
Alternatively, circulation may be initiated with an additive Known as amorphous aluminum silicate, pumice is charac
having an average particle size in the upper quartile of the terized as having a highly porous structure (typically about
range of 100-4000 microns and wherein, in response to 90% porosity) and thus allows for the flow of fluid through the
observed data, circulation is repeated with an additive having particles. Downhole, this has the beneficial property of
a smaller average particle size than the upper quartile. enabling pressure to equalize between the fluid column and
I0086. In the particular case of an underground blowout in the fracture or pore to be sealed/bridged which is believed to
a subterranean formation, the operator may effectively utilize help in the initial plastering of the thief Zone. These pores may
the additives to minimize the effect of an underground blow be subsequently sealed by a colloidal, Smaller particle size
out. In this case, the operator during regular monitoring of plastering agent.
Surface pressure within a well, detect a pressure increase 0.095 Commercially, a variety of different granulations of
indicating fluid influx into the well. In response to the pres pumice are available from a very coarse granule (4.75 mm
sure increase the operator may close in the well and thereafter and finer) to a very fine powder (45 microns and finer). Typi
detect an underground blowout if the well pressure drops and cal granulations useful for the Subject invention are described
fluid loss increases above threshold values. By circulating a in Table 1.
drilling fluid composition including the drilling fluid addi 0096. Other technical advantages of pumice are its lower
tives described and further monitoring of the fluid loss average specific gravity; 1870 kg/m (Bulk Density 250
together with adjusting the size and/or concentration of drill kg/m) as compared to calcium carbonate 2750 kg/m (Bulk
ing fluid additive in response to changes or lack of changes in Density 700 kg/m) allowing for it to be incorporated into
the fluid loss, an underground blowout can be effectively drilling fluid without raising the density of the drilling fluid as
controlled. high as might occur with ground and sized calcium carbonate
0087 Ultimately, the size of the passages through the cir or barite.
culating jets in the drill bit can be a limiting factor for absolute 0097. In addition, the high porosity of pumice may addi
maximum particle size of the additives in “While Drilling tionally provide better return permeability for pay Zones pen
Operations' however for open-ended operations where the etrated with drilling fluids using pumice for seepage control
drill bit has been removed a much broader particle size range over those laden with the more traditional materials discussed
is achievable. However, the particle size of the additive should herein.
be of a small enough size so as to be able to enter the forma 0098. In other embodiments, the high matrix strength and
tion through fissures, Small fractures and large pores. Gener porosity of pumice also make pumice an excellent product for
ally, particles should be sized according to the properties of filling natural and induced fractures in hydrocarbon produc
the formation and the lost circulation Zone. ing horizons, for example in fracturing operations to replace
0088 As additive particles are pumped downhole, they are frac-Sand currently employed in Such applications. Further
ejected from the drill bit wherein as a result of hydrostatic the ability to equalize pressure between the fluid column and
pressure, pumping pressure, formation and particle properties the fracture is understood to improve proppant placement.
will be forced into cracks and fissures in the formation. As a 0099 Anthracite is another loss circulation additive.
result of the increased hardness of the additive particles, it is Anthracite is a hard coal having the highest fixed-carbon
understood that the particles under appropriate impact and content and the lowest amount of volatile material of the
US 2010/0230164 A1 Sep. 16, 2010
14. A drilling fluid composition as in claim 12 wherein the 23. A method as in claim 17 wherein the additive has an
comminuted particles of plant and mineral materials are average particle size between 100 and 4000 microns.
selected from particles derived from nut and seed shells or 24. A method as in claim 17 wherein the concentration of
hulls including peanut, almond, brazil, cocoa bean, coconut, additive is increased during circulation.
cotton, flax, grass, linseed, maize, millet, oat, peach, peanut, 25. A method as in claim 17 wherein stepb) is initiated with
rice, rye, Soybean, Sunflower, walnut, wheat; rice fractions an additive having an average particle size in the lower half of
including rice tips, rice Straw and rice bran; crude pectate the range of 100-4000 microns and wherein stepb) is repeated
pulp; peat moss fibers; flax, cotton; cottonlinters; wool; Sugar with an additive having a larger average particle size than the
cane; paper, shredded paper, ground hemp, paper pulp; cel lower half.
lophane Strips; ground bark; bagasse; bamboo, corn Stalks; 26. A method as in claim 17 wherein stepb) is initiated with
tree fractions including sawdust, wood or bark; Straw; cork; an additive having an average particle size in the upper half of
dehydrated vegetable matter, whole or ground corn cobs; the range of 100-4000 microns and wherein stepb) is repeated
corn cob fractions including light density pith core, corn cob with an additive having a smaller average particle size than
ground woody ring portion, corn cob coarse or fine chaff the upper half.
portion; cotton seed stems; flax stems; wheat stems; Sun 27. A method as in claim 17 wherein stepb) is initiated with
flower seed stems; soybean stems; maize stems, rye grass an additive having an average particle size in the lower quar
stems; millet stem; gilsonite; asphaltine; waxes; and calcium tile of the range of 100-4000 microns and wherein step b) is
carbonate. repeated with an additive having a larger average particle size
15. A drilling fluid composition as in claim 12 wherein the than the lower quartile.
weighting materials are selected from any one of or a combi 28. A method as in claim 17 wherein stepb) is initiated with
nation of barite, barium sulfate, calcium carbonate, galena, an additive having an average particle size in the upper quar
hematite, magnetite, iron oxides, ilmenite, siderite, celestite, tile of the range of 100-4000 microns and wherein step b) is
dolomite, calcite, manganese oxides, Zinc oxide and Zirco repeated with an additive having a smaller average particle
nium oxides. size than the upper quartile.
16. A drilling fluid composition as in claim 12 wherein the 29. A method of recognizing and controlling an under
gelling agents are selected from any one of or a combination ground blowout in a Subterranean formation comprising the
of starch or derivatized starches and chemically modified steps of:
starches including carboxymethyl starch, hydroxyethyl e. monitoring Surface pressure within a well to detect a
starch, hydroxypropyl Starch, acetate starch, Sulfamate pressure increase indicating fluid influx into the well;
starch, phosphate starch, nitrogen modified Starch, starch f. closing in the well in response to the pressure increase;
cross-linked with aldehydes, epichlorohydrin, borates, and g. monitoring Surface pressure and detecting an under
phosphates.
17. A method for ameliorating seepage loss while drilling ground blowout if well pressure drops and fluid loss
a Subterranean well comprising the steps of: increases above threshold values;
c. monitoring seepage loss while drilling; h. circulating a drilling fluid composition comprising a
d. circulating a synthetic oil, oil, or water based drilling liquid carrier and a drilling fluid additive including any
mud into the drill string wherein the drilling fluid com one of or a combination of ground pumice, barium,
prises a liquid carrier and an additive of ground pumice, anthracite or dolomite having an average particle size
barite, anthracite or dolomite or a combination thereof between 100 and 4000 microns; and,
and wherein the liquid carrier is a synthetic, oil, or water i. monitoring the fluid loss and adjusting the size and/or
based drilling mud and the additive is added to the liquid concentration of drilling fluid additive in response to
carrier at a concentration of greater then 0.01 pounds per changes or lack of changes in the fluid loss.
barrel of liquid carrier. 30. A proppant for use in downhole fracturing comprising
18. A method as in claim 17 wherein the additive is barite any one of or a combination of ground pumice, barium,
and the concentration is 0.01-700 ppb. anthracite and dolomite wherein the pumice, barium, anthra
19. A method as in claim 17 wherein the additive is pumice cite or dolomite having an average particle size between 100
and the concentration is 0.01-300 ppb. and 35,000 microns.
20. A method as in claim 17 wherein the additive is dolo 31. A proppant as in claim 30 wherein the proppant is
mite and the concentration is 0.01-300 ppb. anthracite.
21. A method as in claim 17 wherein the additive is anthra 32. A proppant as in claim 30 wherein the proppant is
cite and the concentration is 0.01-300 ppb. pumice.
22. A method as in claim 17 wherein the concentration is
less than 48% by volume additive in liquid carrier.