section 10c

lost circulation
section 10c Scomi Oiltools

introduction 2
definition and classification 3
type of losses 3
severity of losses 4
prevention and control 5
minimise annular loading 5
good drilling fluid properties maintenance 5
minimise surge and swab pressures 6
ecd minimisation 6
surface equipment 6
downhole equipment 6
locate and identify loss zone 6
avoiding stuck pipe 7
water base muds vs. non aqueous fluids 9
lost circulation materials 7
lcm types 7
lcm in productive zones 8
permanent remedial treatments 8
bridging / sealing of porosity and fractures 8
losses into porosity 9
losses into natural fractures 9
losses into induced fractures 9
responding to losses 10
basic strategy 10
seepage losses (< 10 bbl/hr or 1.59 m3/hr) 10
partial losses (10 to 30 bbl/hr or 1.59 to 4.77 m3/hr) 11
Severe Losses (30 to 100 bbl/hr or 4.77 to 15.9 m3/hr) 12
total losses (>100 bbl/hr or 15.9 m3/hr) 13
gunk squeezes 15
gel/polymer gunk squeeze 15
reverse gunk squeeze for use in obm 16
decision tree to identify losses 18
 Section

10c hole problems - lost circulation

hole problems - lost circulation

introduction
Lost circulation is one of the most common and potentially one of the most expensive problems
encountered in a drilling operation. In the best case results are often additional operating time
and increased mud and operating costs, in the worst case results are often blowouts and lost hole.
Lost circulation adversely affects the overall drilling operation by:

ƒ
The loss of hydrostatic head that may result in a well-control situation.
ƒ
The reduction in the pressure gradient may lead to wellbore stability, which could result in hole
collapse and/or stuck pipe.
ƒ
Side tracks or complete loss of the well.
ƒ
Failure to achieve adequate annular cement coverage.
ƒ
Good quality formation evaluation may not be possible.

Lost Circulation Cost Impact

Drilling Cementing Completion/Work-over
Loss of mud Reduced annular Loss of completion
coverage fluid
Lost time Casing corrosion Lost time
Poor cement job Poor zonal isolation Formation damage
Reduced safety Reduced safety Reduced safety
Stuck in hole Lost reserves
Wasted casing string Loss of well
Failure to reach
target TD
Blow out and kill
operations
Downhole blowouts
Environmental
incident

Whenever loss circulation is anticipated a lost circulation contingency plan should be put in place.
This will ensure that, when losses are encountered, the appropriate treatments are executed
competently and methodically. In this manner the time and costs associated with losses can be
controlled.

The Lost Circulation Contingency Plan should set out response guidelines by:

ƒ Defining and classifying the type and severity of losses

ƒ Selecting the most appropriate material available
ƒ Applying the most effective responses and treatments (LCM pill selection)
ƒ Analysing the success of the treatments

It must be emphasised that losses, like any other problem on the rig, should be approached
methodically. Each sequential action should be discussed, planned and then executed. All relevant
data should be documented so that a database can be compiled which will help to analyse and refine
the current responses and treatments.


definition and classification
Losses can simply be defined as the loss of whole mud to the formation. For this to occur both of
the following conditions must exist:

ƒ The dynamic or static pressure exerted by the total mud column exceeds the total formation
pore pressure and or fracture gradient.
ƒ The porosity and permeability of the formation is such that whole mud is lost to the formation
thus preventing the sealing effect of the filter cake.

Lost circulation of differing intensity can occur at any depth in various formations. In order to precisely
and accurately define the situation on the rig the type and volume of losses must be identified and
classified. Therefore, in the vast majority of cases, it should be possible to identify, classify, treat and
report losses using the format set out in this lost circulation contingency plan.

The type of losses can generally be classed as one of the following:

ƒ Naturally occurring losses

ƒ Mechanically induced losses

The severity of losses can arbitrarily be classed as one of the following:

Type of losses Dynamic Losses Dynamic Losses

bbl/hr m3/hr
Seepage losses < 10 < 1.59
Partial losses 10 – 30 1.59 – 4.77
Severe losses 30 – 100 4.77 – 15.9
Total losses > 100 > 15.9

type of losses

naturally occurring losses

Naturally occurring losses can be defined as losses resulting from some aspect of the formation being
drilled. Losses are common in various formations such as:

ƒ
Unconsolidated formations which include sand and gravel.
ƒ
Permeable formations such as poorly cemented sandstone.
ƒ
Cavernous and vugular formations which include gravel, limestone and dolomite.
ƒ
Natural fractures or fissures which can occur at all depths in all formations. Losses increase in
older, harder more consolidated formations with depth. It is common to encounter fractures near
faults and areas exposed to tectonic stress. Voids and fractures can generally be recognised by a
change in the drilling parameters and when this occurs losses can be expected.

Commonly, when losses occur whilst drilling these formations, they will increase proportionally with
depth as more of the formation is exposed. Invariably LCM treatment of some degree, and associated
lost time, is required to minimise or cure these losses.

mechanically induced losses

Mechanically induced losses can be defined as losses resulting from some aspect directly related
to the drilling operation. Losses are caused by overpressuring and fracturing the formation which,
once fractured, will easily re-fracture with l over pressure. The most common causes of mechanically
induced losses are:


 Section

10c hole problems - lost circulation

ƒ High hydrostatic pressure resulting from an excessive mud weight.

ƒ
High hydrostatic pressure resulting from an excessive annular cuttings load.
ƒ High hydrostatic pressure resulting from an excessive ECD.
ƒ High surge pressure resulting from an excessive drillstring or casing running speed.
ƒ High downhole pressure resulting from a restricted annulus.

Commonly, when losses are induced, they can be minimised or cured by altering the drilling or operational
parameters without resort to a loss circulation treatment.

severity of losses

seepage losses
Seepage losses are arbitrarily defined to as dynamic losses of up to 10 bbl (1.59 m3) per hour when
circulating at the minimum pump rate used for drilling. Static losses are generally not associated with
this classification. Commonly, initial seepage losses will be minimal and will increase with drilling as
more of the specific formation is exposed. Losses of this severity are commonly encountered in
porous sands and fractured formations. The type of loss, naturally occurring or mechanically induced,
can usually be resolved by suspending drilling, circulating the hole clean and observing the losses
whilst varying the pump rate and pressure. It is not uncommon for seepage losses to self heal with time
as cuttings bridge the pore throats or microfractures.

partial losses
Partial losses are arbitrarily defined as dynamic losses of 10 – 30 bbl (1.59 – 4.77 m3) per hour when
circulating at the minimum pump rate used for drilling. Static losses are sometimes associated with
this classification. Losses of this severity are commonly encountered in unconsolidated formations,
vugular carbonates and fractured formations. The type of loss, naturally occurring or mechanically
induced, can usually be resolved by suspending drilling, circulating the hole clean and observing the
losses whilst varying the pump rate and pressure.

severe losses
Severe losses are arbitrarily defined as dynamic losses of more than 30 - 100 bbl (4.77 – 15.9 m3) per hour
when circulating at the minimum pump rate used for drilling. Static losses are generally associated with
this classification. Commonly, severe losses are instantaneous as fluid is lost to a void, the initial volume
lost can range from tens to hundreds of barrels after which the losses may moderate or cease. Losses of
this severity are commonly encountered in vugular carbonates and fractured formations. The type of loss
can be assumed to be naturally occurring.

total losses
Total losses are arbitrarily defined as a total absence of returns when circulating at the minimum
pump rate used for drilling. Static losses are also very high which necessitates new mud volume
with which to maintain a full annulus. Commonly, it is often difficult, if not impossible, to mix new
mud volume at the rate required to maintain a full annulus with high static losses, such a situation
may result in a well control situation as the mud column and resultant hydrostatic pressure is
diminished. Losses of this severity are commonly encountered in vugular carbonates and fractured
formations. The type of loss can assumed to be naturally occurring.


prevention and control
Outlined below are general rules of thumb to help cure and prevent losses:
ƒ Geology, rock type and drilling fluid control the location and severity of most mud losses. Ask the
rig, geologist about the rock types.
ƒ If the loss zone occurs within highly soluble rock (evaporites such as salt), cure the loss immediately,
even if at present it is not causing operational problems. Otherwise, it will only become worse if
expecting heavy losses, use as large a bit nozzle as possible.
ƒ First signs of downhole losses will be reduced mud return flow. A good drilling practice when
first encountering losses is to pull off bottom immediately, reduce flowrate to 100 gpm, continue
to rotate string to avoid packing off of cuttings around BHA as the annulus falls and KEEP PIPE
MOVING. Pump initial LCM pill as soon as possible.
ƒ The shape of the mud loggers’ pit level trace often enables the type of loss zone to be diagnosed,
allowing the correct remedial measures to be made.
ƒ For a mud possessing good fluid loss control, major whole mud losses will not occur through the
matrix pores at permeabilities below 10 darcy.
ƒ If possible, try curing losses caused by induced fractures immediately by reducing the ECD.
ƒ If in doubt about the type of loss zone, first use a fine LCM and then progressively increase particle
size, while maintaining, a wide distribution.
ƒ Too high a concentration of LCM can cause problems (thick filter cake and packing off), and generally
does not improve bridging. Instead for problematic zones, increase the viscosity of the pill.
ƒ If possible, displace the pill slowly at approximately 200 gpm.
ƒ If severe losses are anticipated run a circulating sub in the drill string. This will permit high
concentrations of LCM material, including coarse material, to be pumped without risk of plugging bit
or downhole tools.
ƒ If losses are expected, premix a suitable LCM pill, designed for the type of losses expected, and
store it in reserve. As soon as losses occur the LCM pill will then be ready to be pumped immediately,
minimising impact on the operation critical path.

The following potential causes and general measures can be taken to prevent losses from occurring.
The applicability will be dependent on well design and may not be possible in all cases.

minimise annular loading

An increase in annular drilling fluid weight due to drilled cuttings can break down the formation,
particularly in surface holes. The effective increase in annular drilling fluid weight must be calculated
and taken into account. Controlled drilling may be required.

good drilling fluid properties maintenance

ƒ Efficient solids control packages allow the drilling fluid properties to be closely controlled.
ƒ The density should be kept as low as possible to give a satisfactory overbalance. The overbalance
required for wellbore stability is higher in a highly deviated well compared to a vertical well.
ƒ Maintain gel strengths, yield point and 6 rpm reading at lowest levels that will effectively clean
the hole. High viscosities can increase the ECD to a level that will break down the formation while
circulating.
ƒ Maintain low MBT levels.
ƒ Keep fluid loss low to prevent excessive filter cake build up.


 Section

10c hole problems - lost circulation

minimise surge and swab pressures

ƒ Use computer hydraulic modelling for determining trip velocity and acceleration schedule.
ƒ If fluid density or the surge pressures are close to formation fracture pressure then, while tripping
in, break circulation at the shoe and approximately every 1000 ft (305 m) in open hole. Circulate for
at least 5 minutes.
ƒ Bring the pumps up slowly after connections.
ƒ Rotate the pipe before turning on the pumps.
ƒ While tripping out, pump out for the first few stands/single off bottom.
ƒ Keep tripping speeds slow across areas of potential lost circulation.
ƒ Surge pressures calculations should be performed and the driller instructed as to the maximum
allowable speed for running the pipe.
ƒ Consider the use of lubricants to reduce drag.
ƒ Consider the use of sweeps to clear the cuttings from wellbore prior to POOH to run the casing.

ecd minimisation
ƒ Use computer modelling software to calculate equivalent circulating density.
ƒ Reduce restrictions in the annulus by minimising filter cake build-up. This can be done by utilising
high quality fluid loss additives and maintaining low drill solids content.
ƒ Keep hydraulics at the minimum level required to clean the hole.
ƒ Control ROP to avoid loading the annulus.

surface equipment
ƒ Remove pump strainers.
ƒ Line up surface piping so at least one mud pump can be rapidly switched to water or seawater.
ƒ Test all surface equipment in advance. The normal procedure would be to check for leaks in the
surface equipment before assuming losses downhole.
ƒ Ensure that no unnecessary drilling fluid transfers, additions, or dilutions are carried out while
drilling proceeds toward or in a loss zone.

downhole equipment
ƒ As a general rule LCM particles should be less than a third of the nozzle size.
ƒ Remove bit nozzles if large losses are expected.
ƒ Use a circulating sub to pump high concentrations of LCM, including coarse LCM, to avoid
plugging jets or downhole tools. It is important to use a ball made of high density material, relative
to mud density, as this ensures it will sink. A circulating sub is less likely to function, open and
close, the higher the inclination.
ƒ Avoid running tools with limited flow paths or restrictions where possible. This includes core
barrels, MWD, mud motors, floats and survey rings.
ƒ If possible, avoid running drill pipe casing protectors as these can swell and act like a packer.
ƒ Ideally losses should be dealt with as soon as they occur. It is possible to ahead with losses so
long as there is adequate surface volume to sustain it. However, care must be taken if there is the
possibility of penetrating a higher pressure zone as an underground blowout may result.
ƒ If losses are anticipated a LCM pill should be prepared in advance and stored in an agitated pit.
Usually a 100 bbl (15.9 m3) pill is adequate. Treat the pill with biocide if it contains organic matter.
ƒ Prepare a large volume of reserve mud.

locate and identify loss zone

ƒ If losses first occur while drilling ahead, or are accompanied by a change in torque or a drilling break,
the losses are likely to be on bottom.
ƒ If losses occur while tripping or increasing fluid weight, the losses may be off bottom. If necessary,
a temperature or spinner survey can be run.


avoiding stuck pipe
ƒ When losses occur, cuttings will settle out around the BHA and may mechanically stick the pipe.
The cuttings will act as a packer and exacerbate losses below them. Always keep the pipe moving.
Where possible, pull to the shoe before attempting a treatment. As a rule, have enough open hole
volume below the bit to accommodate the whole treatment.
ƒ Reactive clays overlaying the loss formation are likely to become unstable if exposed to uninhibited
fluids.
ƒ As loss zones may be at low pressure beware of differential sticking.

water base muds vs. non aqueous fluids

The incidents of induced fracturing is the same for both WBM and NAF since the fracture initiation
pressure is the same for both fluid types. NAF, however, may have a higher density / ECD downhole
than WBM of equal surface density due to the effects of base fluid compressibility. In addition, NAF
losses are much harder to control owing to the following reasons :

ƒ Fracture propagation pressure is lower with conventional NAF

ƒ Formation fracture generated during LOT may be easily re-opened and extended

Losses are easier to control with WBM because these screen-out in the fracture tip. A pressure
gradient is generated across the filter plug generated in the fracture, preventing transmission of the
mud pressure to the fracture tip that may extend the fracture. NAF do not form solid plugs in fractures.
They generally have very low leak-off and form very effective internal filter cakes, such that the induced
fracture is usually filled with emulsified water and base oil. There is therefore effective communication
with the fracture tip which will results in propagation of the fracture.

The following recommendations are made to minimise LC problems with NAF :

ƒ Relax on filtration and generate an external filter cake, if consistent with balancing differential
pressures; use 100:0 oil/water ratio i.e. all oil if possible, mainly applicable to reservoirs.
ƒ Add fibres/particles of appropriate size to increase fracture propagation pressures.

lost circulation materials

lcm types
Commercially available LCM products encompass a wide array of materials. Moreover, if it can be
pumped down a well, it probably has been at one time or another. Particle shapes are granular, flake
or fibrous at sizes denoted as fine (typically 20 - 60 mesh), medium (16 - 60 mesh) and coarse (16 -
30 mesh) :
(a) Granular LCM - nutshells, calcium carbonate, sized salt, hard rubber, asphalt, gilsonite, plastic.
(b) Flake-shaped LCM - mica, cellulose, cottonseed hulls, wood chips, laminated plastic, graphite,
calcium carbonate.
(c) Fibre-shaped LCM - cellulose fibres’, saw dust, shredded paper, hay, rice husks.
(d) Commercial Blends - Blends of two or three different materials, meant to cover a range of sizes
and shapes, e.g. combining granular, fibrous and flaked in one sack.

Treatments in an active system should typically be at 5 - 20 lb/bbl (14.3 – 57.1 kg/m3), with the choice
of using a single size and shape, combination of shapes and sizes or commercial blends. Pill
treatments are typically at 25 – 50 lb/bbl (71.3 – 142.7 kg/m3) of LCM in slugs of 50 – 100 bbl (7.95 – 15.9
m3).


 Section

10c hole problems - lost circulation

lcm in productive zones

When the loss zone is in or close to a potential production horizon, the use and subsequent removal
of LCM by acid or other alternatives could result in formation damage. Therefore, the selection of
suitable LCM is critical, particularly if open hole completions are planned, perhaps involving open
hole gravel pack placements or sand control screens. In these cases it is best to incorporate LCM that
has a proven history and can be removed by downhole treatments such as acid and hypochlorite
treatments.

ƒ Calcium carbonate can be subsequently removed using acid, typically 15% HCl.
ƒ Cellulose fibres can also be used, with caution. While only about 40% soluble in acid, the fibres
can usually be oxidised and removed by a 2% to 5% hypochlorite solution at high pH. It is
recommended to confirm removal by lab work prior to use in the field.
ƒ Sized salt particles, e.g. NaCl can be used in saturated salt fluids. The salt can be dissolved using
water or dilute brine.
ƒ Oil-soluble resins. Crude oil or condensate can in theory dissolve the resin when the well is
brought on production, or treatments with diesel can be applied. This type of treatment requires
some careful pre-planning and laboratory testing to ensure viability.

Note: Productive formations or injection zones usually use a drilling fluid specifically designed to
prevent formation damage, often referred to as a “Drill-In Fluid”. These fluids may already
incorporate one or more of the aforementioned materials to minimise fluid invasion and
formation damage.

permanent remedial treatments

Various methods can be applied to more permanently isolate formations and heal lost circulation :

ƒ Soft plugs – i.e. cross linked polymers, silicate gels, oil/bentonite mixtures and gunk.
ƒ High Fluid Loss Pills - i.e. EZ-SQUEEZE ®, salt gel slurries.
ƒ Hard Plugs - i.e. cement or cement added to soft plug materials, temperature activated resins that
react in place.

bridging / sealing of porosity and fractures

When lost circulation occurs, first determine the nature of the loss zone. Is the zone of high porosity
or is it likely that fractures have been induced? Use formation and pressure information from:

ƒ on-site geologists, mud loggers.

ƒ relevant MWD logs (e.g. Gamma Ray, sonic).
ƒ Downhole ECD tools, downhole pressure gauges or surface gauges (pay attention to the fact
that compressibility may affect the downhole EMW/ECD of oil base muds).

Next, devise a suitable response. If this response requires LCM to be pumped, than the material
should be sized according to the type and size of the opening to which the losses occur. It should
also take into consideration any downhole restrictions that the LCM must pass through, e.g. bit jets,
downhole tools. Not all materials will work automatically, a successful remedial job requiring two
stages, bridging and subsequent sealing of the loss zone.

Bridging Guidelines

ƒ For parallel slots/fractures - particles of 1/2 the width of the slot size are required.
ƒ For round openings - particles of 1/3 the diameter of the opening are required.


Sealing Guidelines

ƒ
Sealing requires bridging first.
ƒ
After bridging, the sealing material will fill in the gaps between the bridging material. The
gradation of sealing particle sizes lies below that of the bridging particle size.
ƒ
No seal will be formed if all particles are too large or if there are not enough small particles to
bridge.
ƒ
Note that an internal seal may also be formed. This could give problems in the clean-up phase when
production zones are drilled.

losses into porosity

High porosity loss zones are characterised by pore throats that are large enough to allow the passage
of all mud solids, e.g. drill solids and barite. The average particle size for barite is around 15 microns,
so pores must be on the order of 45 microns, assuming a 1/3 rule for plugging, equivalent to a
sandstone permeability of about 2000 mD.

Start with mud carrying a base concentration, 5 – 15 lb/bbl (14.3 – 42.8 kg/m3) of fine lost circulation
material. When losses are noticed and do not quickly self heal, add progressively larger particles to
mud. Use cellulosic fibres and/or granular materials, typically at 5 lb/bbl (14.3 kg/m3) that do not interfere
with shaker screens or that alter rheology.

Pump pills/sweeps of mud treated with higher concentrations, 50 – 100 bbl (7.95 – 15.9 m3) of larger
particles if these cannot be carried in the active system. Repeat pumping after a specific footage e.g.
50 - 100 ft (15 – 30 m) has been drilled.

losses into natural fractures

Naturally fractured formations are characterised by in-situ fractures that must be large enough to
allow the passage of all mud solids e.g. drill solids and barite. The average particle size for barite is
around 15 microns, so fractures must be at least 30 microns or larger. The fracture width can be
increased by increasing the mud density, therefore opening and further propagating the fracture.

Start with mud carrying a base concentration, 5 – 15 lb/bbl (14.3 – 42.8 kg/m3) of fine lost circulation
material. When losses are noticed and do not quickly self heal, add progressively larger particles to
mud. Use cellulosic fibres and/or granular materials, typically at 5 lb/bbl (14.3 kg/m3) that do not interfere
with shaker screens or that alter rheology.

Pump pills/sweeps of mud treated with higher concentrations, 50 – 100 bbl (7.95 – 15.9 m3) of larger
particles if these cannot be carried in the active system. Repeat pumping after a specific footage e.g.
50 – 100 ft (15 – 30 m) has been drilled.

losses into induced fractures

To minimise exposure to induced losses, practice the following :

(a) Use proper technique for running LOT to asses fracture gradients and in-situ minimum horizontal
stress.
(b) Keep mud density / ECD below fracture initiation, or fracturing reopening, pressure.
(c) Keep rheological properties to a manageable minimum:

ƒ Minimise ECD and surge pressures

ƒ Monitor downhole pressure with ECD tools or downhole pressure gauges
ƒ Ensure the rheology, 6 rpm reading, is adequate to prevent sag of the weighting material


 Section

10c hole problems - lost circulation

When fractures are induced and propagated, reduce mud density below fracture gradient. This,
however, may not be possible when other formations are exposed such as over pressurised
zones or weak formations, e.g. shales which require high mud overbalance for stability, or when the
margins between pore-pressure and fracture gradient are low. Remedial treatments are essentially
similar to the remediation of natural fractures.

responding to losses
basic strategy
1. Maintain lowest possible equivalent circulating density (ECD) for conditions. Hole size, angle, and
drilling fluid density requirements affect the ability to use one or more of the following to optimise
ECD as low as possible.
ƒ Reduce plastic viscosity and yield point of drilling fluid. Plastic viscosity may be difficult to reduce
depending upon drilling fluid weight. Minimise yield point while maintaining hole cleaning
ability.
ƒ Reduce flow rate; use computer modelling to calculate requirements for hole cleaning.
ƒ Reduce rotating rate, rpm. Maximum of 100 rpm, 80 - 90 recommended.

2. Use ECD effects to simulate weight up while drilling and circulating.

3. Pre-treat drilling fluid system prior to entering the depleted, potential loss, zone.

Equipment Requirements and Limitations

1. Use of motors to drill generally precludes pre-treatment of the drilling fluid with loss circulation
material, LCM.
2. Use of measurement while drilling, MWD, tools in the drill string can limit the type and amount of
LCM used in the drilling fluid system or pills that may be spotted to heal loss zones. Check
specification of the tools to be used to determine feasibility of pumping LCM-containing drilling fluid
through them.
3. Use of a circulating sub in the drilling string above MWD or motors may provide flexibility to spot or
circulate LCM treated pills in cases where severe losses are possible.
4. Bit Jets: 16 or larger preferred, 14 minimum.
5. Shaker screens: 20 - 40 mesh.

seepage losses < 10 bbl/hr (1.59 m3)

Non Productive Zones:

1. Firstly, decide if the loss rate is acceptable/sustainable. At low loss rates and with inexpensive
mud it may be OK to drill ahead without treatment.
2. If the losses are thought to be induced, reduce ECD, flow rate, viscosity and ROP, and consider a
mud weight reduction. Ensure hole cleaning is maintained. If these approaches are successful
this confirms the losses were induced. Drill ahead - LCM treatment may not be required.
3. If losses continue, drill ahead and add 5 -10 sacks per hour medium LCM to suction pit. Calcium
carbonate is recommended, or it may be substituted with other medium grade LCM. If the mud
does not contain fines, add 2 sacks/hr fine LCM in addition to the medium grade until the fines
build in the system.
4. If seepage continues, increase LCM particle size and quantity, and consider different blends of
materials. e.g. mix 10 sacks per hour of a combination of medium fibre and medium calcium
carbonate.
5. Check that mud weight and viscosity restrictions are not being exceeded. Monitor shaker screens
for blinding.

10
6. If the seepage continues and is unacceptable, locate the loss zone and spot minimum 50 bbl (8 m3)
pill and pull up
ƒ 20 lb/bbl (57.1 kg/m3) medium grade calcium carbonate
ƒ 20 lb/bbl (57.1 kg/m3) medium grade fibre or flake
ƒ 10 lb/bbl (28.53 kg/m3) fine grade calcium carbonate

If the loss zone cannot be located change shaker screens to larger mesh size and treat entire
system with 15 - 25 lb/bbl (42.8 – 71.3 kg/m3) medium/fine LCM blend in ratio 2:1 medium to fine.

Productive Zones
1. If the losses are suspected to be induced, reduce ECD, flow rate, viscosity, and ROP, and consider
a mud weight reduction. Ensure hole cleaning/well bore stability is maintained otherwise pack-off
could occur. If these approaches are successful this confirms the losses were induced. Drill ahead.
LCM treatment may not be required.
2. If losses continue, drill ahead and add 5 - 10 sacks per hour medium LCM to suction pit.
Calcium carbonate must be used unless other materials have been approved for use in the
production zone, such as certain cellulose fibres. If the mud does not contain fines, add 2 sacks/
hr fine calcium carbonate in addition to the medium grade until the fines build in the system.
3. Check that mud weight and viscosity restrictions are not being exceeded. Monitor shaker screens
for blinding.
4. If the seepage continues, locate the loss zone and spot minimum 50 bbl (8 m3) pill, made using active
mud, and pull up and wait 2 – 4 hours. Pill should contain 30 – 50 lb/bbl (85.6 – 142.7 kg/m3) calcium
carbonate or other approved LCM blend:

ƒ
20 lb/bbl (57.1 kg/m3) medium grade calcium carbonate.
ƒ
20 lb/bbl (57.1 kg/m3) medium grade approved cellulose fibre.
ƒ
10 lb/bbl (28.5 kg/m3) fine grade calcium carbonate.

Alternatively, if the loss zone has not been located change shaker screens to larger mesh size and
treat entire system with 15 - 25 lb/bbl (42.8 – 71.3 kg/m3) of medium/fine calcium carbonate blend in
ratio 2:1 medium to fine.

partial losses 10 to 30 bbl/hr (1.59 – 4.77 m3/hr)

Non Productive Zones:

1. Consider reducing mud weight and ECD, if possible. Drill slower, reduce circulation rate and
rheology, ensure adequate hole cleaning and maintain well bore stability, trip in hole slower,
break circulation while rotating and working pipe, etc. Evaluate and eliminate any annular
restrictions which may be causing an imposed annular pressure, such as balling of bit / BHA, mud
rings, cuttings beds, etc. These actions may cure the problem if the losses are induced.
2. Drill ahead but consider treating entire system with 15 – 25 lb/bbl (42.8 – 71.3 kg/m3) medium LCM.
If the mud contains very few fine solids, add 5 lb/bbl (14.3 kg/m3) fine grade LCM initially as well,
until the larger LCM starts to grind down and produce the smaller particles. Check shaker screens for
blinding.
3. If losses continue and loss zone identified, spot 50 -100 bbl (7.95 – 15.9 m3) coarse LCM pill and pull
up and wait 2 - 4 hours. Pill should be mixed using active mud containing:

ƒ
30 lb/bbl (85.6 kg/m3) coarse LCM (e.g. calcium carbonate, fibre, or nut shells).
ƒ
20 lb/bbl (57.1 kg/m3) medium LCM.
ƒ
5 lb/bbl (14.3 kg/m3) fine LCM.

Note: Be sure bit nozzles and any MWD equipment are large enough to allow larger LCM to pass
without plugging. Use circulating ports in the drill string.

11
 Section

10c hole problems - lost circulation

4. If partial losses continue, repeat pill procedure, spotting larger volume pill. Drill ahead and
add 5 – 10 sacks/hr medium LCM to maintain sealing capability of the mud. Check bit nozzles/
MWD can handle the LCM and that shaker screens are not blinding.

Productive Zones:
1. Consider reducing mud weight and ECD, if possible. Drill slower, reduce circulation rate and
rheology, be sure to maintain adequate hole cleaning and well bore stability, trip in hole slower,
break circulation while rotating and working pipe, etc. Evaluate and eliminate any annular restrictions
which may be causing an imposed annular pressure, such as balling of bit / BHA, mud rings, cuttings
beds, etc. These actions may cure the problem if the losses are induced.
2. Drill ahead but consider treating entire system with 15 – 25 lb/bbl (42.8 – 71.3 kg/m3)
medium LCM. Use calcium carbonate unless other LCM has been approved for the pay zone. If the
mud contains very few fine solids, add 5 lb/bbl (14.3 kg/m3) fine calcium carbonate initially as well,
until the larger LCM starts to grind down and produce smaller particles. Check screens for blinding.
3. If losses continue and loss zone identified, spot 50 -100 bbl (7.95 – 15.9 m3) coarse LCM pill and pull
up and wait 2 - 4 hours:
Pill should be made using active mud containing:

ƒ 30 lb/bbl (85.6 kg/m3) coarse grade calcium carbonate, or blend 20 lb/bbl (57 kg/m3) with 10 lb/
bbl (28.5 kg/m3) of approved cellulose fibre.
ƒ 20 lb/bbl (28.5 kg/m3) medium grade calcium carbonate, or blend with approved cellulose fibre.
ƒ 5 lb/bbl (14.3 kg/m3) fine grade calcium carbonate.

Note: Be sure bit nozzles and any MWD equipment is large enough to allow larger LCM to pass
without plugging.

4. If partial losses continue, repeat pill procedure, spotting larger volume pill. Drill ahead and add 5 –
10 sacks/hr approved medium LCM to maintain sealing capability of the mud. Check bit nozzles/
MWD can handle the LCM and shaker screens are not blinding.

Severe Losses 30 to 100 bbl/hr (4.77 – 15.9 m3/hr)

Non Productive Zones:

1. Consider reducing mud weight and ECD, if possible. Drill slower, reduce circulation rate and
rheology, be sure to maintain adequate hole cleaning and well bore stability, trip in hole slower,
break circulation while rotating and working pipe, etc. Evaluate and eliminate any annular
restrictions which may be causing an imposed annular pressure, such as balling of bit / BHA, mud
rings, cuttings beds, etc. These actions may cure the problem if the losses are induced.
2. Identify loss zone, spot 50 –100 bbl (7.95 – 15.9 m3) LCM pill, pull up and wait 2- 4 hrss:
Pill should be made using active mud containing:

ƒ 30-50 lb/bbl (85.6 – 142.7 kg/m3) extra coarse LCM, single additive or blend, preferably containing
fibre or nut shells.
ƒ 20 lb/bbl (57.1 kg/m3) coarse LCM.
ƒ 10 lb/bbl (28.5 kg/m3) medium LCM.

Note: Be sure bit nozzles/downhole equipment are large enough to allow larger LCM to pass
without plugging. Use drillstring circulating subs. Be prepared for shaker blinding.

3. If severe losses continue, repeat the pill. If partial losses now occur, refer to earlier procedures 1
and 2 to suit the new loss rate.
4. If severe losses still continue, consider soft or hard plugs; refer to total loss section, below, for
options.

12
Productive Zones:
1. Consider reducing mud weight and ECD, if possible. Drill slower, reduce circulation rate and
rheology, be sure to maintain adequate hole cleaning and well bore stability, trip in hole slower,
break circulation while rotating and working pipe, etc. Evaluate and eliminate any annular
restrictions which may be causing an imposed annular pressure, such as balling of bit / BHA, mud
rings, cuttings beds, etc. These actions may cure the problem if the losses are induced.
2. Identify loss zone, spot 50 –100 bbl (7.95 – 15.9 m3) LCM pill, pull up and wait 2 - 4 hrs:
Pill should be made using active mud containing:

ƒ 30-50 lb/bbl (85.6 – 142.7 kg/m3) extra coarse grade calcium carbonate, or other approved LCM
for the production zone.
ƒ 20 lb/bbl (57.1 kg/m3) coarse grade calcium carbonate, or other approved LCM for the production
zone.
ƒ 10 lb/bbl (28.5 kg/m3) medium grade calcium carbonate, or other approved LCM for the production
zone.

Note: Be sure bit nozzles/downhole equipment are large enough to allow larger LCM to pass
without plugging. Use drillstring circulating subs. Be prepared for shaker blinding.

3. If severe losses continue, repeat the pill. If partial losses now occur, refer to earlier procedures to
suit the new loss rate.
4. If severe losses still continue, consider soft or hard plugs; refer to total loss section, below, for
options.

total losses >100 bbl/hr (15.9 m3/hr)

There are many options available to address high loss rates, ranging from ordinary cements to
specialised cements, ‘gunks’ and polymer systems.

With such a wide choice of options available it can be difficult to make a selection. In practice, the
exact chemical system chosen is not critical, provided it is the right type of system for the job and is
engineered correctly.

Most failures actually occur because of engineering errors. To avoid engineering errors ensure:

ƒ sufficient pill volume is pumped.

ƒ setting time is correctly calculated.
ƒ no contamination.
ƒ the pill is spotted in the right place.
ƒ appropriate equipment for mixing and pumping is available.

engineering principles
Many of these treatments will require specialised mixing and pumping procedures. The product
supplier should provide detailed instructions on the mixing and placement of the material.

Some general guidelines are as follows:

ƒ Locate the loss zone and design sufficient pill volume.

ƒ Establish how the material will be delivered downhole (i.e. by a pumping unit or with the rig
equipment); make sure the equipment is set up.
ƒ Count pump strokes and be sure to know where the treatment is at any one time.
ƒ Some treatments are polymer systems which are triggered by cross-linking agents. Setting time
is usually very dependent on temperature so accurate downhole temperature prediction is
very important. If possible it is recommended a pilot test is done to confirm cross-linking time at
downhole temperature and pressure. Note that the temperature will normally be less than the
static BHT due to cooling which has occurred due to the losses. So setting times can be longer than
expected. Pills pumped down will take a considerable time to heat up.
13
 Section

10c hole problems - lost circulation

ƒ Monitor pipe and casing pressures to reduce the possibility of induced losses and to verify the
displacement of the LCM from the pipe.
ƒ Squeeze the treatment into the formation, if possible.
ƒ Pull the drill pipe clear of the calculated top of the pill by at least 100 bbl (15.9 m3) of hole volume or
pull into casing - otherwise the string could become cemented in.
ƒ Wait the required time for the treatment to react and take effect.
ƒ To avoid blockage, do not try to pump particles bigger than 1/3rd the nozzle diameter through
the BHA, and check MWD restrictions.
ƒ Use a pill with density equal to the active mud to avoid migration.

treatment selection
Conventional LCM are not effective for very high loss rate situations (>100 bbl/hr or 15.9 m3 /hr). They
work by bridging, and at loss rates >100bbl/hr (15.9 m3 /hr) the fractures/voids are generally too large
for the materials to function. The alternative is to use chemical systems which set and seal the loss
zone.

There are several types of system available:

ƒ Cements/Modified Cements
ƒ Gunks and Reverse Gunks
ƒ Dilatant Slurries
ƒ Cross-linked Polymers & Gelled plugs
ƒ Silicate systems

Points to consider when using these type of pills:

1. Ordinary cements form a hard set which tends to be brittle. This is long-lasting but will not ‘breath’
with the well bore. If flexing of fractures is likely to occur a more flexible plug, e.g. polymer plug
or gunk type system, is more appropriate. Cements also have relatively long setting times and are
not generally pumped through the bit. This can cause long delays.
2. Cements used for extreme losses should be preceded with a silicate type pill which flash-sets
the cement. Otherwise, large volumes would need to be pumped.
3. Gunk and reverse gunk treatments are a cheap and often effective cure in very high loss situations.
They have the advantage they are not very sensitive to temperature, setting time. However, these
systems generally have a limited lifetime and do not withstand high differential pressures. A gunk
pill strengthened with added cement powder will allow it to withstand higher differential pressure,
although this is only suitable for WBM applications.
4. When considering cross-linked polymer treatments for sealing, ensure there are bridging solids
present which will help to screen out and seal any fracture. Many polymer systems already
contain such solids. Ensure the treatment can still be pumped through the BHA, if this is intended.
Be aware of the importance of temperature.
5. Curing losses in the production zone requires special attention. It should be assumed that
damage will occur to the region where the pill is pumped. There are few treatments which are
usable in open hole completions and any solution should be lab tested to ensure it can be removed
at a later date if necessary. It is more effective to try to engineer a treatment with bridging solids
to minimise the invasion of material into the rock matrix.

14
gunk squeezes
Description
The basic system forms a fairly soft plug. Essentially the gunk treatment involves mixing bentonite,
or bentonite/polymer into an oil such as diesel. This mixture is pumped down the drill pipe while
water based mud is pumped down the annulus. When the two streams meet, a thick gunk is formed
as the bentonite or other additives hydrate in the water. This is then squeezed into the formation.
The hardness of the gunk depends on the relative pump rates and the concentration of the pill.
Typically the mud and pill would be pumped at similar rates and the pill would contain around 200 - 400
lb/bbl (571 – 1141 kg/m3) bentonite. In many situations today environmental regulations may preclude
the use of diesel oil. Low toxicity or synthetic base fluids may be used in place of diesel. They should be
pilot tested in the mud laboratory at the wellsite to determine performance.

A cement unit is best for displacing the gunk squeeze. The pumping unit displaces the mixture
down the drill string and the mud pump pumps fluid down the annulus. The slurry reacts with water
so that precautions to keep water from prematurely contacting the slurry are needed. An oil spacer is
pumped in front of and behind the pill.

Benefits:
ƒ Temperature is not very important.
ƒ Soft set avoids sidetracking problems, easy to wash/drill out.
ƒ Slurry will normally pass through BHA.
ƒ Procedures are well established.
ƒ Suited to large fractures/voids.

Limitations:
ƒ Placement – need to generate gunk in the right place.
ƒ Flow rate and mix is important to achieve suitable consistency.
ƒ Suitable experience required.
ƒ Avoid premature mud contamination.
ƒ Possible environmental restrictions dealing with oily returns.
ƒ Effect can be short-lived due to softness of the plug, simple gunk.
ƒ May not work with high salt muds, >50,000 mg/l chlorides.

gel/polymer gunk squeeze

Formulation for 25 bbl (4 m3 )

ƒ 18 bbl (2.86 m3) Diesel or other base fluid.
ƒ 4,800 lbs (2,177 kg) bentonite, final density = +/-10 lb/gal (1.20 SG).
ƒ 750 lbs (340 kg) PHPA powder if available can also be added.

15
 Section

10c hole problems - lost circulation

Recommended Mixing Procedure

Mix in a cementing batch tank. This pill should not be mixed in the pits:

ƒ Ensure the cement unit, batch tank and all associated pipe work is completely drained and
then flushed through with diesel or other suitable base fluid.
ƒ (Add PHPA powder to the diesel or other base fluid first, then add the bentonite. Preferably add
the PHPA through a mixing jet, not directly into the tank, to avoid lumps)
ƒ If the mixture becomes too thick to add the required quantity of bentonite, stop mixing and use
the slurry as it is.
ƒ Test the gunk by mixing a sample of it 50:50 with the mud. Check the quality - it should be a consistency
similar to a thick paste within 30 seconds.

Recommended Pumping Procedure

1. Place the bit above the loss zone such that the height between the bit and loss zone is equivalent
to 50 bbl (8 m3) of hole volume.
2. Line up mud pumps to pump simultaneously down the drill pipe and annulus.
3. Line up cement unit to pump down the drill pipe.
4. With the cement unit pump 10 bbl (1.59 m3) diesel or base fluid followed by 25 bbl (4 m3) gunk
and a further 10 bbl (1.59 m3) diesel/base fluid down the drill pipe.
5. Displace with the mud pump until diesel/base fluid is at the bit. Close annular.
6. Pump at 5 bpm (0.795 m3 /min) down the drill pipe and 10 bpm (1.59 m3 /min) down the annulus
simultaneously until half of the gunk is out of the bit.
7. Pump at 5 bpm (0.795 m3 /min) simultaneously down both the drill pipe and annulus until the gunk
has been over displaced from the drill pipe by 5 bbl (0.795 m3).
8. Squeeze gunk into the loss zone. Leave at least 5 bbl (0.795 m3) gunk inside the wellbore to prevent
over displacement. Try to establish a shut-in pressure at the end.
9. If successful, leave the gunk to firm up for 8 – 10 hours prior to washing out.

Remarks
The gunk pill is inert until it is mixed with water or water based mud. It must only contact water
based fluids as it exits the bit. The purpose of initially pumping down the annulus at twice the
rate down the pipe is to initially produce a slower reacting product that can penetrate the formation
more easily. The last part of the gunk is mixed 50:50 and plugs the loss zone quickly.

The flow rates are designed to deliver the gunk to the loss zone quickly after the gunk has been mixed
with the mud. The progress of the job should be determined and monitored by the volume of
displacement mud pumped down the drill pipe.

reverse gunk squeeze for use in OBM

This is the reverse procedure compared to ordinary WBM gunk squeezes. Typically, organophilic
clay is mixed into an aqueous suspension and pumped down the drill pipe. The oil mud is pumped
simultaneously down the annulus and gelation occurs when the two fluids meet. The gunk is
squeezed into the formation. Note that it is not possible to add cement to strengthen the pill.

Benefits:
ƒ Temperature is not very important.
ƒ Soft set avoids sidetracking problems (easy to wash/drill out).
ƒ Slurry will normally pass through BHA.
ƒ Procedures are well established.
ƒ Suitable for large fractures/voids.

16
Limitations:
ƒ Placement – need to generate gunk in the right place.
ƒ Suitable experience required.
ƒ Avoid premature mud contamination.
ƒ Mixing time/placement often greater than 6 hrs.
ƒ Effect can be short-lived due to soft plug formed.
ƒ The type of clay used to make the treatment can be quite critical.

Recommended Formulations
A. Formulation for 1 bbl (0.159 m3) of unweighted reverse gunk pill

Product Amount
Water 0.72 bbl (0.114 m3)
Caustic Soda 1.5 lb (0.68 kg)
Dispersant (CFL) 3.5 lb (1.59 kg)
Organophilic clay 250 – 350 lb (113.4 – 158.7 kg)

Note: This formulation is provided as a guide only. The yield obtained will vary greatly dependant
on the particular organophilic clay used. Pilot testing of the pill formulation is strongly
recommended. The formulation given above will have a density of approximately 12.0 lb/gal
(1.44 SG).

B. Formulation for 1 bbl (0.159 m3) of weighted 13.0 lb/gal (1.56 SG) reverse gunk pill.

The slurry density can be increased to that of the active mud weight by viscosifying the water/clay
slurry with XCD polymer and adding barite. This must be pilot tested prior to use to determine the
optimum amount of XCD Polymer.

Product Amount
Water .72 bbl (0.114 m3)
Caustic Soda 1.5 lb (0.7 kg)
Dispersant (CFL) 4.4 lb (2 kg)
Organophilic clay 100 lb (45 kg)
Barite 80 lb (36 kg)
XCD Polymer as determined

Recommended Mixing Procedure

The pill should preferably be prepared in the cement batch tank. Ensure that the batch tank and all
associated lines are clean by flushing thoroughly with a water based rig wash followed by large
volumes of water.

Add the ingredients in the order shown utilising as much shear as possible to disperse the
organophilic clay. A minimum pill of 25 bbl is recommended.

The resultant slurry is preferably pumped through open ended pipe but may be pumped through
the bit if it is not practicable to POOH. The following displacement procedure should be strictly
followed to prevent gelation within the drill pipe. Before the displacement the string should be pulled
back to a height sufficient to leave the pill volume of open hole.

17
 Section

10c hole problems - lost circulation

Recommended Pumping Procedure

1. Pump 10 bbl (1.59 m3) oil
2. Pump 10 bbl (1.59 m3) water
3. Pump the slurry 25 bbl (4 m3)
4. Pump 10 bbl (1.59 m3) water
5. Pump 10 (1.59 m3) oil
6. Displace the pill to the bottom of the drill string.
7. If the hole is full, close the annular and squeeze at 300 – 500 psi (2069 – 3448 kPa) into the formation.
8. If the hole is full, close the annular and pump the pill at 1 bbl/min (0.159 m3 /min) down the drill pipe
and mud at 1 bbl/min (0.159 m3 /min) down the annulus.
9. Allow at least 4 hours for the plug to set.

Note: Ensure that the entire pill is pumped out of the string. Do not attempt to reverse circulate.

decision tree to identify losses

Whole mud loss

Is loss occurring downhole?

NO Cure surface loss

YES

Similar loss in same section Were losses

of adjacent well YES successfully treated?

NO NO YES

Unconsolidated or high Repeat cure, using same

Continue analysis in light of
permeability formation in placement
past experience
open hole section? procedure and LCM

YES
NO

Did loss start gradually,

Did loss start while tripping? building up to
maximum rate?

NO
YES
Scenario: Induced Fractures Scenario: Natural Fractures
3or 7 3or 7
o Is loss associated with recent o Is loss associated with drill
increase in ECD? break? NO YES
o Is ECD near anticipated o Is fault or fractured
fracture gradient? interval anticipated in open
o Is formation permeable? hole section?

o Is loss rate highly o Is rock dolomitised or karsti-

fied? Is loss rate highly
sensitive to change in ECD? sensitive to change
o Is loss associated with lithol- o Have small losses in past 10- in ECD?oss
NO
ogy change from shale to 20meters slowed considerably?
sandstone o Is formation interbedded?
More 3than 7 More 3than 7
Natural Fractures Induced Fractures
YES

YES YES

Losses through induced Losses through natural

fractures fractures Losses through pores

18