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Summary
A high-strength, high-stability (HSHS) pill system for controlling
lost circulation has been developed and optimized on the basis of a
physical model of a stable plugged zone. This HSHS pill system provides a stronger and more-effective seal than traditional treatments.
Controlling lost circulation with a plugged zone formed with
lost-circulation material (LCM) in the fracture has achieved tremendous success in past years. However, investigation into the
strength and stability of the plugged zone has not been reported.
Lack of such knowledge often leads to excess costs from repeated
fluid loss and rig time; it increases the difficulty and complexity
of loss-zone diagnosis.
The new HSHS pill system addresses these shortcomings. Surface-friction coefficient, LCM volume fraction, and amount of contact deformation are the main influencing factors of the strength
and stability of the plugged zone. The strength of the plugged zone
is enhanced with the increase of the above factors. A physical
model for stable plugged zone is established considering the three
factors. The pill system that is based on the model provides an
engineered combination of rigid granules, fibers, and resilient particles. The sealing efficiency and the pressure-bearing capacity are
greatly enhanced. It was validated in several field trials in west
China. Operational practices that facilitate the safe use of the
HSHS system with overbalance exceeding 2,174 psi are discussed.
In addition to the field-trial results, this paper also describes the laboratory experiments, that were used for developing the new system.
With the development of the physical model and the HSHS
pill system, it is now possible to optimize and select the types,
properties, and matching relations of the LCM. One can also use
this technology to guide the design of the wellbore-strengthening
scheme and to make sure of the long-term effectiveness of wellbore-strengthening measures.
Introduction
The formation pressure-bearing capacity is the comprehensive reflection of structural integrity and the strength of formation, drilling-fluid
properties, and the interaction between formation and drilling fluid.
Low strength of rock, high development of fracture, and poor plugging ability of drilling fluid often lead to wellbore breakdown or, natural- and induced-fracture propagation. One can see this by formation
low-pressure-bearing capacity and massive losses of drilling fluid
associated with other downhole troubles, which can seriously hinder
the exploration and development of oil and gas resources.
An American Petroleum Institute study published in 1991
includes data indicating that up to 45% of all wells require an intermediate casing string to prevent severe lost circulation while
drilling to total depth (API 1991). Even with the use of these extra
strings, lost-circulation events, still occurred in 18 to 26% of all
hole sections. Some areas reported many more occurrences of
lost-circulation events ranging from 40 to 80% of wells. In recent
years, these percentages have increased because the number of
shallow, easy-to-find reservoirs has steadily declined and industry
operators have intensified their search for deeper reservoirs and
C 2014 Society of Petroleum Engineers
Copyright V
This paper (SPE 172496) was revised for publication from paper IPTC 17127, first presented
at the International Petroleum Technology Conference, Beijing, 2628 March 2013. Original
manuscript received for review 17 January 2013. Revised manuscript received for review 8
October 2013. Paper peer approved 16 June 2014.
334
drilled through depleted or partially depleted formations. Conventional lost-circulation-management methods including pills,
squeezes, pretreatments, and drilling procedures using equivalentcirculating-density (ECD) management have reached their limit
in effectiveness and have become unsuccessful in the deeper-formation conditions, where some formations are depleted, structurally weak, or naturally fractured and faulted.
In the case of occurrences of natural and induced fractures in
which ECD and drilling-fluid weight are already minimized or
cannot be altered, wellbore-strengthening measures are often used
for enhancing the formation pressure-bearing capacity and arresting potential lost circulation. Wellbore-strengthening basics and
successful field applications have been documented many times
(Alberty and McLean 2004; Goud and Joseph 2006; Xu et al.
2011). The most-common wellbore-strengthening theories are
hoop-stress enhancement (stress cage) (Alberty and McLean
2001; Aston et al. 2007), fracture-propagation resistance (FPR)
(Wang et al. 2008; van Oort et al. 2009), and fracture-closure
stress (FCS) (Dupriest 2005; Dupriest et al. 2008). It is a process
of plugging the natural or induced fractures and keeping the fractures propped open with LCM through forming the fracture
plugged zone so that the near-wellbore region is in a state of
compression and the formation pressure-resisting capability is
enhanced. After the fractures are plugged, the pressure-bearing
capacity and the stability of the plugged zone are of prime importance, which is related to the quality of formation strengthening,
formation-damage control, and the smooth proceeding of following measures (Kang et al. 2012; You and Kang 2009). However,
the structure and mechanical property of the plugged zone were
less studied in the previous work. In a word, it is of great importance to describe the structure, analyze the influencing factors,
and finally establish a physical model of the stable plugged zone
so that high plugging strength and stability can be achieved and
relevant field operation can be guided.
Several models were reported to optimize the size distribution
for these granules to maximize their plugging and sealing efficiency: The Abrams model (Abrams 1977), ideal-packing theory
(Dick et al. 2000), and the Vickers model (Vickers et al. 2010).
Even though these algorithms vary in optimizing the particle-size
distribution, they all agree that the optimized granule size is a
function of the loss-zone geometry (i.e., the median granule size
should be equal to one-third of the fracture width). However, not
only does LCM-size distribution affects the plugging effectiveness, but also the LCM types and their combination play important roles in the plugging strength and stability. Moreover, the
plugged zone formed in the fracture must develop enough strength
to sustain crushing and shearing stress exerted by the formation
and fluid. In this paper, the HSHS pill system is developed with a
combination of rigid particles, fiber, and resilient particles to
effectively increase the plugging ability of the drilling fluid and
the plugging stability of the plugged zone.
Plugging Capacity and Stability Analysis of HSHS
System
The plugged zone composed of LCM is a granular-matter system
with internal structure and mechanical properties that, to a large
extent, determine the plugging capacity and stability of the plugging system. On the basis of the relevant knowledge of granularmatter mechanics (Sun and Wang 2009), the granular-matter
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plugged zone
mesoscale
microscale
macroscale
The amount of contact deformation a between each pair of particles is expressed as the ratio of the total deformation D of a force
chain to the number of particles in the chain:
a D=N Dd=L ; . . . . . . . . . . . . . . . . . . . . . . . . . . 1
where
Fig. 1Force-chain network (Sun and Wang 2009).
N L=d ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
system composed of LCM is intrinsically multiscale. Besides microscopic single particle and macroscopic plugged zone formed
in the fracture channel, it also consists of mesoscopic force
chains developed by several particles constantly contacting each
other under external load. Fig. 1 shows the force-chain network
throughout the granule system. The force chain is the main way
for the mascroscopic plugged zone to transfer the external load.
Fig. 2 briefly describes the relations among the three scales. The
performance of microscale depends mainly on the intrinsic property parameter of the LCM. The mesoscale forms the force chain
on the basis of the contact force of the microscale and develops
under the control of the macroscale. Under the action of external
load, the dynamic evolution rules of the mesoscale determine the
mechanical response of the macroscale. The size of force chain is
bigger than the single particle but smaller than the granule system.
It is the mesoscale force chain that supports most crushing and
shearing stress with a direction that is mainly perpendicular to the
compressive stress. The strength of mesoscopic force chains has a
great effect on the strength of the macrosopic plugged zone.
After the composite solution is pumped downhole, the plugs
forming within the open fractures must remain stable and sustain
the FCS, elevated differential pressure, and pressure fluctuation
while surging and swabbing. The FCS mainly holds the fracture
faces closed, and the differential pressures are formed by the different fluid pressures between wellbore and fracture (Fig. 3). Therefore, the mechanical strength and stability of the plugged zone are
greatly important to maintaining the long-term plugging effectiveness. According to granular-matter mechanics, the contact-deformation, LCM-volume-fraction, and surface-friction-coefficient
values are the major factors that influence the strength of mesoscale
force chains and influence further the stability of the plugged zone.
Amount of Contact Deformation. In the case of Fig. 3, the force
chains with the direction mainly perpendicular to the fracture face
are compressed by FCS and sheared by the differential pressure.
. . . . . . . . . . . . . . . . . . . . . . . . 3
Vm
; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vf
where Vm is the volume of LCM and Vf is the fracture-loss channel volume plugged by LCM.
A strong force chain cannot be formed in a less-compacted
granule system with low LCM volume fraction. This will lead to
an unstable force chain and high fluid pressure in the fracture.
Furthermore, it will reduce the strength and stability of the
plugged zone. Fiber material has smaller diameter compared with
particles and can fill in the pore between sized particles. Thus, the
LCM volume fraction and compactness of the plugged zone can
be effectively increased by the addition of fiber. One can determine the LCM volume fraction with the SCMS300-CI porosityand-permeability measurement system. First, the porosity of the
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259.60
249.18
245.14
243.18
243.13
239.95
1197.54
1195.31
1195.27
1158.62
1116.52
1114.43
Fig. 5Image of calcium carbonate and graphite carbon particles with median particle size 500 microns (Kumar et al. 2010).
V c up
Vp
1
; . . . . . . . . . . . . . . . . . . . . . 6
Vf
Vf
where
up
Vp
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vc
coefficient will break off easily even if small shear is applied. The
internal friction angle rises with the increase of the surface-friction
coefficient so that the force chain can rotate under a certain angle
without becoming unstable (Fig. 4). It is indicated that the higher
the surface-friction coefficient the LCM has, the higher the shearing
resistance the force chain possesses. Moreover, the antishear ability
of the force chain is also affected by contact area that can be
enlarged by increasing the amount of contact deformation with the
addition of resilient particles. The surface-friction coefficient is
related to the particle diameter, sphericity, and convexity of LCM
that represent surface roughness (Fig. 5). The value of different
LCM combinations can be measured by the granular-matter surface-friction-coefficient measuring system. A schematic of the
measuring system is shown in Fig. 6. The experimental results in
Fig. 7 and Table 1 show that smaller particle diameter, lower sphericity, and lower convexity will lead to higher surface-friction
coefficient.
According to the preceding analysis, the combination of rigid
granules, fiber, and resilient particles has a positive effect on the
values for contact deformation, LCM volume fraction, and
0.35
plate
spring
tension meter
Friction (N)
0.33
0.31
0.29
0.27
0.25
0.23
0.21
0.19
0.17
0.15
lostcirculation
material
0
quasi-static electronic control translation platform
0.5
1.5
2.5
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LCM Type
Diameter
(mm)
Sphericity
Convexity
Surface-Friction
Coefficient
Accuracy
Calcium carbonate
Calcium carbonate
Calcium carbonate
Graphite carbon
Graphite carbon
Graphite carbon
1000
1000
1000
1000
1000
1000
0.54
0.50
0.54
0.53
0.46
0.53
0.96
0.96
0.90
0.90
0.90
0.88
0.145
0.150
0.149
0.167
0.187
0.179
60.006
60.006
60.006
60.006
60.006
60.006
achieve high values of contact deformation, LCM volume fraction, and surface-friction coefficient, which are key factors for
plugging strength and stability. The measurement methods of the
three parameters are introduced and LCM selection criteria to
achieve high value of the three parameters are also described in
the preceding analysis.
Experimental Design
The objective of the laboratory study reported here is to evaluate
and validate the plugging effectiveness of the LCM combination
that is analyzed to be beneficial for the plugging strength and stability. The optimal concentration for the LCM is also investigated
in the experiments. Considering the property of the loss channels
and the repeatability of the plugging test, the experimental design
focuses on the use of a metal core sample with known fracture
size to replicate the fractured loss channel. A series of experiments was designed to investigate the following factors that
reflect the plugging effectiveness and guide the LCM selection.
Maximal plugging pressure and total loss volume before
sealing
Optimal concentration for rigid granules, fiber, and resilient
particles
The effect of the addition of fiber and resilient particles on
plugging effectiveness
The effect of fracture-surface morphology on plugging
effectiveness
The influence of different LCM combinations on the value
of the values of contact deformation, LCM volume fraction, and
surface-friction coefficient (the corresponding values being measured by the Tinius Olsen Hydraulic Press Tester, the SCMS300CI porosity and permeability measurement system, and the granular-matter surface-friction-coefficient measuring system)
Experimental Equipment for Plugging Test. A series of laboratory experiments were conducted in the State Key Laboratory of
Oil and Gas Reservoir Geology and Exploitation at Southwest Petroleum University. The system applied for plugging-strengthand-stability analysis in this paper is the high-temperature and
high-pressure multifunction horizontal-well damage-evaluation
apparatus (Fig. 8). The experiments follow a simple procedure,
and each test could be repeated for reliability.
The apparatus consists of a cylindrical steel vessel in which
the drilling fluid can be heated to a maximal 150 C, an agitator in
the vessel to simulate the fluid-flow state of the drilling process,
and a core-sample holder with an inner diameter of 2.5 cm that is
connected with the confining-pressure-control system. The vessel
is connected to atmospheric pressure through the core-sample
holder. As the experiment starts, water in an intermediate container is pumped under a known pressure to the top of the vessel
to push the drilling fluid out of the vessel through the core sample
fixed in the holder with known fracture size. Fluid pressure up to
20 MPa (2,900 psi) is achievable with this apparatus. The fluid
pressure, confining pressure, and rotational speed of the agitator
can all be controlled and measured independently. In the plugging
tests, the initial applied fluid pressure is 3.5 MPa, and it increases
1.0-MPa increments. Every pressure point is held constant during
the test, if the pressure balance can be built up within 5 minutes
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intermediate
container
rotor
core
motor
and the pressure drop is less than 5% within 15 minutes, and then
increases the fluid pressure to the next pressure point. If the pressure drop is more than 5% within 15 minutes, then the final pressure is recorded within 30 minutes and is taken it as the maximal
plugging pressure. Sometimes, when the applied fluid pressure
exceeds the critical pressure point, the pressure balance cannot be
built up, and the plugged zone will break down with the applied
fluid pressure dropping to zero quickly. In this case, the maximal
plugging pressure is taken as the prior pressure point.
Metal core samples with a fixed length of 50 mm and width of 1
mm are used to simulate the fracture loss channel (Fig. 9). The
flow of the drilling fluid is restricted by the size of the fracture of
the core sample and LCM in the fluid. Evidently, if LCMs can
manage to plug the fracture and form the plugged zone in the fracture, the fluid loss from the vessel to the fracture can be prevented.
Experimental Boundary Conditions. On the basis of the rockmechanics parameter and in-situ stress data of several thief zones,
the dynamic fracture width is simulated and the slot width for the
metal core samples is selected on the basis of the simulation
results. According to the finite-element simulation, the in-situ
fracture width can increase to a maximum of 1.0 mm considering
the positive pressure applied by the drilling fluid (Fig. 10). Thus,
a fracture with a width of 1.0 mm is used in the laboratory study.
Fracture core sample with smooth fracture surface is the most difficult condition to plug. Thus, the smooth fracture is used to evaluate the plugging ability of the LCM. If the core sample with a
smooth fracture surface can be plugged and sealed effectively, the
recommended HSHS solution can also be applied to the core sample with more rough fracture surface. The boundary conditions
used in the plugging experiment are as follows:
Initial wellbore pressure or drilling-fluid application pressure
3.5 MPa (507.5 psi).
Maximal plugging pressure 20 MPa (2,900 psi).
z
fracture
v
D
E
F
P2
P1
monitor
3 MPa
5 MPa
7 MPa
10 MPa
15 MPa
20 MPa
0.5
0.4
0.3
0.2
0.1
0.0
0
200
400
600
800
1000
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After 16 Hours
of Aging at 100 C
600 rev/min
300 rev/min
200 rev/min
100 rev/min
6 rev/min
3 rev/per/min
Plastic viscosity (mPas)
Yield point (Pa)
Funnel viscosity (seconds)
Fluid leaking (cm3/30 min)
74
44
35
27
16
13
30
7.1
85
4.9
69
41
33
25
14
12
28
6.6
81
4.5
16.0
14.0
rigid granule
12.0
10.0
8.0
6.0
4.0
2.0
0.0
fiber based
14.0
12.0
10.0
8.0
6.0
4.0
0.0
3.0
4.0
5.0
6.0
Fig. 12Maximal plugging pressure with different concentration of fiber on the basis of 3% rigid granules that has been
added into the carrier fluid.
In Fig. 12, fiber (DTR) is added into the carrier fluid with 3%
ZD-C to plug and seal the fracture. Fiber can fill in the pores
between particles and increase the LCM volume fraction, which
improve the compactness and plugging effectiveness. The combination of rigid particle and fiber greatly improves the maximal
plugging capacity from 5.5 to 11.5 MPa (Fig. 13). With fiber-concentration increase, the content of fiber in the plugged zone will
increase accordingly. Excessive fiber will reduce the rigid-granule
content in the plugged zone and further have a negative impact on
the plugging effectiveness. Therefore, the maximal plugging pressure reduces slightly with the continuous increase of the fiber concentration. The optimal concentration for fiber is 2 to 3%.
20.0
18.0
16.0
14.0
12.0
resilient particlebased on 3% rigidgranule
and 2% fiber
8.0
6.0
4.0
2.0
0.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
10
rigid particle
8
6
4
2
0
-C
-C
-C
-C
ZD
2%
ZD
3%
ZD
4%
-C
6.0
TR
TR
ZD
-C
3%
ZD
5
2.
+3
-C
-C
ZD
TR
+2
3%
TR
5%
10.0
5.0
12
1%
2.0
4.0
3.0
14
ZD
2.0
1.0
2.0
18.0
0.0
1.0
20.0
16.0
18.0
0.0
Fluid Property
Before
Aging
20.0
-C
ZD
3%
5
3.
ZD
3%
Then, resilient particle (graphite carbon) is added into the drilling fluid with 3% ZD-C and 2% DTR to evaluate the plugging
effectiveness. Resilient particle can improve the resilience and
amount of contact deformation of the plugged zone, which prevents the rigid granule from crushing under pressure and increases
the plugging stability. Therefore, the maximal plugging pressure
is improved to 15.5 MPa with the optimal concentration of 1 to
2.5% of the resilient particle (Fig. 14). Similarly, excessive resilient-particle concentration will reduce the rigid-granule content in
the plugged zone and lead to the slight decrease of the plugging
effectiveness. Compared with Fig. 14 in which the resilient particle
is added on the basis of 3% ZD-C only, the optimal concentration
for the resilient particles is only 1%. This is because the plugged
zone has low compactness without fiber filled into the pore
between particles. In this case, the deformation of the plugged zone
is mainly inelastic and structural deformation so the optimal concentration range is less than that of the resilient particles added in
the carrier fluid with rigid granules and fiber. Fig. 15 presents the
entire experimental results for the maximum plugging pressure
with different concentration of LCM.
Fig. 16 and Fig. 17 show the test results for maximal plugging
pressure and total loss volume before sealing in four kinds of circumstances: rigid granules only, fiber only, resilient particles
only, and a combination of all the three types. The concentrations
of LCM are the same 5% when it is used separately. In the LCM
combination, the concentration is 3, 2, and 1% for rigid, fibrous,
and resilient separately, respectively. When the LCM in the plugging slurry is rigid granule only, fiber only, and resilient particle
only, the maximal plugging pressure is 5.5, 4.1, and 4.9 MPa,
respectively. The total loss volume before sealing is 865, 470, and
846 cm3, respectively. From the experiment results, we can see
that the combination of the three types of LCMs can greatly
improve the plugging effectiveness and efficiency. As a result of
synergy, the maximal plugging pressure is increased to 15.5 MPa,
339
rigidgranule
22.5
fiberbased on 3% rigidgranule
20.0
Stage:
17.5
15.0
12.5
10.0
7.5
15.5
10
5.5
4.1
2.0
3.0
4.0
5.0
6.0
7.0
Concentration (%)
846
470
50
rigid granule only fiber only resilient particle combination of
only
all the three types
Types of LCM
Fig. 17Total loss volume before sealing with different plugging system (average results of 30 sets of experiments).
where Q is volume flow rate, cm3/s; l is the viscosity of drillingfluid filtrate, mPas; L is the length of fracture plugged zone, cm;
25
20
15
18.2
19.5
15.0
4
3
2
1
0
10
20
30
40
Time (min)
50
60
70
10
5
0
type I
type II
type III
5
Cumulative filtration volume cm3
865
fiber only
4.9
2.5
1.0
Total Pages: 10
15
5.0
0.0
0.0
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20
25.0
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25%
15 MPa
30 MPa
20%
15.7%
15%
12.2%
10%
5%
2.2%
0.0%
2.7%
0.3%
0%
rigid granular
100%
89.1%
90%
92.3%
79.5%
80%
70%
Number
LCM Type
60%
1
2
3
Rigid granules
Rigid granules and fiber
Rigid granules, fiber,
and resilient particles
50%
rigid granular
and resilient particles. Fiber can fill in the pores between particles
and increase the LCM volume fraction, which improves the compactness and plugging effectiveness of the plugged zone. Compared
with rigid granules, resilient particles have higher sphericity and
convexity that are related to their surface-friction coefficient. Also,
the resilience of resilient particles can greatly improve the amount
of contact deformation of the plugged zone. On the basis of the
LCM selection criteria, the values for amount of contact deformation, LCM volume fraction, and surface-friction coefficient are
greatly increased by the combination of rigid granules, fiber, and
resilient particles (Fig. 20, Fig. 21, and Table 3). Fig. 24 shows the
HSHS plugged zone formed in the laboratory.
5.5
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
0.01
Accuracy
0.150
0.185
0.256
60.006
60.006
60.006
its performance in terms of the ability to plug the loss zone and
remain effective until the trouble zone is cased off. In addition to
this objective, much analysis was performed and laboratory
experiments were conducted.
Western Sichuan deep carbonate gas reservoirs are characterized by developed natural fractures. For Well 4 in the Puguang
structure of Sichuan basin drilled with water-based drilling fluid,
serious lost circulations of 1.74-g/cm3 drilling fluid were observed
on the top of the Feixianguan target zone in which natural fractures were developed. On the basis of the analysis of pump pressure, formation pressure, and the loss rate, the HSHS pill system
was selected as the composite solution. The HSHS pill system
included 3% rigid granules (calcium carbonate), 2% fiber (LF-1),
and 1% resilient particles (EP-2), which were added to the original drilling fluid. After the pill was in contact with the loss zones,
squeeze pressure was applied to strengthen the properties of the
composite plug. Operationally, a pill of a 7.9-m3 volume was
placed through the drill bit to plug and seal the loss zone. After 30
minutes, the lost circulation was stopped. A test was then conducted, and the test pressure could reach 15 MPa (2,175 psi) with
100
80
60
40
20
0.1
10
100
1000
Volume (%)
Field Trials
Case History 1. For a land well drilled in western China, the
HSHS system was tested during the drilling operation to validate
Surface-Friction
Coefficient l
0
3000
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Fig. 23In the physical model of the stable plugged zone, the
color red represents rigid granules, the color yellow represents
fiber, and the color black represents resilient particles.
Vf
Vm
Vp
D
ub
up
r
rfu
s
Acknowledgments
The authors gratefully acknowledge the financial support from
Chinese State Municipal Science and Technology Project (No.
2011ZX05005-006-008HZ) and The National Basic Research
Program (973) of China (No. 2010CB226705). The authors express
their sincere appreciation to the reviewers for their constructive
comments.
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