Lost Circulation Solutions for Limestones and Induced Fractures

(or any rock type)

Richard Jachnik Technical Sales Manager

Alex Wienzek Product Line Manager

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History
Lost circulation of Drilling Fluids have been experienced

ever since Drilling Fluids were introduced-especially when drilling porous/fractured and vuggy formations. Many types of Lost Circulation Material (LCM) have been proposed, tried (with little science) and many are still in use. Many technical papers have been written on the subject and if those concerned with minimising formation damage through bridging are also considered the list is extensive indeed So what is new regarding both our understanding and ability to seal natural fractures/vugs in limestones or induced fractures in various rock types?
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Examples of Fractured Chalks

Tectonic

Discontinuous

Healed

Stylolite-assoc.

f f
1 ft

f f

Efficiency...Data accuracy...People-oriented service

Quantification of Losses
Seepage Loss (<4m3/hr) Partial Loss (4 -80 m3/hr) Severe Loss (>80 m3 /hr) These numbers vary according to author and rounding up from bbl to

m3 ! (In mud man parlance loosing >60 m3 per hour is ~2 pits per hour! sufficient!). In 8 hole pumping at 2 m3 per min means returns at 50% or less. Seepage loss is normally loss to porous formations or small discontinuous fractures which may be natural or induced This type of loss can be cured either with small doses of effective LCM (possibly using the application of bridging theory with particulates)

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SPE 18022
This seminal paper by Sandia Natl Labs contains some very useful information.
Converting to mm - if we look at the width of the fracture opening (b) at 0.12 in (3.05mm) we see that even if the particle size diameter is 2mm the fracture will never plug. (Multiple particle bridges do not form with the same material or can sustain the applied pressure) For half the fracture width the same size particle can plug at only 5 ppb (14.3 kg/m3) They also showed that when the particle size was shifted to a larger size distribution they achieved better bridging (next slide)

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Jamming
When flakes were mixed with the particulate (rubber) Sandia

achieved even greater effectiveness this is due to the morphology of flakes and the ability to randomly orient and jam. The use of LC Lube (more elongated morphology than ground marble) at concentrations of 57 kg/m3 in OBM allowed Brent sands to be drilled significantly overbalance with pressures between 3000 and 5400 psi. The material has been used successfully at concentrations as low as 2.85 kg/m3, more often at 15-20 kg/m3 with 100 kg/hr additions while drilling 8 holes. The resiliency of the synthetic graphite is much higher than solid particulates this provides an increase in Frac pressure (wellbore strengthening) and can be used injunction with marble to lower cost
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LC Lube synthetic graphite

Issues Larger is better than finer! Particle Size Distribution Mesh Size 40 50 60 80 Micron 425 m 300 m 250 m 180 m % Retained 27 22 12 19

D50 of LC Lube is around 320 microns or 48 mesh

Initial drilling requires 84/52 mesh screens 145/120 mesh can be used once the mud is warm and fully sheared Some losses at the shakers are inevitable Finer product is less effective at plugging induced fractures in Brent sands

25 x

Seepage loss materials

Fine Mica

These by their very nature

of smaller particle size will not plug large fractures but can be effective for seepage loss into porous formations or into short drilling/ECD induced fractures So at what fracture width will they fail?

Chek-Loss (cellulose fibre)

Max-Bridge Slot Failure

Max-Bridge is a

combination formulation of Soltex or Sulphatrol, MaxShield (latex polymer ~1 micron), LC Lube and LC lube fine designed for Saudi drilling Tested on 200 micron slots it functioned, but failed on 300 micron (next slide)

Particle Size Distribution

100 90 80 70

Percentage

60 50 40 30 20 10 0 0 100 200 300 400 500 600 700

LC Lube Fine LC Lube

Micron

Aquadrill Mud + Max-Bridge + LCM

Note the addition of various LCM used for seepage loss

and the results!

Increasing the pressure to 900 psi and at 150 F doubled the spurt result for test 4 and 8.

RDIF Mud + Sized marbles

Note that the addition of extra calcarb particulates failed to

bridge effectively 100 micron slots

TFL= Total Fluid Loss

No Surprise!
Multiple particle bridges will not form when none of the

particulates has at least a D90 >than the fracture width!

100 90
Fordacal 30

PSD of Fordacal Grades - 2005 data from supplier

Fordacal 10

80 70 Cumulative % 60 50 40 30

Fordacal 45
Fordacal 300 Fordacal 200 Fordacal 100 Fordacal 60 Fordacal 25 Fordacal 36

20 10 0 1 10 Diameter (microns) 100 1000

Fordacal 16 max Fordacal 16 max

but flakes are another story!

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Baker-Squeez
This is a recent product introduction based on a fibrous pill formulation for loss circulation problems. (See SPE papers 139817 & 149120). It is a formulated one sack additive that can be weighted to 18 ppg (2.16 sg) and seals both porous sands, gravels and fractures
The fracture limitation?

From our testing ~1300-1400 micron as it failed at 1500 micron in WBM and at 1000 micron in OBM though bridged 800 micron
Useful for overburden drilling. Convenient and avoids issues of how much LCM to add, which LCM to add and in what combination. Also simplifies rig inventory.

Comparative testing on 1500 micron slots

Only Formulations C & D bridged but with high fluid loss.

Note E failed with more Nut Plug (the surmise is greater sphericity in the mix).

So while formulations C & D would have sealed smaller fractures as well as Baker-Squeez , the formulations are more complex to engineer and liable to failure.
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Solu-Squeez

This material was designed where a degree of solubility in 15% HCl was desired (>90%) and seals up to ~700 micron slots although this could be extended with Soluflake
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What can bridge above 3000 micron? 10 mm?

We can successfully bridge in the laboratory apertures up to 8 mm wide with Soluflake and calcarb blends. Holes appear slightly easier to bridge than these apertures. The concentration of additives is now such coupled with the large size of the coarse materials that these slurries cannot be pumped through tools or small nozzles and are best displaced/squeezed open ended. The point is approached where either losses are lived with, or a lower fluid density is used such as air drilling if this is possible. Alternative techniques such as pressured mud cap drilling or variants can also be used in some circumstances.

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Sufficient material to Jam

While not optimised for coarse material dose Table 4 data shows that even a high concentration of flaked and particulate materials can fail to bridge. This and other data goes someway to explain the cases where LCM pills have failed. They just do not have sufficient coarse flaky or fibrous material to enable multiple bridges to form. Bridges will form on 8 mm apertures with 150 ppb material blend (428 kg/m3)

Largest particulate size can be < than actual aperture width provided there are enough other large flakes/smaller particulates to help bridge

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Solu-Flake D
This is a recent addition to our flaked Calcium carbonate line. The difference to Soluflake is the slightly lower acid solubility >80% vs~95% and a slightly harder more brittle flake. It was introduced due to the large demand for Soluflake in Saudi and supply line issues.

Picture of experimental Extra Coarse Soluflake

Intellibore
Drilling Fluids have recently introduced a methodology

that allows detailed design of drilling fluids for wellbore strengthening in areas of weak fracture pressure or low operating margins between mud weight and fracture initiation pressure. It is aimed at expensive offshore wells where the cost of the analysis and the time savings for successful implementation warrant its use. The methodology requires a variety of geomechanical inputs (15) into the Borewise model.

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Geomechanics Model Input

IntelliBore - Wellbore Strengthening

Geomechanics analysis requires fifteen input parameters

Formation Properties Youngs modulus Poissons ratio Biots constant Tensile strength UCS Internal friction angle Linear thermal coefficient Formation Stresses Pore pressure Overburden Sh min SHmax Smax azimuth Fracture Parameters Height Length Toughness

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Borewise Model example output

IntelliBore - Wellbore Strengthening

Functions / Capabilities Temperature effects on Formation Breakdown Pressure Formation properties data base Single point / batch analysis Range options sensitivity analysis Inclination Azimuth Youngs modulus Pore pressure

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IntelliBore Integrated Solution Process

IntelliBore - Wellbore Strengthening

GeoWise
Well Data
Customer E-Log Pore Pressure Offset wells Mud System

BoreWise - Geomechanics Model

Fracture Characterization: Depth & Width Single Point Analysis - Fracture Pressures Inclination / Azimuth changes Drilling Window Analysis

BridgeWise Bridging
PSD Optimization Drill-In Fluid Design Wellbore Strengthening Fracture Closure Pressure

Dynamic Temperature Modeling

Circulating Temperature Profile Tripping Schedule ECD Spike

Advantage Engineering
Hydraulics Hole Cleaning ECD/ESD Bit Optimization Swab / Surge

Laboratory
Formulation Optimization Return Perm

Drilling Fluid Formulation

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Happiness is a plugged fracture!

Questions?

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