A Novel Phase Transition Loss Circulation Solution for Severe Losses Scenario: Case Histories from Middle East and Africa

Abstract

Abstract Lost circulation is a major contributor to non-productive time (NPT). Any efforts to better understand the factors that lead to it and subsequently identify a suitable cure will translate to tremendous savings of time and money for operators. Conventional materials such as calcium carbonate, nut shells, graphites and fibers are successful in curing many cases of seepage and partial lost circulation. However, there is a practical limit to the concentration of these materials used to combat the most severe losses due to the limitation of pumps and drilling assembly. In porous formations, high fluid loss squeeze pills have seen some success in reducing losses by forming a high compressive strength plug, but these pills do not have a good success rate in large fractures or vugular formations. Such challenges are better addressed by cross-linking pills, but even this solution does not always have a high success rate due to the low compressive strength of the formed plug. The new phase-transforming loss circulation material (PTLCM) was designed to be pumped easily and achieve thixotropic behaviour under downhole conditions, resisting losses in the thief zone prior to setting as a rigid plug with high compressive strength. A setting-control additive ensures the LCM does not prematurely set. The additive is used at a concentration calculated by considering the time required for pumping and the bottom hole temperature (BHT) in the thief zone. After the LCM sets, a high compressive strength solid plug is formed that can resist fluid loss to the formation. The LCM has a high acid solubility of ~95%, making this system a viable option for deploying in reservoir sections, depending on the client requirement and well conditions. This paper describes two recent successful applications deploying this novel technology. Case Study #1: While drilling in sandstone, the well experienced total losses, which presented an immediate challenge to maintain hydrostatic pressure. The operator responded by pumping several conventional pills loaded with a broad particle size range of fibers, granules and polymers. These pills were unsuccessful at healing the losses, so the operator opted to deploy the new technology LCM. The losses were cured successfully with a single application. Case study #2: Wells drilled in the Western Desert have traditionally experienced severe to total losses while drilling fractured dolomite. Frequently, such events have been difficult to cure by conventional means. The only solution has been multiple applications of cement plugs to heal the losses. This case study describes a well with dynamic losses of more than 150 bbl/hr that were healed by spotting one pill through the circulating sub across the thief zone. The losses were successfully cured, allowing the operator to continue drilling.