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Summary
Lost circulation has been one of the major challenges that cause
much nonproductive rig time each year. With recent advances,
curing lost circulation has migrated from plugging a hole to
borehole strengthening that involves more rock mechanics and
engineering. These advances have improved the industrys understanding of mechanisms that can eventually be translated into better solutions and higher success rates. This paper provides a review
of the current status of the approaches and a further understanding
on some controversial points.
There are two general approaches to lost circulation solutions:
proactive and corrective, based on whether lost circulation has
occurred or not at the time of the application. This paper provides
a review of both approaches and discusses the pros and cons related to different methodsfrom an understanding of rock mechanics and operational challenges.
Introduction
Lost circulation (LC) is defined as the loss of whole mud (e.g.,
solids and liquids) into the formation (Messenger 1981). There are
two distinguishable categories of losses derived from its leakoff
flowpath: Natural and Artificial. Natural lost circulation occurs
when drilling operations penetrate formations with large pores,
vugs, leaky faults, natural fractures, etc. Artificial lost circulation
occurs when pressure exerted at the wellbore exceeds the maximum the wellbore can contain. In this case, hydraulic fractures are
generally created.
During the last century, lost circulation presented great challenges to the petroleum industry, causing significant expenditure
of cash and time in fighting the problem. Trouble costs have continued into this century for mud losses, wasted rig time, and ineffective remediation materials and techniques. In worst cases, these
losses can also include costs for lost holes, sidetracks, bypassed
reserves, abandoned wells, relief wells, and lost petroleum reserves. The risk of drilling wells in areas known to contain these
problematic formations is a key factor in decisions to approve or
cancel exploration and development projects.
Background literature (Messenger 1981) on the subject describes many methods and materials used to remedy lost circulation. Many of these methods worked in some wells but not in
others. Trial and error applications almost always resulted in a
costly learning curve.
A field practices study (API 1991) of cementing wells, published by the American Petroleum Institute (API) in 1991, compiled drilling and production surveys and trade journal data for 339
fields worldwide between 1980 and 1989. The number of fields in
each area is presented for general information and may not represent all wells or fields in that specific area. The North American
fields include fields in Canada, Mexico, and the USA. Listed
among the many types of data sourced in this study is LC information in relevant fields. This LC data was analyzed for this paper
to obtain the LC event frequencies of occurrence presented in
Table 1. The LC data analysis indicates that up to 45% of all wells
168
KI = c Po S2 + 2
R
c
P Po arcsin . . . . . . . . . (3)
w
c
Fig. 3Addition of synthetic graphite particulates substantially increased the fracture reopening pressure.
w=
81 2c
E
2
R
c
Po S2 + Pw Po
R
c
arcsin
R
1
c
R
+
c
n=1
sin 2n arcsin
R
c
R
R sin 2n arcsin
R
c
cos 2n arcsin
+
c
cn
2n 12n + 1
(4)
Four sets of fracture width and length are calculated and displayed
in Figs. 4a and 4b to show their relationships. Fracture width tends
to be larger with a longer fracture length.
Corrective Borehole Strengthening
Hookes law states that stress is proportional to strain. When the
fracture width increases, additional stress higher than Sh is induced
locally along the propped fracture. The increase in stress observed
in the near-wellbore region depends directly on fracture width. The
fluid pressure within the fracture (including the pressure distribution throughout the fracture), length of the fracture, formation
elastic modulus, and Poissons ratio determine the fracture width.
Dupriest (2005) pointed out that mud losses are either cured or
borehole pressure integrity is increased by improving formation
closure stress (FCS). Widening the fracture results in an increased
compressive stress at the fracture face. This fracture face stress is
the sum of the net stress increase caused by the fracture-widening
effect and the least principal stress, Sh. Deeg and Wang (2004)
used a hydraulic-fracturing approach to study the stresses induced
by opening a slit-like hydraulic fracture, finding that the stress
perpendicular to and parallel to the fracture directions (Sh and SH)
becomes more compressive with increased fracture width. It is the
net stress increase higher than Sh that results in higher pressure
required to reopen the fracture filled with sealant.
Fracture width is created by propping the fracture open. To
keep fluid pressure away from the fracture tip, the propping material must remain immobile, and no drilling fluid should bypass or
penetrate it at the highest wellbore pressure expected. It can be
June 2008 SPE Drilling & Completion
Fig. 4(a) Incipient crack length for several in-situ stresspore pressure combinations (S1,S2,Po in kpsi). Wellbore pressures in
each series are as follows: Pb,1.1Pb,1.2Pb,1.3Pb,1.4Pb,1.5Pb. (b) Incipient crack width for several in-situ stresspore pressure
combinations (S1,S2,Po in kpsi). Wellbore pressures in each series are as follows: Pb,1.1Pb,1.2Pb,1.3Pb,1.4Pb,1.5Pb.
The challenge for this system occurs when (1) a large volume
of sealant must travel a long distance along the wellbore to reach
the weak zone, and (2) the squeeze pressure is limited by another
weak formation (e.g., around the casing shoe). In this case, the
material may not reach the zone before the pressure limitation
dictates. If this is the case, a treatment can be staged into a treatment train, separating the treatment into discontinuous, smaller
subtreatments. Although this method has been used effectively in
the field, it is often unclear when a stage treatment should be used.
Attempts during the last few decades to develop reliable DVC
systems (e.g., gunk squeezes) have had mixed resultsworking
in some cases and not in others. New DVC systems developed in
the last decade (Sweatman et al. 1997, 2001; Webb et al. 2001)
have performed much better than the gunk-type systems, as evidenced by many treatment applications in which gunk squeezes
failed to seal, followed by successful DVC system applications.
172
173
S1
S2
Sh
SH
w
x
175