Lost Circulation

Lost Circulation
Lost Circulation

1 Introduction
1.

Lost circulation is defined as the total or

partial loss of drilling fluids or cement slurries

into highly permeable zones, cavernous

formations, and natural or induced fractures

during drilling or cementing operations.

Lost circulation must not be confused with

fluid loss which is more related to primary

porosity, whereas lost circulation can occur in

formations with both primary and secondary

porosities.
Lost Circulation

The major consequences of lost circulation

include the following:

 The possibility of a blowout because of a

drop in the mud level.

 The possibility of sticking the drill pipe

because of poor cuttings removal.

 No zonal isolation due to insufficient cement

fill up.
fill-up.

 Losses to the producing zone resulting in

extensive formation damage.

 The loss of the well Seeping losses can

occur with any type of lost circulation zone,

when
h th solids
the lid in
i the
th mud
d are nott sufficiently
ffi i tl

fine to seal the formation face.

Lost Circulation

Partial losses frequently occur in highly

permeable gravels, small natural fractures, or as

a result of fracture initiation.

Complete losses are usually confined to long

gravel sections, large natural fractures, wide

induced fractures, or cavernous formations.

2. Classification of lost-circulation zones

Severity classification for lost circulation is as

follows:

Type of losses Severity

Seeping (minor) Less than 10 bbl/hr

Partial (medium) 10 to 500 bbl/hr

Complete (severe) Total, unable to keep

the hole full

Lost Circulation

In addition, it is common to classify lost-circulation

zones into four categories:

 Unconsolidated or highly permeable formations

 Natural fractures or fissures

 Induced vertical or horizontal fractures

 Cavernous or vugular formations

3. Identifying features of lost circulation

zones:

a) Porous Sands and Gravels

 Gradual lowering of the mud level in pits

 Losses may become complete, if drilling is

continued.
ti d
Lost Circulation

b) Natural Fractures

 May occur in any type of rock

 Loss is evidenced by gradual lowering of the

mud in the pits. If drilling is continued and more

fractures are exposed, complete loss of returns

may be experienced.

 Fracture must have a finite supported with to

t k mud.
take d

c) Induced Fractures

 Occur where fractures are horizontal in any

formation under mud rings.

 Loss is usually sudden and accompanied by

complete loss of returns.

Lost Circulation

Conditions are conductive to forming induced

fractures when mud weight exceeds 10.5 lb/gal.

 Loss may follow any surge of pressure of trip.

 When loss of circulation occurs and adjacent

wells have not experienced lost circulation,

induced factures should be expected.

d) Cavernous Zones

 Normally
N ll confined
fi d to
t limestone
li t

 Loss of returns may be sudden and complete

 Bit may drop several inches to several feet just

preceding loss.

 Drilling may be rough before loss

Lost Circulation

4. Lost Circulation While Drilling

It is possible to classify the available solutions in

three categories and there is an optimum

technique for solving each particular type and

severity of a lost circulation problem.

a) Bridging Agents in the Drilling Fluid

When the loss of mud is first detected, immediate

consideration
id ti should
h ld be
b given
i t the
to th possibility
ibilit off

reducing and maintaining the mud weight at the

minimum necessary to control the formation pore

pressure.

Reduced mud pressure will help combat losses no

matter what types of formations are exposed.

Lost Circulation

Continuing partial loss of returns is indicative of

seepage, and can usually be solved by decreasing

the equivalent mud circulating density, or by

adding Lost Circulation Materials (LCM’s) to the

drilling mud.

Decreasing the weight of the mud or its downhole

rheological properties can reduce the equivalent

mud
d circulating
i l ti d
density.
it
Lost Circulation

According to their physical nature and mechanism

of action; LCM’s can be classified into four

categories;

 Granular

 Lamellar

 Fibrous

 Encapsulated
Lost Circulation

 The granular LCM’s form two types of bridges;

one at the formation face and one within the

formation matrix.

The effectiveness of granular LCM’s depends

primarily on a proper particle-size distribution,

with larger particles first forming a bridge across

or within the void, and the smaller particles

b id i
bridging th
the openings
i b t
between th
the l
larger

particles.

This process continues until the void spaces

become smaller than the drilling mud solids.

A blend of large, medium, and small particles, or

one of large and small particles, is most commonly

used.
Lost Circulation

 Fibrous materials are best used for controlling

losses to porous and highly permeable formations,

because they are able to form a mat

mat-like
like bridge

over the pore openings.

The mat reduces the size of the openings to the

formation, permitting the colloidal particles in the

mud to rapidly deposit a filter cake.

 Flake materials are also designed to bridge and

form a mat on the formation face, also providing

the best results when treating losses to permeable

and porous formations.

Bl d off granular,
Blends l fl k
flake, and
d fibrous
fib LCM are
LCMs

effective in solving actual field problems.

Lost Circulation

This strategy provides a gradation of particles size

as well as variation of material types for sealing

different classes of lost circulation zones.

Another important parameter is that; the

effectiveness of a plug in preventing fluid loss into

a fracture depends on the mechanical strength

of the plug as well as its permeability.

Th
The portion
ti off th
the plug
l responsible
ibl f
for it
its

mechanical strength is the bridge, and the portion

that controls the plug permeability is the filter.

Lost Circulation

 Single Particle Bridging

If the dimension of a particle normal to the

fracture direction is larger than the width of the

fracture opening; single-particle bridging is

possible.

This type of bridging can also occur inside a

fracture at locations where it undergoes a sudden

reduction
d ti i Width.
in Width
Lost Circulation

 Multiple Particle Bridging

If all particle dimensions are smaller than the

fracture width, bridges are possible only when

two-three particles interact to form a stable arch

from one fracture wall to the other.

Consider a two-particle bridge at the fracture

undergoes a sudden reduction in width.

It is
i assumed
d for
f simplicity
i li it that
th t the
th two
t particles
ti l

are identical in shape, size, and mechanical

properties.
Lost Circulation

b) Surface Mixed Systems

 Cement Plugs

Cement slurries are effective for solving seeping or

minor loss, with the advantage of providing high

final compressive strengths.

Slurries with a limited degree of fluid-loss control

can be used to solve seeping, partial, or total

l
losses, and
d contain
t i a mixture
i t off clays,
l

diatomaceous earth, and LCMs.

The size of the LCM is increased as the losses

become more severe.

Lost Circulation

In practical terms, thixotropic systems are fluid

during mixing and displacement, but rapidly form

a rigid, self-supporting
self supporting gel structure when

pumping ceases.

When thixotropic slurry enters a lost circulation

zone, the velocity of the leading edge decreases

and a gel structure starts to form.

A the
As th gell strength
t th develops,
d l resistance
i t t flow
to fl

increases until the entire zone is plugged.

Such systems are very effective for solving severe

lost circulation to naturally fractured formations.

Lost Circulation

 Other Surface- Mixed Systems

Systems that do not contain Portland cement

usually involve a gelling agent with an activator.

After a given period of time, or due to an increase

in temperature, the components react to form a

no flowing mass.

In general they are most applicable to partial lost-

circulation
i l ti problems
bl i
in hi h
high-permeability
bilit

sandstones, or for sealing micro fissures.

Lost Circulation

In cases, where the lost circulation zone is also a

zone of interest, either for production or injection

purposes, it may be necessary to design the

plugging material for eventual removal during the

completion of the well.

Typical bridging materials include ground calcium

carbonate particles with diameters ranging from

0 0003 in.
0.0003 i tot 0.01
0 01 in.
i

They are used at concentrations up to 10 lb/bbl of

carrying fluid.
Lost Circulation

b) Downhole Mixed Systems

Downhole mixed systems consist of two or more

fluids, which, upon making contact in the wellbore

or the lost circulation zone, form a viscous plug or

a precipitate, which seals the zone.

In common practice to prevent the mixing of the

fluids until they are in front of the lost circulation

zone, by
b pumping
i a spacer or by
b pumping
i one

fluid down the drillstring while the other fluid is

simultaneously pumped down the annulus.

Lost Circulation

For partial losses better success is achieved by

Mud-Diesel-Oil-Bentonite (M-DOB) plugs instead

of LCMs.

M-DOB plugs are a combination of diesel oil and

bentonite and are sometimes called ‘gunk plugs’.

When this mixture contacts water or water base

mud, a mass with high gel strength is formed.

Lost Circulation

 M-DOB plugs suffer from several

drawbacks

 They break down with time

 They are difficult to apply in long open hole

intervals.

 When losses are severe, it is impossible to

achieve a reliable pumping rate down the annulus;

th
therefore,
f th
the d
degree off mixing
i i cannott b
be

controlled.

 No compressive strength is developed

Lost Circulation

5. Lost Circulation During Cementing

Before initiating a conventional primary cementing

operation, the lost circulation problem should be

eliminated or significantly reduced by the

techniques described above.

If this is not possible, or losses are anticipated

during primary cementing job, there are two

possible
ibl options.
ti

 The first is to maintain the downhole pressures

during the job below the maximum equivalent

mud circulating density, by reducing the density of

the cement slurry, minimizing the height of the

cement column, or limiting the casing and annular

friction pressures during the placement of the

cement slurry
Lost Circulation

 The second option is to pump a plugging

material as a spacer in front of the cement slurry,

add lost circulation materials to the cement slurry

itself, or use special additives which impart

thixotropic properties to the cement slurry.

When trying to prevent cement losses to highly

fractured or vugular formations, it is often

necessary to
t use a combination
bi ti off techniques.
t h i
Lost Circulation

a) Downhole Pressure Reduction

Computer simulators can calculate the estimated

downhole pressures at particular depth in the well,

and at any time during the cementing operation.

This enables the operator to know exactly which

cement slurry parameters and job procedures are

required to prevent lost circulation and maintain

adequate
d t h d
hydrostatic
t ti pressure i
in f
front
t off

permeable zones.

The most relevant parameter is the cement slurry

density, which may be reduced by adding one or

more cement extenders.

Lost Circulation

The rheological properties of cement slurry may

also be adjusted to provide lower friction pressure

losses during placement. This is especially critical

in narrow annulis where viscous slurries can cause

very high friction pressures.

b) Lost Circulation Materials for Cement

Slurries

Wh
When LCM’ are used
LCM’s d in
i the
th cementt slurry,
l care

must be taken to ensure that the materials are

inert to the cement composition.

Also the size and the concentration of the

materials should be selected to avoid bridging or

plugging of the downhole equipment.

Lost Circulation

The most common LCMs for cement slurries are of

the granular type, designed to bridge at the

formation face or within the matrix.

Gilsonite, a naturally occurring black asphalite

hydrocarbon with a particle size between 8 and 60

mesh, is widely used.

Crushed coal, with a standard mesh size of 14 to

200 is
i applied
li d in
i the
th same manner as gilstone
il t and
d

can be used in high temperature wells.

Cellophane flake with diameters of ¾ in. is the

most common flake material.

Lost Circulation

Fibrous materials are seldom used in cement

slurries because they can plug cementing

equipment.

In addition, some organic chemicals may be

present that may retard the thickening time of the

cement slurry.
Lost Circulation

6. Identification of Type of Loss Zone

a) Find the exact depth of the loss zone

Loss zones usually are not at the bit depth as

reported with the expectation of the point of first

loss.

In most cases, losses occur at the point of the first

loss where the loss zone was sealed but reopened

as the
th drilling
d illi continued.
ti d

Drilling and mud logs will help to find the point of

first loss.

Temperature survey or gamma-ray log and

radioactive material can be used.

Lost Circulation

b) Find the Type of Lost Zone

It is the best determined by lithology and amount

of losses.

Depth is the factor that gives an indicator of

whether fractures are vertical or horizontal.

c) Severity of Loss Zone

It is the best determines by the amount of losses

and
d the
th static
t ti mud
d column
l weight.
i ht
Lost Circulation

7. Lost Circulation Techniques and materials

a) Technique 1

 Pull up and Wait:

This procedure can solve seeping, partial or

complete losses due to induced vertical fractures.

If pressure is released, the fracture will close and

heal, and will support virtually the same pressure

as before
b f b i
being f
fractured.
t d

b. Technique 2

 Plug of Bridging Agents in Mud

Used in mud against seeping and partial losses

can be successful in all types of loss zone.

Size and concentration of bridging agent must be

adjusted to the severity of the losses.

Lost Circulation

c) Technique 3

 High Filter Loss Slurry Squeeze

This technique consists in squeezing into the loss

zone a thick slurry carrying different kind of lost

circulation materials.

The kind and size of the lost circulation material

depend on the severity of the loss.

 Technique
T h i 3A

The addition of cement into the high water loss,

high solids slurry might convert the temporary

plug to a permanent one.

The dehydration of the slurry will leave the

fracture packed with solids and further setting of

cement will plug the loss permanently.

Lost Circulation

d) Technique 4

Cements (Neat, Extended, Thixotropic)

The facility of changing cement slurry properties

makes it a very useful tool for lost circulation.

They can be used against complete losses to

gravels, horizontal natural or induced fractures

and natural vertical fractures.

 Neat
N t Portland
P tl d Cement
C t

 Bentonite or Attapulgite Cement

 Portland Cement with Lost Circulation Materials

Gilsonite or Kolite can be added to cement slurries

that are being used to regain cements.

They will act as bridging agent preventing the

slurry to go further into the fractures.

Lost Circulation

 Portland Cement with frac sand

Frac sand will provide bridging properties required

to start the bridge against which dehydration

starts.

 Light weight cement systems

Loss zones which do not have fluids flowing

through can be sealed with special light weight

slurries,
l i b l
balancing
i squeezing
i and
d letting
l tti th slurry
the l

to set.

 Thixotropic cements

Developing of high gel strength once stopped help

the cement to remain close to the well bore.

Lost Circulation

d) Technique 5

Downhole Mixed Soft Plugs

Best application against induced fractures and to

hold cement slurries at or near the well bore until

they set.

Mud Diesel Oil Bentonite DOB is mixed and

displaced through the pipe.

M d is
Mud i pumped
d to
t the
th annulus
l when
h th slurry
the l

reaches the sub.

This will form a soft plug M + DOB into the

fracture.
Lost Circulation

e) Technique 6

Downhole Mixed Soft-Hard Plugs

Diesel Oil Bentonite

Bentonite-2-Cement
2 Cement

This technique is similar to the DOB plug but

cement once in contact with formation water will

set leaving a permanent hard seal.

It is not applicable where oil muds are in use.

Lost Circulation

f) Choosing type of LCM

RESULTS

GOOD
IF USED
CEMENT WITH...
GOOD NO GOOD NONE

"PLASTIC" PLUGS

PERLITE

GRANULAR

(COTTON) FLAKE

FIBROUS

CELLOPHANE

MICA

MACROFRACTURES/CARSIMS FRACTURES GRAVEL SAND PORES

Lost Circulation

g) LCM - Efficiency
60 60

50 50

40 40
Kg//m3 OF LCM

30 30

20 20

10 10

0 0
0 1 2 3 4 5 6
FRACTURE WIDTH (mm)

FIBROUS LAMELLAR GRANULAR