Lost Circulation

Download as docx, pdf, or txt
Download as docx, pdf, or txt
You are on page 1of 11

The development of a rheology modifier that increases the rheology at a high

temperature while does not work at a low temperature, optimization of the solid
components including bentonites and weight materials, rational design of the
molecular structure of polymers, and selection of the additives that do not cause
remarkable thickening can help to control the low-temperature rheology of WBDF.
Based on this method, a thermosensitive copolymer rheological modifier and a
low-molecular-weight coating agent were developed, and two high performance
WBDFs were optimized. Their rheological properties were found to be more stable
than those of the three typical WBDFs over a wide temperature range from 4 to
75 °C. Therefore, the rheology control method proposed in this study can help to
design a WBDF with good low-temperature rheology.

Lost circulation
Lost-circulation problems in deepwater are exacerbated by low fracture gradients,
tight casing/hole clearances, and muds made denser and more viscous by low
fluid temperatures. In ultra-deepwater, shallow formations cannot support the
weight of the mud column and may prevent use of a riser.
Lost circulation while running casing in high-unit-cost synthetic-based muds
(SBMs) and oil-based muds (OBMs) is arguably the most challenging mud-related
problem in deepwater drilling. Key supporting points are as follows:
 Despite superior performance in many areas, SBMs and OBMs are
very sensitive to cold temperatures. Resulting increases in density
and rheological properties further intensify surge pressures and
promote lost circulation.
 Low fracture gradients can require more casing strings. This can
narrow annular clearances and increase surge pressures. Reduction
of the number of casing strings is one of the advantages being
promoted by riserless drilling technology.
 Pressure-while-drilling (PWD) data are not available when running
casing. Fortunately, true real-time calculations are proving effective
for monitoring and helping control excessive surge pressures.
 Severe lost circulation may require displacement from SBM to water-
based mud (WBM). A flow chart such as the one shown in Fig. 2 is
helpful in this regard.
Deeper water systematically lowers fracture gradients at shallow to
moderate depths because of the substantial reduction in overburden
gradient. This effect is less pronounced at deep depths, but mud-weight
requirements for high pressures and wellbore stability can create very
narrow margins between proper well control and lost circulation. Pore-
pressure prediction is another emerging real-time technique that is
improving management of narrow operating windows.
Every deepwater operation requires accurate prediction of fracture
gradients for well planning and for continual updates to ensure safe and
efficient operations. Numerous models for predicting deepwater fracture
gradients have been proposed. The more practical and accurate models
incorporate location specific overburden gradients and measured leak-off
data. Barker’s method3 works well in the GoM for 2,000 - 7,000-ft water
depths, and depths below the mud line to about 8,000 ft.
Techniques proposed by Eaton, et al.4 and Zamora5 are applicable in all
deepwater basins. Equations for the latter method are summarized in Table
1; an example deepwater fracture gradient chart for the GoM is plotted in
Fig. 3.

FUNCTIONS OF DRILLING FLUIDS


3.3.2 Physicochemical Functions. The drilling-fl uid system should remain stable
when exposed to contaminants and hostile downhole conditions. Among the
common natural contaminants are reactive drill solids, corrosive acid gases (e.g.,
H2S), saltwater fl ows, and evaporites (e.g., gypsum). The cement used in setting
casing and liner strings is also a contaminant to some water-based muds. Wells
in certain areas have extremely high bottomhole temperatures, at times
approaching 500°F, and, likewise, arctic locations may expose the drilling fl uid to
subzero temperatures at surface.

3.3.6 Help Support the Drillstring and Casing Weight. Any time a material is
submerged in a fluid in a gravitational field, there is a reaction that offsets the
force that gravity exerts. This is often called buoyancy, although there are a lot of
misconceptions related to this term. Nonetheless, in heavily weighted situations,
this “buoyancy force” can assist by offsetting some of the weight of a drillstring or
casing. This offset is dependent upon the density of the fluid, with higher-density
fl uids giving more of an offset and lower density “fluids” (e.g., air) not helping
much, if at all.

3.3.7 Ensure Maximum Logging Information. The drilling fl uid has a profound
impact on the electrical and acoustical properties of a rock. Because these
properties are what logging tools measure, it is imperative that the correct
selection of wireline logging tool or logging-while-drilling (LWD) tool for a given
drilling fluid be made.
Or, lacking that, then the correct drilling fluid must be used for a given logging
tool. In addition, the drilling fluid should facilitate retrieval of information by
means of cuttings analysis.

3.3.8 Transmit Hydraulic Horsepower to the Rotating Bit. The hydraulic force is
transmitted to the rotating bit when the fluid is ejected through the bit nozzles at
a very high velocity. This force moves the rock fragments or cuttings away from
the drilled formation beneath the bit. In directional-drilling operations, the
hydraulic force powers the downhole hydraulic motor and turns electric-power
generators (turbines) for measurement-while-drilling (MWD) and LWD drillstring
equipment.
These problems range from: narrow pore/fracture pressure gradient
margins, wellbore stability, clay swelling, gas hydrates formation, formation
damage, salt formations, lost circulation, stuck pipe, cuttings transport and
environmental and safety aspects
1. Solids Transport (Hole Cleaning and Barite Sag)
Hole cleaning and barite sag are related in concept and often discussed
together, as they are here. More often than not, actions taken to enhance
one are concurrently beneficial to the other, even though the actions may
be at odds with other concerns.
For example,
· Flow rates and rheological properties required to minimize hole-cleaning
and barite-sag problems can cause excessive pressures while drilling,
tripping, and running casing, and
· Efforts to offset low-temperature effects on rheology can exacerbate
barite sag.
Many field procedures in use for hole cleaning and barite sag today are the
product of extensive flow-loop testing by the industry and correlations with
field results. For hole cleaning, analytical models developed over the years
have been complemented by practical field guidelines.9 For barite sag, the
major hurdle was overcome when the problem was identified as a dynamic
settling problem.10 Recent JIP studies11 have reinforced the major roles of
pipe rotation, pipe eccentricity, angle, and sag-bed characteristics.
Hole-cleaning concerns are likely in all deepwater wells, while barite-sag
problems require weighted muds and directional well paths. Annular
velocity generally is still considered the key physical parameter, but pipe
rotation, especially with eccentricity, can be equally important. The use of
riser-booster pumps has greatly improved hole cleaning in larger diameter
risers.

SLIM HOLE DRILLING


Slim-hole drilling is different from conventional oil and gas well drilling because of
(1)high rotation speed of drillpipe;
(2)the very slim annulus, the small annular gap.
These main differential characteristics make it absolutely essential the drilling
hydraulics study,and make the slim-hole hydraulics totally different from
convential wells.In slim-hole drilling,the “Couette effect” resulting from pipe
higher rotation speed and “Crescent effect” due to pipe axis highly deviated from
the axis of wellbore must be taken into account,and these two characterics which
are of different points between slim-hole and conventional wells governes the
slim-hole hydraulics calculation accurcy. Early field pratice and labortary studies
showed that in convential well drilling APL rarely exceeds 15% of the total pump
pressure.However in a slim-hole up to 30-50%pump pressure is due to pressure
loss in the annulus,some people consider it is up to 90%.Therefore slim-hole
drilling hydraulics becomes one of the major concerns. This theoretical study and
field application will allow a better understanding of phenomenon occurring in the
annulus and thus an optimization of hydraulic parameters for a successful slim-
hole drilling.

SLIMHOLE HYDRAULICS
A model based on fluid mechanics helps optimize slim-hole drilling hydraulics by
taking into account mud rheology, drill-string rotation, and the eccentric position
of the drill-string. Drilling hydraulics can become a problem in sedimentary
formations drilled with slim-hole drilling equipment because of the typically utilized
high rotational speeds and small annuli.
The crucial areas include the lifting of cuttings in the annulus, well bore stability
bit cleaning, differential mud pressure in the annulus, and the hydrodynamic
lubrication between the drillstring and the well bore.
The annular mud velocity profile must be kept as uniform as possible to ensure
that cuttings are transported to the surface without balling up in the annulus. In
general, a mud velocity of about 0.5 m/sec (1.6 fps) should keep cuttings moving
faster than the sedimentation velocity in the annulus.
In soft sedimentary formations, a laminar flow regime is important in the annulus
to minimize the shear stress close to the borehole wall. High shear stresses close
to the wall can cause erosion and caving.
In slim-hole drilling, the trajectory of the mud and cuttings becomes helicoidally,
and not straight as in conventional wells. The rotating drill-string forces the mud
to rotate because of the viscous “Coquette” effect.
Another slim-hole drilling hydraulics phenomenon, the “Crescent” effect, occurs
when the drill-string rotates eccentrically in the well, with the eccentric geometry
influencing the pressure losses in the annulus. Although eccentricity occurs in
conventional wells, the effect on pressure losses is not as great.
Thus, the dynamic component of the annular pressure is much more important in
slim-hole drilling than in conventional drilling.
However, even with the highest grade tubulars in the well, some of the standard
well design criteria cannot be met. During a well control situation, for example,
the ability to force a hydrocarbon influx back into formation by pumping water
under pressure to the last installed casing depth, is a typical load case used for
standard casing design. A deepwater well design will not normally pass this test
and the industry has made adjustments to deepwater load cases so that casing
burst ratings are not exceeded18.
Directional Drilling
In deep and ultra-deepwater scenarios, the low temperatures found near to the
sea bottom often causes interruption of oil production due to hydrates and wax
formation. In such situation, projects based on dry completion units (DCU) such
as TLP or SPAR become technically attractive since oil will flow through directional
wells instead of flowing throughout production lines placed on the cold sea bottom.
Similar to shallow water templates, developing a deepwater oil field from a DCU
requires directional wells departing from a central cluster in direction to their
targets.
However, it may also require drilling a number extended reach wells (ERW) in
deep and ultra-deepwater.
Despite of the benefits, the use of ERW in deepwater is somehow limited due to
the effect of water depth. The chances of fracturing the formation due to high
annular pressure losses or having serious wellbore instability problems due to well
inclination augment with both, the increase of water depth and well displacement.
Fig 12 shows a schematic view of two well trajectories in two different water
depths scenarios. As the length of sediments in deepwater location is smaller than
the length of sediments in shallow water site, wellbore inclination in deepwater
well must be higher. In consequence, bore hole instability will probably occur in
the deepwater well.
In addition, the high horizontal displacement compared to the total vertical depth,
main characteristics of ERW, leads to a crucial problem, that is, the long well
length and the associated increase in annular pressure loss with measured depth,
is not followed by a correspondent increase of the fracture pressure gradient with
depth. As a result, departures of deepwater directional wells are generally shorter
compared to similar onshore and shallow water directional wells [6]. Fig. 13
displays the trajectory of deepwater directional well drilled in Marlim Sul Oilfield,
offshore Rio de Janeiro, Brazil. The initial assumption used to design this well was
based on the fact that displacements of 5,000 meters and 7”OD production tubing
would be enough to guarantee flow assurance by avoiding wax and hydrate
formation. However, new studies indicated that reducing well displacement to
3200 meters would also assure the same oil production. Thus, a shorter well with
the following characteristics was drilled:
Water depth (WD) = 1205 meters
Displacement (D) = 3210 meters
Total vertical depth (TVD) = 2903 meters
Total Measured depth (MD) = 5211 meters
Inclination of the Slant Section = 700
Ratio = D / (TVD-WD) = 1.89
Ratio = MD / (TVD-WD) = 3.07

Although well instability and fracturing the formation due to high ECD were still
concerns, drilling occurred without any problem, confirming all previous studies.
However, malfunction of the BOP, after an unexpected blackout followed by
disconnection of the riser, left the well open to the sea reducing the hydrostatic
pressure inside the hole. The total collapse of the borehole walls observed after
the situation was normalized, confirmed wellbore instability as a serious issue for
this deepwater well. On the other hand, the lessons learnt from this well and the
subsequent wellbore stability and hydraulic related studies indicated that higher
displacements are likely to be achieved in this area.

Drilling Fluids
Environmental friendly, easy to handle, good chemical inhibition, versatile
composition and good transporting capability are some of the main characteristics
a drilling fluid must have to overcome the following challenges:
- Keep chemically reactive, fragile and unstable formations in place,
- Allow high rates of penetration,
- Deliver caliper under the desired tolerance,
- Be economically feasible.
Both, water base mud and oil base mud have been used by Petrobras in its drilling
operations. A summary [7,8] of its usage is presented next.
Water Base Mud
In the earlier stage of deepwater drilling in Brazil, saline fluids, treated with
hydrated calcium and amide, fabricated with seawater were utilized. However,
problems such as borehole enlargement, wellbore instability and fluid density
management required mud engineers to look for other solutions. A number of
alternatives were tried with limited success before the use of saline-drilling fluids
treated with cationic polymers. This type fluid has succeeded in more than 200
wells drilled in water depths up to 2800 meters.
Oil Base Mud
By the end of the eighties, environmental regulations had already forbidden the
use of diesel base mud in Campos Basin. After 1995, with the increment of
horizontal drilling activities, new types of drilling fluid were tested and recently a
synthetic fluid, specially developed by Petrobras engineers, have proved to be
quite effective. High lubricity capacity, good inhibition properties, relative low cost
and environmental acceptance friend are some of the main characteristics of this
new drilling fluid.
SLIMHOLE FLUID HYDRAULICS
Drilling hydraulics can become a problem in sedimentary formations drilled
with slim-hole drilling equipment because of the typically utilized high
rotational speeds and small annuli.
The crucial areas include the lifting of cuttings in the annulus, well bore
stability bit cleaning, differential mud pressure in the annulus, and the
hydrodynamic lubrication between the drillstring and the well bore. The
annular mud velocity profile must be kept as uniform as possible to ensure
that cuttings are transported to the surface without balling up in the
annulus. In general, a mud velocity of about 0.5 m/sec (1.6 fps) should
keep cuttings moving faster than the sedimentation velocity in the annulus.
In soft sedimentary formations, a laminar flow regime is important in the
annulus to minimize the shear stress close to the borehole wall. High shear
stresses close to the wall can cause erosion and caving.
In slim-hole drilling, the trajectory of the mud and cuttings becomes
helicoidally, and not straight as in conventional wells. The rotating drill-
string forces the mud to rotate because of the viscous “Coquette” effect.
Another slim-hole drilling hydraulics phenomenon, the “Crescent” effect,
occurs when the drill-string rotates eccentrically in the well, with the
eccentric geometry influencing the pressure losses in the annulus. Although
eccentricity occurs in conventional wells, the effect on pressure losses is not
as great.
Thus, the dynamic component of the annular pressure is much more
important in slim-hole drilling than in conventional drilling.

You might also like