CHAPTER

14 Lost Circulation

Introduction

Losses of Losses of whole mud to subsurface for-

whole mud mations is called lost circulation or lost
returns. Lost circulation has historically
to subsurface been one of the primary contributors to
formations is high mud costs. Other hole problems a

called lost such as wellbore instability, stuck pipe

and even blowouts have been the result
circulation… of lost circulation. Besides the obvious
benefits of maintaining circulation, pre- d
venting or curing mud losses is impor-
tant to other drilling objectives such as
obtaining good quality formation evalu-
ation and achieving an effective primary b
cement bond on casing.
Lost circulation occurs in one of two
basic ways:
1. Invasion or mud loss to formations
that are cavernous, vugular, frac-
a
tured or unconsolidated.
2. Fracturing which is mud loss due to
hydraulic fracturing from excessive
d
induced pressures (see Figure 1).

Figure 1: Lost-circulation sections:

a: High-permeability unconsolidated
sands and gravel.
b: Cavernous or vugular zones
in carbonates (limestone or dolomite).
c: Natural fractures, faults and
transition zones in carbonates or hard shales.
d: Induced fractures from excessive pressure.

Lost Circulation 14.1 Revision No: A-0 / Revision Date: 03·31·98

 CHAPTER

14 Lost Circulation

Causes of Lost Circulation

________________________ 1. Invasion. In many cases, lost cir- in more easily from overburden
________________________ culation cannot be prevented in and rig weight.
formations that are cavernous, b. Another potential loss zone is
________________________
vugular, fractured or unconsoli- in depleted formations (usually
________________________ dated. Depleted low-pressure for- sands). Producing formations in
________________________ mations (usually sands) are similar the same field, or general vicinity,
relative to lost-circulation potential. may cause subnormal (depleted)
________________________
a. Coarse, unconsolidated formations formation pressure due to the
________________________ can have sufficiently high perme- extraction of the formation flu-
________________________ ability for whole mud to invade ids. In such a case, mud weights
________________________
the formation matrix, resulting required to control other exposed
in lost circulation. This high formation pressures may be too
________________________ permeability is often present in high for the depleted formation,
________________________ shallow sands and gravel beds. forcing mud to invade the low-
________________________
Formations that were once reefs pressure depleted formation (see
and oyster beds also have similar Figure 2). If this situation exists,
________________________
tendencies. One important reason plans should be formulated to pre-
________________________ for preventing mud loss in shallow vent lost circulation or stuck pipe
________________________ intervals is that it may cause these from occurring in the depleted
unconsolidated formations to zone. Special bridging agents and
wash out, forming a large cavity sealing materials should be used to
that is less stable which could cave form a good seal and filter cake on
the depleted zone.

Mud weight 12.5 lb/gal

(1.5 kg/L)

Producing well

Shale

Limestone

Potential loss zone

Shale

Depleted sand 10.5 lb/gal

10.5 lb/gal (1.3 kg/L)
(1.3 kg/L)

Figure 2: Depleted sand.

Lost Circulation 14.2 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

Cavernous c. Cavernous or vugular zones are a. Setting intermediate casing in the

or vugular usually associated with low-pressure wrong place. If casing is set above
carbonate (limestone and dolomite) the transition zone crossing from
zones are or volcanic formations. In lime- normal to abnormal pressures,
usually stone, vugs are created by the pre- the pressures exerted by the heav-
associated vious continuous flow of water ier mud (required to balance the
that dissolved part of the rock increasing pressures) will often
with matrix (leaching), creating a void induce fracturing at the weak cas-
low-pressure space often later filled with oil. ing seat. Losses due to fracturing
carbonate… When these vugular formations are most commonly near the pre-
are drilled, the drillstring may fall vious casing seat, not at bit depth,
freely through the void zone and even if casing is properly set.
a rapid loss of mud is usually expe- b. Excessive downhole pressures are
rienced. The volume and persis- the result of many conditions
tence of this kind of loss depends including:
on the degree to which the vugs i. Mechanical forces.
are interconnected. Similar vugs a) Improper hydraulics.
and caverns can develop during Excessive pump rates and
the cooling of volcanic magma or velocities causing high
Cavernous ash. Cavernous and vugular for- Equivalent Circulating
and vugular mations are often easily traceable Density (ECD) pressures.
from offset wells and predictable b) Drilling practices.
formations from mud logs and lithology. 1) Increasing pump rates
are often d. Mud loss also occurs to fissures or too rapidly after connec-
easily fractures in wells where no coarsely tions and trips. This can be
permeable or cavernous formations extremely important when
traceable… exist. These fissures or fractures dealing with oil-base fluids.
and may occur naturally, or may be ini- Failure to bring the pumps
predictable… tiated or extended by hydraulically up to speed slowly can put
imposed pressures. Natural fractures much higher circulating
exist in many cases, which may be pressures on the formation
impermeable under balanced pres- due to the tendency of oil-
sure conditions. Losses may also base muds to thin at higher
occur at unsealed fault boundaries. temperatures generated
2. Fracturing. Hydraulic fracturing is while circulating and to
initiated and lost circulation occurs thicken at lower tempera-
when some critical fracture pressure is tures during trips. It is
reached or exceeded. Once a fracture common for circulating
is created or opened by an imposed pressures to decrease 100+
pressure, it may be difficult to repair psi (6.9+ bar) as the mud
(heal) and it may never regain the heats to circulating tem-
original formation strength, as shown perature.
later in Figure 5. Lost circulation may 2) Raising or lowering the
persist even though the pressure is pipe too fast (surge/swab).
later reduced. This is one reason why c) Spudding bridges.
it is better to pretreat for, and prevent, d) Excessive Rate of Penetration
lost circulation than to permit it to (ROP) for a given flow rate
occur. Lost circulation resulting from will result in high cuttings
induced pressure is usually caused by concentration in the annular
one of two situations: fluid causing a high ECD.

Lost Circulation 14.3 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

e) Pipe whipping. e) Kicks and well-control

ii. Hole conditions. procedures.
a) Sloughing shale or increased iii. Mud properties.
solids loading in the annu- a) Excessive viscosities and
lus and high equivalent gel strengths.
circulating density. b) Buildup of drilled solids.
b) Accumulation of cuttings in c) Thick filter cakes that reduce
a washed-out portion of the the hydraulic diameter of
hole or in the mud. the wellbore.
c) Cuttings beds or barite sag d) Excessive mud density or
forming on the low side of a increasing mud density
directional well, or possible too fast.
slumping. e) Unbalanced mud columns.
d) Bridges. f) Barite sag.

Preventive Measures
Good Good planning and proper drilling 2. Minimize downhole pressures.
planning practices are the keys to preventing lost a. Pipe movement should not exceed
circulation by minimizing excessive critical speeds when tripping. When
and proper pressures on the formation. the drillstring is run in the hole,
drilling Several measures can be taken to there is a surging pressure from the
practices prevent or minimize lost circulation: piston effect of the bit and collars
1. Set the casing in the appropriate zone increasing the pressure exerted on
are the so the fracture gradient of the forma- the bottom of the hole. Good drill-
keys to tion at the casing shoe will be suffi- ing practices will keep these pres-
preventing cient to support the hydrostatic head sure surges within the fracture and
of heavier muds required to balance formation pressure, as shown in
lost
pressures in the formations below. Figure 3.
circulation…
16

15 Fracture pressure
Equivalent mud weight (lb/gal)

Breaking Reaming
Circulating
14 circulation
hole clean

13

12
Increase in ECD
due to cuttings Circ
11
RIH Drlg POOH

Pore pressure
10

Time

Figure 3: Bottom-hole pressure for normal drilling cycle (after Clark).

Lost Circulation 14.4 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

Many wells experience lost circu- 1.2

Pressure surge (psi x 1,000)

lation while running pipe or cas- 1.0
15,000-ft
ing into the hole. The length of (4,572-m) well 31⁄2 in.
0.8 8-in. hole 41⁄2 in.
pipe in the hole affects the mag-
0.6
nitude of the surge. Tests show
that the flow of mud along the 0.4
The longer pipe creates most of the pressure 0.2

the pipe, the surge. The longer the pipe, the 0

10 20 30 40
greater the surge. Therefore, the
greater the deeper the well, the slower the
Running speed (sec per stand)

surge. pipe should be run into the hole Figure 4: Effect of running speed and annular
as the depth of the bit increases. clearance on pressure surges.
Smaller annular clearances also ECD is near the fracture pressure.
increase surge pressures much in Maintain the cuttings concentra-
the same way annular pressure tion in the annulus below 4% to
losses are increased as annular minimize the effect of cuttings
clearances decrease (see Figure 4). on ECD.
b. Rapid movement of pipe while d. Rapid starting or stopping of the
circulating also causes even mud pumps can cause pressure
Starting the greater pressure surges. Rapid surges. Starting the pumps too
“spudding” of the pipe or fast rapidly will create a pressure that
pumps too reaming while circulating can can cause lost circulation, espe-
rapidly will create large surges. cially when breaking circulation
create a c. Very high ROP loads the annulus on bottom after a trip. Part of the
with cuttings, thus increases the surge is caused by pressure required
pressure ECD, making any further surging to break the gel structure of the
that can on connections more likely to mud. Rotating the pipe when start-
cause lost cause fracturing as shown in ing circulation will aid breaking the
Figure 5. It is important to con- gel strengths and greatly reduce the
circulation… trol the ROP and circulate prior surge pressure. The other part of
to making connections when the

16
Break down Loss of circulation

15 Initial fracture pressure

Equivalent mud weight (lb/gal)

Breaking Reaming
14 circulation Regain formation strength

13

Increase in ECD due

12 to cuttings Regained
Wait circulation
Spot LCM
Pull Fill Circulating
11 up hole hole clean
RIH Drlg
Pore pressure
10

Time

Figure 5: Drilling cycle causing fracturing and subsequent regain of some formation strength (after Clark).

Lost Circulation 14.5 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

________________________ the surge is the pressure required 300

________________________ to accelerate the mud column
Depth: 7,000 ft (2,134 m)
to the normal circulating rate. 103⁄4-in. (273-mm) casing
________________________ 250
Maintaining low gel structure and 41⁄2-in. (114-mm) drill pipe
________________________ gradually increasing the pump rate

Pressure surge (psi)

200
________________________ will reduce this type of surge pres-
sure. Breaking circulation at several
________________________
intervals when tripping in hole is 150
________________________ another way to minimize these
________________________ pressures. 100

________________________
e. Use enough drill collars to keep
the neutral point in the Bottom- 50
________________________ Hole Assembly (BHA) to minimize
________________________ drillstring whipping.
0
________________________
f. During the planning phase of 0 6 12 24 36
the well, casings and drillstring Gel strength (lb/100 ft2)
________________________
design should be engineered for Figure 6: Effect of gel strength on pressure surge.
________________________ proper and safe operation, and
________________________ also to optimize hydraulics for increase the ECD while drilling.
good hole cleaning and minimum These values should be optimized
ECD, especially in sensitive areas. to ensure good hole cleaning and
g. Wash and ream cautiously solids suspension, and minimize
through bridges. ECD, surge and swab pressures.
h. Avoid kicks if possible. Shut-in Many times mud properties
pressure at the surface is trans- can not be kept at a level which
mitted down the wellbore, often will provide adequate hole clean-
breaking the formation down at ing due to other operational con-
the weakest point. This not only siderations. Higher flow rates and
results in loss of circulation, but aggressive drill pipe rotation are
losing control of the well. Proper the best methods to improve hole
research, well planning and exe- cleaning. High viscosity sweeps
cution will minimize the possibil- are recommended in such cases
ity and severity of a kick. Those where good hole cleaning is
responsible for the operation at the questionable. These sweeps are
wellsite should always be aware of usually made of mud from the
the maximum shut-in casing pres- active system that has been vis-
sure and volume. The volume cosified by additions of bentonite,
of the intruding fluid is directly polymers or Lost-Circulation
related to the shut-in pressures and Material (LCM). The use of
should be minimized. If a well has LCM in these sweeps is prefer-
to be shut-in, proper kill proce- able in many cases since they
dures should be used to maintain are screened out at the surface
the right constant bottom-hole and have no permanent effect
pressure required to kill the well. on the viscosity of the mud.
i. Control mud properties in the Controlling the ROP may be
proper ranges. necessary if efficient hole cleaning
i. High viscosity and gel strengths can not be achieved. Although
increase surge pressures each time this may lengthen the rotating
circulation is interrupted and hours, it will generally be less
restored (see Figure 6). They also

Lost Circulation 14.6 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

expensive than the costs incurred reduce the annular clearance.

by losing returns. The smaller annular space
ii. Control drill solids at the mini- increases the ECD. Therefore,
mum practical level and add fluid loss and filter-cake thick-
proper treatment to minimize ness should always be con-
filter-cake build-up. Anything trolled in the proper range.
that reduces the annular clear- Mud that develops a thin,
ance causes a pressure increase. strong filter cake is more
Balling of the bit, collars, stabi- effective in preventing lost
lizers or tool joints decreases circulation to small fractures
the annular clearance. In the or pores.
case of extensive bit and/or iv. Drill with minimum mud den-
stabilizer balling, a significant sity. This not only enhances
pressure will be exerted on the ROP but also diminishes
the formation. An increase in other mud-related effects.
drag or swabbing on connec- v. A good selection of the proper
tions are possible indicators of size of bridging materials helps
balling. Sometimes a ball can reduce and eliminate whole mud
be pumped off a bit, but if losses into porous formations.
that fails, the common prac- The choice of such bridging
tice of spudding the bit should agents will depend on the for-
be avoided. The combination mation characteristics. Generally,
of the reduced annular clear- particles that are one-third to
ance and the pipe surge can one-half the square root of the
cause the pressure to exceed permeability in millidarcies
the fracture pressure. (md) should be able to bridge
iii. High fluid-loss muds deposit such formations.
a thick filter cake that can

When Lost Circulation Occurs

ANALYSIS OF THE PROBLEM 1. Formation information.

When lost circulation is first noted, the a. Carbonate formations contain
conditions at the time the loss occurred cavernous and vugular zones.
should be accurately recorded and stud- This type of loss would be indi-
ied. The time of the occurrence (while cated if the loss was swift, large
The probable drilling, circulating or tripping), the type and accompanied by a drop in
location of the loss (seeping, partial or complete) the drillstring.
of the loss and the severity of the loss with respect b. Shale formations tend toward frac-
to the exposed formations should be turing that may be a slower type
zone may be of loss. This loss needs to be con-
considered. This information will help
determined determine why the loss occurred, where trolled quickly, as continued losses
from in the hole the loss occurred and the will enlarge the fracture and com-
best remedy for the situation. The prob- promise formation integrity.
knowledge c. A change in the drill rate may
able location of the loss zone may be
available determined from knowledge available indicate a formation change
at the rigsite. at the rigsite. For example: with possible change in for-
mation integrity.

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 CHAPTER

14 Lost Circulation

2. Operational information. the mud. The RPMs of the rotor

a. Some type of hydraulic-pressure- are recorded on film as a series
induced lost circulation would be of dashes or spaces. The RPM will
indicated if the mud weight was be very slow until the point of
being increased at the time of loss. loss is reached. There is a definite
This type of loss may seal itself increase in the rotor’s speed at
(seepage) or require treatment the point of loss.
(induced fracture) depending on There are two objections to
the severity of the loss. this method:
b. Rapid movement of the drillstring ii. It requires deliberate loss of
will cause pressure surges that can large volumes of mud.
induce fractures or reopen previ- ii. It is not effective where sealing
ously sealed loss zones. Unless a material is already present in
previously sealed loss zone has been the mud.
pressure tested it should always be b. Temperature survey.
assumed this area remains a poten- The temperature survey depends
tial source of losses. The rate of pipe on a subsurface thermometer for
movement during trips and while measuring the difference in the
reaming should be adjusted to mud temperature and the forma-
compensate for this weakness. tion temperature. It is made by
running a sensitive element in the
A more informed decision can be
hole that changes its resistance as
made regarding the proper steps to elim-
the temperature changes. Two sur-
inate the losses with the information
veys are run. The first is run to
gathered above.
establish the temperature gradient
LOCATING THE ZONE of the well after the mud has come
Restoring Restoring circulation as quickly as possi- to equilibrium with the formation.
ble is very important since lost circula- The second survey is run immedi-
circulation ately after adding fresh cool mud
tion increases mud cost and can cause
as quickly other wellbore problems that result in to the well. A sharp temperature
as possible additional operational costs. discrepancy will occur at the point
is very 1. Locate the exact point of lost circula- of loss.
tion. Contrary to the common belief, c. Radioactive tracer survey.
important… the majority of the losses do not Radioactive surveys for locating
occur at the bottom of the hole. It the point of loss consist of making
has been established that more than two gamma ray surveys. A base log
half of the losses occur just below the is run before the introduction of
last casing shoe. Several methods are radioactive material. A slug of mud
available for locating the point of lost containing radioactive material is
circulation. These include: then pumped down the hole and
a. Spinner survey. a new log is run. High concentra-
The spinner survey is made by tions of the radioactive material
running a small spinner attach- will be located at the point of loss.
ment into the well on a single con- This method provides accurate data
ductor cable in such a manner that for locating the point of loss, but
the vaned rotor will spin or turn if requires expensive equipment and
there is any horizontal motion of additional deliberate loss of mud to
obtain the desired information.

Lost Circulation 14.8 Revision No: A-0 / Revision Date: 03·31·98

 CHAPTER

14 Lost Circulation

________________________ d. Hot wire survey. Though it is good practice to locate

________________________ The hot wire tool is essentially the thief zone, there are several reasons
a calibrated resistance wire that is why surveys are not run more often:
________________________
sensitive to temperature changes. It iii. Considerable time is spent getting
________________________ is run to a desired point in the hole the necessary equipment to the
________________________ and the resistance is noted. Mud is rig, and a deliberate loss of mud
then pumped into the hole. If the is required for these surveys.
________________________
tool is above the point of loss, mud iii. The results of these surveys are
________________________ will flow by it, changing the resis- sometimes difficult to interpret.
________________________ tance. If the resistance does not iii. Conditions are not always such
________________________
change, the tool is below the point that the tools may be run because
of loss. The tool can be used in of abnormal subsurface pressure.
________________________ any kind of mud, but a large 2. Determine the severity of loss. This
________________________ amount of mud is required is best determined by the amount
________________________
while making the survey. of loss and the static mud column
e. Pressure transducer survey. height. If the static mud column
________________________
This type of survey involves height is not visible it can be deter-
________________________ using a short cylinder open at the mined by running a piece of wood
________________________ top and swaged at the bottom to (4 in. x 4 in. x 4 ft [4 mm x 4 mm
restrict the flow of mud through x 1.2 m]) on a wireline. Another
the tube. A window with a neo- option is the use of a sonic echo-
prene diaphragm is fitted on one measuring device.
side of the tube. There is an elec- a. Loss zones can be classified as:
trode that moves back and forth i. Seeping losses (1 to 10 bbl/hr).
between the two fixed electrodes ii. Partial losses (10 to 500 bbl/hr).
on the diaphragm. As the pres- iii. Complete loss (hole full to
sure differential varies across the mud level at 200 to 500 ft
diaphragm, the potential varies [61 to 152 m]).
in the electric circuit indicating iv. Partial or complete loss to
the rate of flow of the mud and deep induced fractures.
where the mud becomes static. v. Severe complete loss (hole full to
This method appears to have mud level at 500 to 1,000+ ft
certain advantages: [152 to 305+ m]).
• It is simple in construction and 3. Determine the type of loss. This is
operation. best determined by the lithology.
• It is not easily clogged by lost- Lost circulation as it relates to lithol-
circulation material. ogy is discussed above in “Causes of
• It is workable in almost any Lost Circulation.” These classifica-
type of mud. tions can be related to the four types
• It can be used to locate a hole of formations in which mud losses
inside of casing. occur (see Figure 1).
Two apparent disadvantages are: a. Shallow, unconsolidated forma-
• Considerable mud flow is tions where rock permeability
required. can exceed 14 darcies (see “a”
• The equipment may not be in Figure 1).
readily available.

Lost Circulation 14.9 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

________________________ Identifying features. Identifying features.

________________________ iii. Offset records that identify the i. Normally confined to
zone and its characteristics. limestone and dolomite.
________________________
iii. Gradual lowering of mud level ii. Loss of returns is usually
________________________ in pits. sudden and complete.
________________________ iii. Loss may become complete if iii. Bit may drop from a few inches
drilling is continued. to a few feet just preceding loss.
________________________
b. Formations that have natural iv. Excessive torque may be
________________________ fractures such as limestone and experienced before loss.
________________________ some hard shale formations (see 4. Classification of loss by determining
________________________
“c” in Figure 1). the pressure within the zone.
Identifying features. a. Position the bottom of the drill
________________________ i. Offset records and geological pipe at the top of the suspected
________________________ markers. loss zone.
________________________
ii. May occur in any type of b. Attach a suitably sized length of
hard, brittle rock. wood, approximately 4-ft (1.2-m)
________________________
iii. Loss is evidenced by gradual long, to the rig survey line and
________________________ lowering of mud in pits. run it down through the drill
________________________ iv. Loss may become complete if pipe until the static fluid level
drilling is continued and more is found. A sonic echo-measuring
fractures are exposed. sthe fluid level.
c. Fractures that are induced c. The pressure within the loss zone
through mechanical or hydraulic is then calculated as follows:
forces exerted on the formation Pz = (Dz - Df)(MWp)(0.052)
(see “d” in Figure 1).
Identifying features. Where:
i. Offset records that include Pz = Pressure of the loss
excessive annular hydraulics. zone (psi)
ii. Could occur in any type rock, Dz = True Vertical Depth
but would be expected in for- (TVD) of the loss
mations with characteristically zone (ft)
weak planes, such as soft shales. Df = Fluid drop inside the
iii. Loss is usually sudden and drill pipe (ft)
complete. MWp = Fluid density inside the
iv. Loss may follow any increase drill pipe (lb/gal)
in mud weight or sudden d. The static mud density which
surge in pressure. the zone will support is calculated
v. Can be in competent or as follows:
incompetent formations. Pz
d. Cavernous zones normally MWz =
(0.052 x Dz)
confined to limestone (see
“b” in Figure 1). Where:
MWz = Mud weight that the
zone will support (lb/gal)

Lost Circulation 14.10 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

Corrective Measures

CORRELATION OF TECHNIQUE a. The pull-up-and-wait technique

TO SEVERITY should be the first technique used
The best approach to control lost cir- to attempt to regain full returns
…make an culation is to make an assessment of (see pull-up-and-wait technique).
the severity of a loss zone and match b. Use high-filter-loss slurry squeeze
assessment technique (see high-filter-loss
the remedial material and technique
of the sever- to it in terms of both the size of the squeeze technique).
ity of a loss material and its function. c. If returns are not regained with this
zone and 1. Seeping losses can occur in any technique, a hard plug such as a
formation type when the bridging cement, cement-bentonite, cement-
match the agents are not large enough to form gilsonite or diesel-oil-bentonite-
remedial a seal (see Figure 8a), or when there cement is recommended (see
material and are no fine particles to complete techniques for cement slurries).
the seal. d. Reduce mud weight if possible.
technique to a. The pull-up-and-wait technique 4. Partial or complete loss to deep,
it in terms… should be the first technique used induced fractures.
to attempt to regain full returns a. The pull-up-and-wait technique (4
(see pull-up-and-wait technique). to 8 hr) should be the first tech-
b. If the hole will not stand full nique used to attempt to regain
while waiting, the technique of full returns (see pull-up-and-wait
mixing an LCM slurry containing technique).
fine to medium bridging agents b. Apply soft plug squeeze (see
or utilizing a high-filter-loss slurry techniques on soft plugs).
squeeze should be considered. c. If the hole will not stand full
c. Reduce mud weight if possible. while waiting, the technique of
2. Partial losses occur in gravel, small mixing an LCM slurry containing
natural fractures and barely opened a blend of large bridging agents
induced fractures (see Figure 1). The or utilizing a high-filter-loss slurry
same techniques used in seeping squeeze should be considered.
losses should be used in partial losses. d. Reduce mud weight if possible.
a. The pull-up-and-wait technique 5. Severe complete losses occur to large,
should be the first technique used open natural fractures, caverns and
to attempt to regain full returns open induced fractures.
(see pull-up-and-wait technique). a. Squeeze with either a high-filter-
b. If the hole will not stand full while loss slurry squeeze or large amounts
waiting, the technique of mixing of diesel-oil-bentonite-cement
an LCM slurry containing a blend slurries (see techniques for each).
of medium to large bridging agents b. If the severe, complete losses
or utilizing a high-filter loss slurry continue to occur as more open,
squeeze should be considered. natural fractures or caverns are
c. Reduce mud weight if possible. penetrated, the technique of
3. Complete losses occur to long, open drilling blind or with aerated
sections of gravel, long intervals of mud and setting casing should
small natural fractures, large natural be considered.
fractures or open induced fractures c. Reduce mud weight if possible.
(see Figure 1).

Lost Circulation 14.11 Revision No: A-0 / Revision Date: 03·31·98

 CHAPTER

14 Lost Circulation

CAUSES FOR FAILURE TO concentrations of the same or similar

REGAIN CIRCULATION materials. The next step should be to
Some of the most usual causes, directly increase the size of the bridging materials.
or indirectly, for failure to control loss NOTE: It cannot be stressed too strongly
of circulation are: that the lost-circulation technique must be
1. The location of the loss zone is not matched to the severity of the loss zone.
established many times, resulting in PULL-UP-AND-WAIT TECHNIQUE
attempts to place materials at the
This technique should be used against
wrong spot. Loss zones are usually
seeping and partial losses, and losses
not on bottom but are near the last
to induced fractures.
casing seat or lost-circulation point.
Except for sudden, complete losses
2. Lost-circulation materials are not sys-
to limestones where large fractures,
…lost- tematically matched to the type and
vugs or caverns occur, drilling and cir-
severity of the loss zone. There must
circulation be a mixture of particle sizes to initi-
culation should be stopped at the first
techniques indication of lost circulation.
ate and propagate an effective seal.
The bit should be pulled to a point of
and 3. There is sometimes a reluctance to
safety and the hole permitted to remain
proceed to the technique required to
materials match the severity of the loss zone
static for a period of 4 to 8 hr. Carefully
must be monitor the well for signs of intruding
(i.e. drilling blind and setting pipe).
fluids and risk of a kick. After the wait-
functionally 4. Adequate records are not kept that
ing period, good drilling techniques
describe the losses and the materials
related to and techniques used against them.
must be followed in getting back to
the losses bottom to keep minimum pressures
Accurate accounts of experience in
on the formations.
they cure. an area are valuable.
On the speculation that returns will
5. In cementing, the columns are not
not be obtained by waiting, a 100-bbl
balanced and drilling mud breaks
LCM slurry or a similar volume of high-
through the plug before it sets. In
filter-loss slurry can be mixed during the
addition, when the pipe is withdrawn
waiting period. If it is anticipated that
from the hole after placement, the
the LCM pill will remain in storage for
mud level in the annulus goes down
any length of time a biocide should be
and mud from the formation can
added to prevent bacterial degradation
break through the freshly placed
of any organic components.
slurry. Balanced columns and plug-
Half of the losses in the Gulf Coast
dropping techniques should be
area were corrected by using this tech-
employed.
Fractured 6. The formation strength is too weak
nique. Fractured shales exposed to
shales water-base muds will generally heal
to support the hydrostatic pressure of
and circulation can be regained, espe-
exposed to the fluid column needed to control
cially if pressures can be reduced with
the pressure in other exposed zones.
water-base improved hydraulics and drilling prac-
muds will To be effective, the lost-circulation tices. Oil-base fluids do not exhibit
techniques and materials must be func- this self-healing behavior to the
generally tionally related to the losses they cure. same extent.
heal and For example, where a reasonable This technique is particularly applic-
circulation amount (15 to 20 lb/bbl) of LCM has able to deep-induced fractures.
not worked in a high-filter-loss slurry, NOTE: The remaining techniques require
can be it is usually useless to use higher the use of lost-circulation materials.
regained…

Lost Circulation 14.12 Revision No: A-0 / Revision Date: 03·31·98

 CHAPTER

14 Lost Circulation

LOST-CIRCULATION MATERIALS (LCM) mud, height the mud stands in the

Fibrous hole and the rate of loss. The most
• M-I-X* II. probable point of the loss is just
• M-I CEDAR FIBER* (wood fiber). below the casing shoe if a fracture of
• Sawdust (wood fiber). the formation due to a pressure surge
• Drilling paper (paper). is suspected.
• Magma Fiber (mineral fiber). 2. Use open-ended drill pipe for
placement of the plug if practical.
Granular
Otherwise use open watercourse bits
• NUT PLUG* (nut shells - fine, medium or jet bits with the nozzles removed.
and coarse). If materials must be placed through a
• G-SEAL* (coarse graphite). jet bit or MWD/LWD tools, medium-
• Calcium carbonate (fine, medium to-fine, sized bridging agents should
and coarse). be used to prevent plugging the bit.
Blends NOTE: Use acid-soluble materials for
• Kwikseal (blend of fibrous, granular losses to the reservoir.
and flakes). 3. Mix a 100- to 250-bbl LCM slurry.
• M-I SEAL* (blend of flake, granular Blends of coarse, medium and fine
and fibrous). granular, fiber and flake bridging
Flakes agents are commercially available
• Flake (cellophane). and could be substituted for those
• Mica (fine and coarse). added separately. Use mud from
• Pheno Seal. the circulating system or mix
LCM in a freshly prepared, viscous,
REINFORCING PLUGS bentonite slurry.
Water-base squeezes Add 15 lb/bbl of coarse NUT PLUG.
• High-filter-loss squeeze (Salt gel — Add 5 lb/bbl coarse-to-medium
diatomaceous earth). fibers.
• Diesel-Oil/Bentonite (DOB) (soft plug). Add 5 lb/bbl of medium-to-fine fibers.
• Bentonite — Bengum (soft plug). Add 5 lb/bbl of 1⁄2-in. (13-mm)
• Crosslinked polymer (soft plug). cellophane flake.
The size of • Diesel-oil/bentonite/cement NOTE: The size of the bridging material
the bridging (hard plug). must be tailored to the severity of loss since
• Cement slurry (hard plug). the size of the openings taking the mud are
material seldom known. This logic is based on the
Oil-base squeezes
must be • Diatomaceous earth.
knowledge that low rates of loss occur
tailored to through small openings and higher rates of
• Calcium carbonate — M-I-X II.
loss occur through larger openings. Figure 7
the severity • Gunk squeeze for oil muds (VG-69*
illustrates how materials that are too large
of loss… in water).
will form a bridge at the face of the open-
USE OF PLUGGING OR ing, while properly sized materials form a
BRIDGING AGENTS bridge in the opening where it is not as
This technique should be used against likely to be eroded away when circulation is
seeping and partial losses and the less resumed. Figure 8 illustrates how the use of
severe complete losses. A plug of bridg- materials that are too small go through the
ing agents in the mud is mixed and opening and do not form a bridge. When
applied as follows: selecting the size of materials to use, the
1. Establish the approximate point of size of the nozzles in the bit and other pos-
the loss, type of formation taking the sible restrictions (e.g. MWD tools, mud
motors) should always be considered.

Lost Circulation 14.13 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

________________________

________________________ A B A B

________________________

________________________

________________________ Figure 7a: Fracture seal at face of wellbore. Figure 8a: Small lost-circulation materials failing to
________________________ Figure 7b: Fracture seal within the formation. form a bridge. Figure 8b: Initial bridge being formed by
large particle with final seal by smaller particles.
________________________

________________________ 4. Pump the LCM slurry through the 20

Concentration (lb/bbl)
open-ended drill pipe opposite the A typical A typical
________________________ 16 fibrous lamellated
loss zone. Pump at a slow rate until material material
________________________ the materials have stopped the loss. 12

________________________ Repeat once more if the hole does not 8 A typical

fill and then proceed to a high-filter- 4 granular
________________________ material
loss slurry squeeze technique, if there 0
________________________ still is no indication of success. If the 0 .02 .04 .06 .08 .10 .12 .14 .16 .18 .20
hole fills, close the blowout preventers Largest fracture sealed (in.)
________________________

________________________
(rams) and squeeze the annulus with Figure 9: Effect of concentration and type of
50 psi (3.4 bar) for 30 min. Measure lost-circulation material on sealing fractures
the pressure on the annulus using (after Howard and Scott).
a 0- to 300-psi (0- to 20.7-bar) gauge.
LCM slurries containing a blend of trouble and poor mud properties may
materials are most effective. Bridging result from higher concentrations.
agents must contain at least granular However, if bridging agents are to
and fibrous agents to be effective. A be applied in a slug of mud, then con-
useful LCM mixture is 3 to 6 parts centrations up to 30 lb/bbl can be
granular, 2 parts fibrous and 1 part more effective (see Tables 1 and 2).
flake material. It is important to increase the size
and amount of the granular agent if
The size of the granular and flake conventionally-sized materials are not
bridging agents should be matched to effective. The effectiveness of granular,
the severity of the loss. No advantage fibrous and flake bridging agents in
is gained if the concentration of lost- plugging a simulated fracture is shown
circulation materials in the total mud in Figure 9.
system or high-filter loss slurry exceeds
15 to 20 lb/bbl (see Figure 9). Pump
Static Slot Marble Bed BB-Shot Bed
Largest Slot Volume Thru Volume Thru Volume Thru
Concentration Sealed at 1,000 psi at 1,000 psi at 1,000 psi
(lb/bbl) (in.) (mL) (mL) Seal (mL) Seal
10 0.10 500 All No 1,700 Yes
20 0.13 250 1,900 Yes 2,050 Yes
30 0.16 400 1,700 Yes 800 Yes
40 0.20 300 1,700 Yes 1,800 Yes

Table 1: Performance of various concentrations of mixed sealing materials (after Lummus).

Lost Circulation 14.14 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

30 lb/bbl Coarse- 30 lb/bbl Medium-

Test Grind Material Grind Material
1 Pumping test through 9⁄32-in. standard jet bit nozzles Plugged Flowed through
immediately at 200 psi (13.8 bar)
2 Static slot:
Largest slot sealed (in.) 0.16 0.08
Total vol through (mL) 400 100
3 Dynamic slot:
Largest slot sealed (in.) 0.13 0.06
Total vol through (mL) 600 0.50
4 Static marble bed:
Vol through at 100 psi (mL) 500 400
Vol through at 1,000 psi (mL) 1,700 1,200
5 BB-shot bed:
Vol through at 100 psi (mL) 400 300
Vol through at 1,000 psi (mL) 800 800

Table 2: Comparison of coarse and medium grinds of mixed sealing material in mud (after Lummus).

Mud losses ranging in severity from stimulation industry this is called frac-
seeps to complete losses into 1⁄8- to 1⁄4-in. ture-tip “screen out.” Fluids treated with
3.2- to 6.3-mm) natural and induced 15 to 30 lb/bbl of material having a par-
For a fractures can be stopped by using ticle size similar to medium and coarse
bridging bridging agents. For a bridging agent NUT PLUG, G-SEAL and extra-coarse
to function, some of it must be of suffi- calcium carbonate have the potential
agent to cient size to bridge the opening to be to limit hydraulic fracturing in weak
function, plugged (see Figure 10). Accordingly, sandstones.
some of it fine granular material, fine fiber and Coarse granular material, coarse
cellophane flake should be used against fiber, medium fiber, fine fiber and
must be of seeping losses. coarse flake should be used against
sufficient There is considerable evidence that complete losses.
size to bridge a sufficient quantity of properly-sized NOTE: As the severity of the loss zone
granular material can prevent the propa- increases, only the size of the bridging
the opening gation of induced fractures in permeable agent should be increased — not the con-
to be plugged. formations. This occurs when the gran- centration. Concentrations above 20 to
ular material can pack into the fracture 30 lb/bbl do not improve effectiveness
tip openings and prevent fluid and pres- (See Figure 9).
sure from being transmitted. In the

Lost Circulation 14.15 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

Concentration Largest Fracture Sealed

Material Type Description (lb/bbl) (in.)
0 .04 .08 .12 .16 .20
Nut shell Granular 50% – 3⁄16+ 10 mesh 20
50% – 10+ 100 mesh
Plastic Granular 50% – 3⁄16+ 10 mesh 20
50% – 10+ 100 mesh
Limestone Granular 50% – 3⁄16+ 10 mesh 40
50% – 10+ 100 mesh
Sulphur Granular 50% – 3⁄16+ 10 mesh 120
50% – 10+ 100 mesh
Nut shell Granular 50% – 10+ 16 mesh 20
50% – 30+ 100 mesh
Expanded perlite Granular 50% – 3⁄16+ 10 mesh 60
50% – 10+ 100 mesh
3
Cellophane Lamellated ⁄4-in. flakes 8
1
Sawdust Fibrous ⁄4-in. particles 10
1
Prairie hay Fibrous ⁄2-in. fibers 10
3
Bark Fibrous ⁄8-in. fibers 10
Cotton seed hulls Granular Fine 10
3
Prairie hay Fibrous ⁄8-in. particles 12
1
Cellophane Lamellated ⁄2-in. flakes 8
1
Shredded wood Fibrous ⁄4-in. fibers 8
1
Sawdust Fibrous ⁄16-in. particles 20

Figure 10: Summary of lost-circulation material tests (after Howard and Scott).

HIGH-FILTER-LOSS-SLURRY SQUEEZE
Almost any mud can be used as a carry-
Water
ing fluid for spotting lost-circulation
materials, but fluids that have extremely
It is through high-filtration rates are best. It is through
filtration filtration that the lost-circulation materi-
als and mud solids are left as a firm plug
that the in the opening taking mud. The princi-
lost- Figure 11: High-fluid-loss-squeeze technique for
ple of this technique is illustrated in
lost circulation showing water being lost through
circulation Figure 11. Once the initial bridge forms,
filtration depositing solids within fracture.
filtration allows filtrate to be lost from
materials the slurry depositing a firm filter cake of high-filter-loss slurries and their appli-
and mud within the fracture itself. This very cation to loss zones varying in severity
solids are much resembles a wedge being driven from seeping to partial to complete are
into the fracture. This wedge is not described later.
left as a only difficult to move, but serves to There are slight differences in appli-
firm plug in stop fracturing the wellbore. cation to these zones, but the main dis-
the opening This technique should be used against tinction is increasing the size of the
taking mud. seeping and partial losses, and the less bridging agent as the loss zone becomes
severe complete losses. The preparation more severe.

Lost Circulation 14.16 Revision No: A-0 / Revision Date: 03·31·98

 CHAPTER

14 Lost Circulation

First, the severity of the loss should To avoid fracturing other zones, safe
be established from the fluid level and squeeze pressures in excess of mud
the rate of loss. Then, the approximate hydrostatic pressure should be used.
point of the loss should be established For example:
and the type of formation taking mud
Depth (ft) Squeeze Pressure (psi)
If hydraulic defined. If hydraulic fracturing of the
0 - 1,000 0 - 200
fracturing formation is suspected, the most prob-
1,000 - 5,000 100 - 500
able point of loss is just below the
of the casing shoe.
5,000 and deeper 500

formation is NOTE: Surface pressure plus mud-

FOR SEEPING LOSS
suspected, 1. Mix 100 bbl of slurry: column pressure should never exceed
the most a. Add 10 to 20 lb/bbl of attapulgite overburden pressure (1 psi/ft).
probable or sepiolite clay to 80 bbl of water FOR PARTIAL LOSS
(attapulgite and sepiolite clays 1. Mix 100 bbl of slurry:
point of behave similarly in saltwater). If Add 10 to 20 lb/bbl of attapulgite
loss is just these clays are not available, use or sepiolite clay to 80 bbl of water.
below the 5 to 20 lb/bbl bentonite and pre- If these clays are not available and
casing shoe. treat the water with 1⁄4 lb/bbl of bentonite is used as the viscosifier,
soda ash and 1⁄4 lb/bbl of caustic add 1⁄2 lb/bbl of lime to flocculate
soda to remove calcium and mag- the clays and increase the fluid loss.
nesium ions. Allow clay to yield. or:
If bentonite is used, add 1⁄2 lb/bbl Add 50 lb/bbl of diatomaceous
of lime to flocculate the bentonite earth materials (as before) or a suit-
and increase the fluid loss. able substitute (LO-WATE). Use barite
or: only if the mud weight is 12 lb/gal
b. Add 50 lb/bbl of diatomaceous (1.4 kg/L) or higher or if it is the only
earth materials (Diacel^ D, inert powdered material available.
Diaseal M or a suitable substitute
such as LO-WATE*). Diaseal M is a Add a combination of different LCM
To avoid sizes and shapes to obtain a 15-lb/bbl
mixture of diatomaceous earth,
fracturing lime and paper. If this mixture is total concentration of LCM.
other zones, used, attapulgite is not required. 2. Set the drill pipe with the open end at
the top of or opposite the loss zone.
safe squeeze Add different LCM sizes and shapes 3. Displace 25 bbl of slurry into the
pressures to obtain a 10- to 20-lb/bbl total con- zone at a rate of 2 to 4 bbl/min.
centration of LCM. 4. Shut down for 20 to 30 min.
in excess 2. Set the bit at the top of, or opposite, 5. Displace another 25 bbl of slurry at
of mud the loss zone. Displace the LCM the same rate.
hydrostatic slurry to the end of the drill pipe. 6. Continue this procedure, alternately
pressure 3. Close the rams. Gently squeeze waiting and displacing until the hole
(50 psi [3.4 bar] maximum) mate- fills. Sometimes two 100-bbl batches
should be rial into the loss zone at a rate of will be required. The drill pipe should
used. 1 bbl/min. Hold the squeeze pres- be reciprocated during these opera-
sure 4 to 8 hr or until it dissipates. tions to prevent it from sticking.
Measure the squeeze pressure on the
annulus using a 0- to 300-psi (0- to
20.7-bar) gauge.

Lost Circulation 14.17 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

7. When the hole fills, close the rams hay, paper, wood, etc. should be
and squeeze the annulus with 50 to considered prior to pumping
100 psi (3.4 to 6.9 bar) by displacing cement plugs.
the slurry very slowly (1 bbl/min)
down the drill pipe. Attach a 0- to
HARD PLUGS
Various hard 300-psi (0- to 20.7-bar) gauge to Various hard cement plugs are often
cement plugs the annulus so that low pressure effective against complete losses and
values can be easily read. Maintain severe complete losses.
are often The composition and technique of
the squeeze for 30 to 60 min.
effective 8. Pull out of the hole, pick up the bit application of the cement slurry being
against and continue drilling. used to combat lost circulation must
be functionally adequate if the job is
complete FOR COMPLETE LOSS to succeed.
losses The procedure for complete loss is the 1. Cement slurry composition.
and severe same as the procedure for “partial loss” Cement, or cement plus bentonite,
complete except for the composition of the bridg- is an important lost-circulation
ing agents. The composition of these remedy because these slurries will
losses. materials should be as follows: often seal vugular loss zones.
1. Add 10 to 15 lb/bbl of attapulgite or Three Portland cement slurries
sepiolite clay to 80 bbl of water. If are recommended: neat, bentonite
these clays are not available, treat the and gilsonite. These have been cho-
water as before. Add 1⁄2 lb/bbl of lime. sen because a wide variety of prop-
or: erties can be obtained and they are
Add 50 lb/bbl of diatomaceous usually available.
earth materials (as before). Use barite Neat-Portland cement. Mix to
only if the mud weight is 12 lb/gal 15.6 lb/gal (1.9 kg/L) using 46%
(1.4 kg/L) or higher or if it is the only water and cement. This slurry is
inert powdered material available. a dense fluid and develops high-
Add a combination of different LCM compressive strength when it sets.
sizes and shapes to obtain a 20- to Bentonite or gel cement. Bentonite
30-lb/bbl total concentration of LCM. cement formed by adding cement to
For displacement, see Steps 2 water containing prehydrated ben-
through 8 in “For partial loss.” tonite gives optimum properties. The
2. When severe, complete loss returns slurry formed has lower density and
occur in formations with large, nat- higher gel strength. It also has a
urally occurring fractures, vugs, higher set strength than a slurry
channels or caverns; at least one formed by adding water to a dry
conventional lost-circulation pill mixture of bentonite and cement.
such as those previously discussed In mixing the slurry, treat the
should be spotted. If this procedure freshwater to be used with 1⁄4 lb/bbl
fails to improve the lost-circulation of soda ash and 1⁄4 lb/bbl of caustic
problem, cavern treatments with to remove calcium and magnesium
bulk fillers such as rags, mud sacks, ions. Add 10 lb/bbl of bentonite

Lost Circulation 14.18 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

________________________ and allow this to yield. Use this 3. Choose a cement slurry. According
________________________ bentonite slurry to mix a 14.5 to to the severity of the loss zone, mix
15 lb/gal (1.7 to 1.8 kg/L) bentonite- and run 100 to 300 sacks.
________________________
cement slurry. Use 100 sacks of 4. Locate the loss zone, using an
________________________ cement or more for large hole sizes. appropriate technique described
________________________ Gilsonite-Portland cement. Gilsonite previously.
can be added to cement slurries that 5. Run the drill pipe and cementing
________________________
are being used to regain returns. It sub past the loss zone to make sure
________________________ it is exposed. Clean the hole past the
decreases the density of the slurry
________________________ and acts as a bridging agent, both of zone if required. Pull up the cement-
________________________ which help to keep the slurry in the ing sub at a point 50 ft (15.2 m)
vicinity of the wellbore. It should be above the top of the loss zone.
________________________ 6. Calculate the slurry volume of
run exactly like bentonite-cement
________________________ slurries and should be squeezed if cement needed to be spotted. Mix
________________________ the hole fills during its applica- and pump the cement until the
tion. Between 25 to 100 lb (11.3 to desired volume is pumped. Displace
________________________
45 kg) of gilsonite per sack of cement the drill pipe at ±10 bbl/min.
________________________ are recommended. Leave enough cement inside the
________________________ These three cements are recom- drillstring to balance the plug in
mended because they provide slur- the annulus. This will eliminate
ries with a range of properties from the U-tube effect and minimize
thin, heavy slurries that set hard, to cement contamination.
lighter, thick slurries having bridging 7. Slowly pull out of the hole. As the
properties. They are also available pipe is withdrawn, the mud level in
everywhere. However, they are not the annulus will fall and cause an
intended to be used to the exclusion imbalance of pressure from the for-
of all other cement formulations. mation to the hole. This may cause
mud or formation fluids to break
1. Techniques for applying cement. through the cement slurry. To pre-
Cement slurries should be used to vent this, very carefully add mud to
combat losses to natural fractures the annulus through the fill-up line.
1
⁄3 in. to 1 ft (8.5 mm to 0.3 m) in Adding too much mud to the
diameter, and to broken limestones annulus will force mud from the
or boulders. annulus into the formation through
NOTE: Cementing loss zones fails many the cement slurry before it has a
times because mud has broken through the chance to set. The amount of mud
unset slurry. “Balancing columns” will usu- pumped must match the volume dis-
ally prevent this, particularly if column placement (not capacity) of the pipe.
weights are carefully calculated. If it is done carelessly, it can do more
BALANCED-COLUMN METHOD harm than good. Pump the required
1. If possible, drill without returns amount of mud every 10 stands. Wait
through the entire lost-circulation on cement at least 8 hr.
zone. 8. Measure fluid level. If it is lower or
2. Pull out of the hole. Measure the higher than the original static level,
static mud level using a piece of do not attempt to adjust. If it is
wood (4 in. x 4 in. x 4 ft [4 mm x higher and another plug is run,
4 mm x 1.2 m) on a wireline or a adjust by adding proportionately
sonic echo fluid level meter. less mud as the pipe is withdrawn.

Lost Circulation 14.19 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

________________________ DIESEL-OIL/BENTONITE/CEMENT slurry volume to the mud volume

________________________ SLURRY SQUEEZE is 2:1. Pump rates of 4 bbl/min
Use this technique against complete down the drill pipe and 2 bbl/min
________________________
losses and severe complete losses. These down the annulus will usually be
________________________ steps should be used in applying this satisfactory with 41⁄2-in. drill pipe
________________________ technique: in 77⁄8-in. and larger holes.
11. If possible, drill without returns 19. Displace one-half of the slurry into
________________________
through the entire lost-circulation the formation at this fast pumping
________________________ rate. The drill pipe may occasionally
zone.
________________________ 12. Pull out of the hole. Measure static be reciprocated slowly to indicate
________________________ mud level as previously mentioned. whether the slurry might be moving
13. Locate the loss zone as in Step 4, up the annulus. If the weight indica-
________________________ tor shows any increased drag, break
balanced-column method.
________________________ 14. After locating the loss interval, the connections and raise the pipe
________________________ set the bottom of the mixing sub until it is free. Make connections
50 ft (15.2 m) above it. Set a and continue displacement. There
________________________
maximum squeeze pressure. is no need for concern over short
________________________ 15. Pump in a 10-bbl cushion of shutdown periods since the slurry
________________________ water-free diesel oil ahead of has no pumping time limitation
the slurry. inside the pipe.
16. Mix 100 sacks of regular cement 10. Displace the next quarter of vol-
and 100 sacks of bentonite with ume of slurry and mud at one-half
50 bbl of diesel oil. For volumes the rate used in Step 9.
other than 50 bbl, mix two, 96-lb 11. Displace the remaining quarter
(44-kg) sacks of cement and two, volume of slurry at one-half of the
100-lb (45-kg) sacks of bentonite rates used in Step 10. If the hole
with each barrel of diesel oil. For fills, as shown by pressure on the
large fractures or long sections of annulus, attempt (by a hesitation
honeycombed vugs, 300 sacks of squeeze) to obtain a pressure
each material should be used. buildup using rates of 1 bbl/min
For large batches, use a cementer into drill pipe and 0.5 bbl/min
and mix the dry materials with the into annulus.
diesel oil continuously. For small NOTE: One barrel of slurry should
batches use a suitable tank. This be left in the drill pipe at the comple-
mixture will yield 1.39 bbl of slurry tion of the squeeze, if pressure has
for each barrel of diesel oil. This developed. Balance columns if no
slurry will weigh 11.5 lb/gal pressure develops. Do not attempt
(1.4 kg/L). to reverse circulate because mud will
17. Displace the slurry down the drill contact the slurry and gel up inside
pipe and follow it with 5 bbl of the drill pipe.
diesel oil. 12. After the squeeze job, pull out of the
18. Start pumping drilling mud into hole and wait a minimum of 8 hr
the annulus when the 10-bbl cush- for the cement to set before drilling
ion of diesel oil reaches the mixing out. If the first attempt is unsuc-
sub. Close the rams. Control the cessful, repeat the procedure after
pumping rates so the ratio of the waiting on the cement for 8 hr.

Lost Circulation 14.20 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

PRECAUTIONS 12. Pull out of the hole. Measure the

Avoid conta- Avoid contamination of the slurry with static mud level as previously
mud or water in the suction lines and described.
mination of 13. Locate the loss zone as previously
pumps. The following steps will mini-
the slurry mize the possibility of contamination. described.
with mud or 1. Field test for diesel-oil suitability. 14. After locating the loss interval, run
a. Fill a sand content tube to the the placement sub past the loss
water in the zone to make sure it is exposed.
20% line with the diesel oil.
suction lines b. Add water to the “mud to Place the bottom of the mixing
and pumps. here” line. sub 50 ft (15.2 m) above it. Set a
c. Shake vigorously for 10 sec and maximum squeeze pressure.
allow to stand for 10 min. 15. Pump in a 10-bbl cushion of water-
d. If the oil and water separate into free diesel oil ahead of the slurry.
two distinct layers, the diesel oil 16. Mix 200, 100-lb (45-kg) sacks of
is suitable for use. However, if the bentonite with 50 bbl of diesel oil.
fluid separates into three layers with For volumes of other sizes, mix 4
the oil on top, the water on bottom sacks of bentonite with each barrel
and a white emulsion between, of diesel oil. Mixing can be done
the diesel oil is not suitable and continuously using a cementing
should not be used. truck. This mixture will yield
2. Drain all water and mud out of 1.39 bbl of slurry for each barrel
all pumps, lines and tanks prior of diesel oil. For severe loss zones,
to mixing. 600 sacks of bentonite in 150 bbl
3. Use diesel oil to thoroughly flush of diesel oil mixed continuously
the pumps, lines and mixing should be used.
facilities prior to mixing. 17. Displace the slurry down the drill
pipe and follow with 5 bbl of diesel
SOFT PLUGS oil. When the front of the 10-bbl
Downhole-mixed soft plugs (diesel-oil/ diesel oil cushion reaches the end
bentonite, Bengum). Use this technique of the drill pipe, begin pumping
against induced fractures and to hold drilling mud into the annulus at
cement slurries at or near the wellbore a rate of 4 bbl/min with a second
until they set. pump. Close the rams.
The success The success of downhole-mixed 18. Control the pumping rates so
of downhole- soft plugs depends on having the that the ratio of slurry volume to
right amount of components meet mud volume is 1:1. Pump rates
mixed and mix near the loss zone. Close of 4 bbl/min down the drill pipe
soft plugs attention should be paid to this. and 4 bbl/min down the annulus
depends on For example, in using diesel-oil/ will usually be satisfactory with
bentonite, mud can be pumped into 41⁄2-in. drill pipe in 77⁄8-in. and
having the annulus to establish the optimum larger holes.
the right constant mudflow rate before the 19. Displace one-half of the slurry into
amount of diesel-oil/bentonite slurry leaves the the formation at this fast pumping
drill pipe. rate or until pressure begins to build
components
How to mix and apply up on the annulus. When pressure
meet and diesel-oil/bentonite: is obtained, slow the pump rate on
mix near the 11. If possible, drill without returns both the drill pipe and annulus to
loss zone. through the entire lost-circulation get the slurry into the loss zone
zone. without exceeding the maximum

Lost Circulation 14.21 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

________________________ pressure set (100 to 500 psi [6.9 HOW TO MIX AND APPLY A
________________________ to 3.4 bar]). Attach a 0- to 300-psi BENGUM SQUEEZE
(0- ot 21-bar) gauge to the annulus Halliburton Bengum No. 1 is a natural
________________________
so that low-pressure values can be guar gum plus a preservative and a com-
________________________ easily read. pleting agent. Bengum mix is a 10 wt %
________________________ The drill pipe may occasionally Bengum No. 1 and 90 wt % bentonite
be reciprocated slowly to obtain an premixed together.
________________________
indication as to whether the slurry Bengum slurry is prepared by adding
________________________ might be moving up the annulus. 100 lb (45 kg) of Bengum-bentonite
________________________ If the weight indicator shows any mix to 13 to 15 gal (49 to 57 L) of diesel
________________________
increased drag, break the connec- oil. It sets harder than diesel-oil/ben-
tions and raise the pipe until it is tonite because of the organics it con-
________________________ free. Make connections and con- tains, particularly when mixed in saline
________________________ tinue displacement. There is no waters and muds. Its set strength falls
________________________
need for concern over the short between that of diesel-oil/bentonite
shutdown periods since the slurry and diesel-oil/bentonite/cement but
________________________
has no pumping time limitation is more nearly like diesel-oil/bentonite.
________________________ inside the pipe. It should be used:
________________________ 10. Displace the next quarter of slurry • Where more strength than that given
volume and mud at one-half the by diesel-oil/bentonite is required.
rate used in Step 9. • Where saline mixing waters are sig-
11. Displace all except 1 bbl of the nificantly lowering the strength of
remaining quarter volume of slurry diesel-oil/bentonite. For application,
at a rate of one-half the rate used follow the instructions for diesel-oil/
in Step 10. Attempt, by a hesitation bentonite above. The recommended
squeeze, to get a pressure buildup. ratio of mud to Bengum varies from
NOTE: One barrel of slurry should 4:1 to 1:1 according to the strength
be left in the drill pipe at the comple- required.
tion of the squeeze. Do not attempt
to reverse circulate because mud will CROSSLINKED-POLYMER SQUEEZES
contact the slurry and gel up inside Several companies offer crosslinked-
the drill pipe. polymer-squeeze pills in addition to
12. In instances where the hole cannot the gunk and high-fluid-loss squeezes
be filled, a packer should be set in designed for lost-circulation applica-
the bottom of the casing. Mud and tions. M-I SWACO FORM-A-SET* is a
slurries should be displaced down crosslinked polymer and LCM slurry.
These pills the drill pipe in alternate batches These pills are usually a blend of
of 20 bbl of slurry to 5 bbl of mud polymers and lost-circulation materi-
may also using a spacer of 1 or 2 bbl of oil als that crosslink with temperature
be used to between slurries. and time to form a rubbery, spongy
prevent 13. After the squeeze job, pull out ductile consistency that effectively
of the hole for the bit, drill out stops loss of fluid by sealing fractures
water and vugular formations. These pills
the plug and then drill ahead.
flow and Repeat the procedure if no may also be used to prevent water
consolidate squeeze pressure develops. flow and consolidate loose gravels.
Depending on the manufacturer, the
loose gravels. PRECAUTIONS: Observe the same pre- product may be a one-sack additive con-
cautions mentioned previously for the taining polymers and lost-circulation
diesel-oil/bentonite/cement slurry squeeze.

Lost Circulation 14.22 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

materials or be individually packaged. the slurry from the bit, pull up and
Most offer a retarder and accelerator squeeze the pill.
for specific cases if needed. In most sit- Pilot testing is highly recommended
uations, the retarder will be required to determine the correct concentration
to delay premature crosslinking until of retarder or accelerator to be used.
the slurry can be placed opposite the Typically, the pills will reach consis-
loss zone. tency at 115°F (46°C) in approximately
The pills may be weighted with 60 min with no retarder or accelerator
M-I BAR* or FER-OX*, if needed for well used. The crosslinking is faster at higher
control. Depending on the manufac- temperatures. Therefore, in most situa-
turer and the specific product, the tions a retarder will be needed. Again,
materials may generally be mixed in consult the manufacturers’ recommen-
salt water up to saturation but cannot dations to avoid premature setup of
be used with calcium-based brines. the pill.
Salt usually acts as a retarder for the
crosslinking mechanism. They may
DRILLING BLIND/AERATED MUD

be used with non-aqueous (oil-base) Drill blind or with aerated mud and set
systems by incorporating spacers while pipe. Use this technique against severe
the slurries are mixed in water. The man- complete losses. In the case of very
ufacturers’ recommendations should be severe loss zones such as big caverns
closely followed due to the differences (with or without water movement) or
in the crosslinking mechanisms and long (500 to 1,000 ft [152 to 305 m])
product limitations. zones of honeycombed vugs or frac-
After mixing according to the indi- tures, drilling blind or with aerated
vidual manufacturers’ recommenda- mud through all the loss zones and
tions, the pill is spotted similarly to then setting pipe is often the only tech-
other lost-circulation pills. Pump the nique that can succeed.
slurry to the drill pipe and displace

Techniques for Treating Lost Circulation in Oil-Base Muds

Although there should be no difference most oil-base fluids. This allows changes
between water- and oil-base muds in the in wellbore pressures to be transmitted
pressure needed to initiate a hydraulic to the formation more readily and fur-
Water-base fracturing of the formation, there is a ther propagate the fracture. Studies have
fluids significant difference once the fractures shown that the pressure required to
are formed. Water-base fluids typically re-open a fracture is also lower when
typically
have a higher “spurt” fluid loss causing using an oil-base fluid. A further com-
have a an almost instantaneous filter cake to plication is introduced if the lost-
higher form that aids in formation sealing in circulation material being used acts
“spurt” permeable formations. to prop open the fracture.
Oil-base fluids do not display the same As mentioned earlier, properties
fluid loss characteristics. Once a fracture is initi- unique to oil-base muds need to be
causing ated by an oil-base fluid, the pressure considered when preventing lost cir-
an almost necessary to propagate the fracture is culation. The major properties and
much smaller by comparison. This is their effects are:
instantaneous compounded by lack of a significant • Flow property differences caused by
filter cake… pressure drop across the filter cake of temperature. After a bit trip, it may be

Lost Circulation 14.23 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

necessary to operate at a reduced flow the system. Recommended materials

rate until a full hole cycle is complete. and concentrations are as follows:
This allows the mud to heat to normal Use 2 to 6 lb/bbl of M-I-X II and/or
circulating temperature and viscosity, 2 to 5 lb/bbl of LO-WATE (calcium car-
preventing unnecessarily high equiva- bonate). Small concentrations of fine
…these lent circulating densities. Pump pres- NUT PLUG (1 to 10 lb/bbl) may also be
sure differences in excess of 100 psi used. Other lost-circulation materials
materials (6.9 bar) in heavier fluids are not tend to cause water-wetting and loss
increase the uncommon as the fluid heats up. of electrical stability. If circumstances
equivalent • Due to greater fluid expansion in com- require the use of these other materi-
parison to water-base fluids, the mea- als, the system should be monitored
circulating sured mud weight will often increase for their effects and treated accord-
density. as the fluid cools on surface as during ingly. Pretreating with a wetting agent
a trip. Again, these differences are (VERSAWET) may minimize these effects
magnified at higher mud weights. For in some cases.
this reason, the temperature at which Oil-base-mud squeezes. These have
mud is weighed should always be proven to be the most effective method
recorded. The temptation to reduce the of sealing a loss zone. These squeezes
mud weight in the pits during a trip should be of a volume sufficient to at
should be resisted unless the weights least fill the hole 50 ft (15.2 m) above
were taken at the same temperature. and below the loss zone. The following
squeezes have been most effective in
INCORPORATING LOST-CIRCULATION
sealing loss zones when oil-base muds
MATERIAL INTO THE SYSTEM
are used.
Incorporating large concentrations
of lost-circulation materials into the DIATOMACEOUS-EARTH
whole system is not recommended (DIASEAL M)/DIESEL-OIL SQUEEZE
since these materials increase the 1. The chart below should be used
equivalent circulating density. This for mixing a diatomaceous earth
often compounds the lost-circulation (Diaseal M) slurry. After the slurry
problem instead of solving it. However, is mixed, 5 lb/bbl each of fine mica,
there are some cases in which seepage medium NUT PLUG, M-I-X II and cal-
losses can be temporarily stopped or cium carbonate (LO-WATE) should
minimized by carrying small concen- be added. These concentrations
trations of lost-circulation materials in may be modified depending on
drillstring geometry.

Density Diaseal M M-I BAR* Diesel Oil VERSAWET*

(lb/gal) lb sacks lb sacks gal bbl gal lb
8 44.0 1.100 20 0.20 38.92 0.926 0.140 1.00
9 41.2 1.030 73 0.73 37.58 0.895 0.210 1.50
10 38.5 0.963 128 1.28 36.18 0.861 0.250 1.75
11 35.7 0.893 181 1.81 34.85 0.829 0.250 1.75
12 32.9 0.823 237 2.37 33.43 0.796 0.250 1.75
13 30.0 0.750 291 2.91 32.06 0.763 0.250 1.75
14 27.2 0.680 346 3.46 30.67 0.730 0.250 1.75
15 24.5 0.613 400 4.00 29.30 0.698 0.285 2.00
16 21.8 0.545 454 4.54 27.93 0.665 0.285 2.00
17 18.9 0.473 509 5.09 26.55 0.632 0.357 2.50
18 17.0 0.425 563 5.63 25.13 0.598 0.428 3.00

Formulations for preparing one barrel of weighted Diaseal M slurry in diesel oil.

Lost Circulation 14.24 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

________________________ 2. Set the bit at the top of, or oppo- b. Restrictions in the drillstring.
________________________ site, the loss zone. Displace the The size of the bit nozzles, inter-
slurry to the end of the drill pipe. nal restrictions from MWD,
________________________
3. Close the rams. Gently squeeze motors and other tools affect
________________________ (50 psi [3.4 bar] maximum) mate- permissible lost-circulation
________________________ rial into the loss zone at a rate of material concentrations.
1 bbl/min. Hold the squeeze pres- c. Always check if the pumps or
________________________
sure 4 to 8 hr or until it dissipates. pumping units are equipped with
________________________ Measure the squeeze pressure on suction screens. If so, the screens
________________________ the annulus using a 0- to 300-psi may need to be removed prior to
________________________
(0 to 20.7-bar) gauge. pumping the pill.
To avoid fracturing other zones, safe 2. Set the bit at the top of, or oppo-
________________________ squeeze pressures in excess of mud site, the loss zone. Displace the
________________________ hydrostatic pressure should be used. slurry to the end of the drill pipe.
________________________
For example: 3. Close the rams. Gently squeeze
(50 psi [3.4 bar] maximum) mate-
________________________ Depth (ft) Squeeze Pressure (psi)
rial into the loss zone at a rate of
0 - 1,000 0 - 200
________________________ 1 bbl/min. Hold the squeeze pressure
1,000 - 5,000 100 - 500
________________________ 5,000 and deeper 500
4 to 8 hr or until it dissipates.
Measure the squeeze pressure on
NOTE: Surface pressure plus mud- the annulus using a 0- to 300-psi
column pressure should never exceed (0 to 20.7-bar) gauge.
overburden pressure (1 psi/ft). To avoid fracturing other zones, safe
squeeze pressures in excess of mud
CALCIUM-CARBONATE/ hydrostatic pressure should be used.
M-I-X II SQUEEZE For example:
1. Mud from the active system can be
used as the base for this slurry. To Depth (ft) Squeeze Pressure (psi)
0 - 1,000 0 - 200
the base mud, add 5 to 25 lb/bbl
1,000 - 5,000 100 - 500
fine mica, 5 to 25 lb/bbl medium
5,000 and deeper 500
NUT PLUG, 10 lb/bbl calcium car-
bonate (LO-WATE) and 10 lb/bbl NOTE: Surface pressure plus mud-
M-I-X II. The quantity of material column pressure should never exceed
mixed in the pill will depend on overburden pressure (1 psi/ft).
several conditions.
a. The current mud weight. As fluid
density increases, the quantity of
lost-circulation material that can be
added and maintain a pumpable
fluid decreases.

Lost Circulation 14.25 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

GUNK SQUEEZE FOR OIL MUDS 10. Displace the next quarter of vol-
11. If possible, drill without returns ume of slurry and mud at one-half
________________________ through the entire lost-circulation the rate used in Step 9.
zone. 11. Displace the remaining quarter vol-
________________________
12. Pull out of the hole. Measure the ume of slurry at one-half of the rates
________________________ static mud level as previously used in Step 10. If the hole fills, as
________________________ described. shown by pressure on the annulus,
13. Locate the loss zone, using attempt (by a hesitation squeeze) to
________________________
an appropriate technique as obtain a pressure buildup using rates
________________________ previously described. of 1 bbl/min into drill pipe and
________________________ 14. After locating the loss interval, 0.5 bbl/min into annulus.
________________________
set the bottom of the mixing sub NOTE: One barrel of slurry should be
50 ft (15.2 m) above it. Set a maxi- left in the drill pipe at the completion of
________________________ the squeeze. Do not attempt to reverse
mum squeeze pressure.
________________________ 15. Pump in a 10-bbl cushion of water circulate because mud will contact the
________________________ ahead of the slurry. slurry and gel up inside the drill pipe.
16. Mix 1⁄2 lb/bbl of DUO-VIS* polymer 12. In instances where the hole can-
________________________
and 250 lb/bbl of VG-69 in water not be filled, a packer should be
________________________ to the desired volume of slurry. set in the bottom of the casing.
________________________ 17. Displace the slurry down the drill Oil-base mud and slurries should
pipe and follow it with 10 bbl of be displaced down the drill pipe
________________________
water. in alternate batches of 20 bbl of
18. Start pumping oil-base mud into slurry to 5 bbl of oil-base mud
the annulus when the 10-bbl cush- using a spacer of 1 or 2 bbl of oil
ion of water reaches the mixing between slurries.
sub. Close the rams. Control the 13. After the squeeze job, pull out of
pumping rates so the ratio of slurry the hole and wait on the slurry to
volume to the oil mud volume is set a minimum of 8 hr before drill-
2:1. Pump rates of 4 bbl/min down ing out. If the first attempt is unsuc-
the drill pipe and 2 bbl/min down cessful, repeat the procedure after
the annulus will usually be satisfac- waiting on the slurry for 8 hr.
tory with 41⁄2-in. drill pipe in 77⁄8-in.
PRECAUTIONS
and larger holes.
19. Displace one-half of the slurry into Avoid contamination of the slurry
the formation at this fast pumping with oil-base mud or water in the suc-
rate. The drill pipe may occasionally tion lines and pumps. The following
be reciprocated slowly to indicate steps will minimize the possibility of
whether the slurry might be moving contamination.
up the annulus. If the weight indica- 1. Drain all oil mud out of all pumps,
tor shows any increased drag, break lines and tanks prior to mixing.
the connections and raise the pipe 2. Use water to thoroughly flush the
until it is free. Make connections pumps, lines and mixing facilities
and continue displacement. There is prior to mixing.
no need for concern over short shut-
down periods since the slurry has
no pumping time limitation inside
the pipe.

Lost Circulation 14.26 Revision No: A-2 / Revision Date: 12·31·06

 CHAPTER

14 Lost Circulation

________________________ Losing fluid while drilling

________________________
Stop drilling and observe levels
________________________
Losses on surface?
________________________

________________________
Yes No
________________________
Locate and stop loss Well flowing?
________________________

________________________
Yes No
________________________
Record shut-in pressures Measure rate of loss
________________________

________________________
Kill well Seepage Partial Total
________________________

________________________ Oil-mud in use Water-mud in use Oil-mud in use Water-mud in use Oil-mud in use Water-mud in use

________________________ Fine Fine or medium Fine or medium Medium and coarse Medium and coarse
Fine
mica, NUT PLUG, M-I-X II, NUT PLUG, mica, NUT PLUG, LCM LCM
________________________ M-I-X* II, LO-WATE*,
LO-WATE and mica and Kwik-Seal and reverse gunk, gunk squeeze,
NUT PLUG* and mica
Kwik-Seal calcium carbonate calcium carbonate Diaseal M and cement Diaseal M and cement

Flowchart 1: Losing fluid while drilling.

Losses start while RIH

Seepage or partial loss Total loss

RIH at reduced speed Keep annulus full

Rotate and establish circulation Flow check

Losses continue?
No flow Well flows

No Yes Continue RIH at reduced rate Shut in

to above loss zone
Continue RIH Squeeze LCM or cement
Squeeze LCM or cement
Losses reduced?

Dynamic losses only

Yes No
Use Flowchart 1
to select LCM pill Well dead? Squeeze LCM or cement
until losses reduced

Yes No

Strip in and kill

Flowchart 2: Losses start while RIH.

Lost Circulation 14.27 Revision No: A-2 / Revision Date: 12·31·06