Well Blueprint TM Drilling Conditions

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SOP Code: LC
Revision Date: 02/12/97

Lost Circulation

Introduction
Lost circulation or loss of returns describes the complete or partial loss of whole
mud to a formation as a result of hydrostatic and annular pressure loss exerted by
a drilling fluid. Losses can result from natural or induced causes. Lost circulation
is identified by a reduction in the rate of mud returns from the well compared to
the rate at which it is pumped down hole (flow out < flow in). This leads to a
decrease in the mud volume and impairment of drilling operations. In extreme
cases, lost circulation can lead to well control problems, including blowouts.
Losses can add extensively to the overall well cost, both in time and mud
requirements.

Better planning, preparation, and having probable solutions on hand, before a loss
of circulation occurs, can help eliminate substantial lost time and money. In the
past emphasis was placed on cheap lost circulation materials that were commonly
used in the area and easily available. Currently, losses in particular areas are being
studied and recommendations of materials, techniques, and methods for
prevention are being made.

Potential Types of Lost Circulation Zones

Lost circulation is classified into four basic types:
• Highly permeable formations
• Naturally fractured formations
• Cavernous formations
• Induced fractures due to a pressure imbalance

Permeable Zones (Pores/Matrixes)

Losses to permeable zones may be anywhere up to 100% of the pumped volume.
A permeable zone typically consists of coarse sands and/or gravel, particularly in
surface holes. Shell beds, gravel beds, reef deposits and depleted reservoirs can
also be classified as permeable formations. If some returns are evident at the flow
line, the hole should stand full with the pumps off, however, the fluid level may
start to fall slowly.
Naturally Fractured Formations
Losses to naturally fractured formations can be 100% loss of returns with no
preceding gradual losses. These losses may occur at overbalances as low as 50
psi. The hole normally will not stand full. Natural fractures can be encountered at
any depth but most often occur at shallow to intermediate depths, particularly in
tectonically stressed areas.

Cavernous/Vugular Formations
Losses to cavernous/vugular formations are normally the easiest type to
recognize. Immediate 100% loss of returns takes place, accompanied by loss of
weight on bit. Over geological periods of time, limestones, dolomites, and salts
were dissolved by ground water, creating fractures and caverns which vary in
size. The likelihood of success in regaining returns is limited. Some small zones
may respond to diesel/oil/cement pills, however, several attempts are usually
required. The most common solution is to drill blind for several feet below the
zone, then to running casing.

Induced Fractures

Losses to induced fractures is the most common type of lost circulation. The
losses can be slow, moderate or complete, at any depth. Induced fractures
generally occur when ECD exceeds the fracture gradient causing the formation to
break down. These losses can also occur during pressure surges, i.e. during
connections or during trips. Induced fractures often occur during routine increases
of mud weight or during a kick and kill operation. The hole may stand full or drop
to an equilibrium point. In an induced case, it is possible that the hole will give
mud volume back when the mud pumps are turned off. It is very important to
understand pore pressures, and fracture gradients versus equivalent circulating
densities, and surge pressures with the mud properties being used in a particular
area.
Classification of Losses
The correct treatment of lost circulation requires an appreciation of the loss rate
and the type of loss zone.

There are four primary loss types in drilling operations:

Loss Severity % of Loss Rate Typical Formations
Seepage <10% Porous and permeable shell beds/reef
deposits
Unconsolidated sands and gravel:
Partial 10-50%
small open fractures

Severe 100% Large sections of unconsolidated

sands/fractures

Total 100%/No returns Cavernous/large fractures

Seepage Losses
Seepage losses usually occur slowly and are sometimes very difficult to identify.
There may be filtrate loss due to poor fluid loss control in some instances.
Seepage losses can usually be controlled or prevented with the appropriate
treatment. Seepage losses may be economically acceptable if there are high rig
rates with a relatively low cost drilling fluid. If pressure control is critical, the
losses will have to be cured. It is always important to check all surface equipment
and for any fluid transfers prior to diagnosing an apparent loss of returns.

Partial Losses

Partial losses are more severe than seepage losses, and usually require lost
circulation material additions to cure or slow down the losses. Normally drilling
must be stopped because the drilling fluid cannot perform its proper functions.
The cost of mud and rig time lost becomes important. Logistics and mud building
capabilities may be limited, so it may be necessary to take rig time to cure these
losses.
Severe Losses
Severe losses can be a serious problem. Large volumes of mud may be lost in
short periods of time. This can create a well control situation, as the fluid level
falls in the annulus and hydrostatic pressure is reduced. Severe losses can also
cause hole stability problems. It is important that the hole is filled with water or
base oil and kept full to the equilibrium point. An accurate record of all volumes
and pills pumped must be kept so that hydrostatic head can be calculated.

Complete Losses
Complete lost circulation is when there are no returns at all. The fluid level may
drop out of sight. When a complete loss occurs the annulus should be refilled with
monitored volumes of lighter mud and/or water or base oil. Determine the
reduction in hydrostatic head and reduce the active system to this calculated
equivalent mud weight. The hole must be monitored very closely for possible well
control problems.
Note: Prior to assuming that lost circulation to the formation has taken place, all
surface equipment must be examined for leaks or breaks i.e. mud pits, solids
control equipment, mud mixing system, riser slip joints, and/or incorrectly lined
up pumps or circulating lines.

Causes of Lost Circulation

Lost circulation can be caused by higher than needed mud weights and/or poor
drilling practices and may occur more easily in certain types of formations. Prior
to drilling, all parties should be fully aware of potential loss zones so that drilling
practices and mud properties can be controlled, minimizing the potential for
inducing losses.

Many mud losses, particularly in deep wells, are due to mechanically induced
fractures. They can occur in several ways:
• Connection techniques, such as high pipe speed or bringing pumps on line too
rapidly.
• Running drill string or casing too fast, producing high surge pressures.
• Running the drill string with a plugged bit.
• Mud weight and rheology contributing to excessively high ECD.
• Annulus restricted, i.e., swelling clays or bit balling.
• Inefficient hole cleaning (Annulus loads up with drilled cuttings and/or packs
off)
• Excessive penetration rate (Mud in the annulus is “weighted up” by large
amounts of cuttings)
Preventing Lost Circulation
Prevention of lost circulation is the key. Consideration should be given to the
potential causes of losses and the location of potential loss zones. In many cases
loss zones are not in newly drilled rock but are at or near the last casing shoe.
Typically this is the lowest exposed fracture gradient. Losses to previously
drilled, shallower formations are almost always induced, and are a result of
hydrostatic overpressures caused by excessively high ECD, poor drilling/tripping
practices, or unplanned mud density increases.

If it can be established from available evidence whether losses are porous,

cavernous or fractured formations, an appropriate treatment can be recommended.
If a reduction of mud weight or pump rate is not possible, or does not achieve the
desired results, then some type of lost circulation material must be used to help
seal the thief zone.

Reduce Mechanical Pressures

A few of the numerous possible mechanical reduction procedures are shown
below. In practice, these methods cannot all be used simultaneously and some
form of compromise is necessary.
• Control ROP based on calculations of the effective increase in annular mud
weight from cuttings
• Minimum practical mud weight, for maximum allowable annular pressure
loss.
• Minimum rheologies reduce ECD and surge and swab pressures.
• Maintain optimum flow rate.
• Keep pipe movement slow - minimize surge and swab pressures.
• Break circulation slowly several times before reaching bottom during a trip,
especially after logging.
• Run formation integrity test rather than a leak-off test.
• Do not exceed the calculated equivalent mud weight for kick tolerance.
• Use good hole cleaning practices to avoid losses due to over loading of the
annulus.
• Avoid bit balling and sloughing shale. It causes increased pressure on
formations if the annulus is overloaded or blocked off.
Choose Deep, Strong Casing Points
Whenever possible, casing should be set in non porous formations with high
fracture gradients. By setting casing as deep as possible, some formations with
higher pore pressures may be drilled safely. A formation of high matrix strength is
recognized by one or more of the following:
• Reduction in penetration rates
• Mud Logging data
• MWD Data

Pre-Treat Mud with Lost Circulation Material as a Bridging

Agent
When excessive overbalance is unavoidable, pre-treating the mud with bridging
material can effectively bridge porous zones and minimize seepage losses. With
correct particle size distribution, these bridging materials can also slow down the
filtrate invasion and help reduce wall cake build up.

Treatments for Lost Circulation

There are numerous approaches to curing lost circulation, and many treatments
have proven successful in the field. One or more may be suitable for any given
situation. A key factor to consider is whether the losses are to a payzone and the
acid solubility of the lost circulation material (LCM). Downhole tools and motors
may not allow the use of certain LCM. The first approach should normally be to
reduce flow rate and/or mud weight if possible whenever losses are encountered.

Seepage Losses
Seepage losses may be treated with:
• BAROFIBRE / STEELSEAL / BARACARB pre-treatments of the mud
system
• AQUAGEL GOLD SEAL additions to invert emulsion systems
• MICATEX can be used in surface holes
• Pills containing high concentration of LCM, spotted frequently
• Spot LCM pills prior to tripping out of hole
• Increase AQUAGEL content of water-based muds (unless DRIL-N)
• Use LCM with a particle size distribution (PSD) matched to the sand being
drilled
Partial Losses
Partial losses may be treated with:
• STEELSEAL additions have been shown to increase fracture initiation
pressures
• Spot pills with a mixture of granular/fiber and flake LCM
• Spot pills with a wide range of particle sizes
• Mixtures of BARACARB 150/BAROFIBRE C & F, up to 80 lb/bbl in water-
based mud
• STEELSEAL up to 100 lb/bbl in water-based mud

Severe Losses
Severe losses may be treated with:
• Use of coarse materials, wide size distribution, mix as thick as rig will allow
to be pumped
• Mixture of fiber/flakes/granular material
• BARARESIN pill works well if no oil in system and with high overbalance
• MAXDRIL-N thixotropic pill has reduced losses. LCM can be added as well.
• 1Gunk squeezes
• Cement/sodium silicate squeezes
• Cement/STEELSEAL squeezes
• Diaseal-M squeezes
• If invert emulsion is being used, spot a water based LCM pill

Total Losses
Total losses may be treated with:
• Use of coarse materials, big size distribution, mix as thick as rig will allow to
be pumped
• 1Gunk squeezes
• Cement/sodium silicate squeezes
• Cement/STEELSEAL squeezes
• Diaseal-M squeezes
• Mud Cap drilling
• Drill blind until a casing point can be reached
• Should there be simutaneous kicking and lost circulation, a 2barite plug
should be considered
1Refer to Well Blueprint TM "Gunk Squeezes" for further detail.

2Refer to Well Blueprint TM "Barite Plugs" for further detail.

Lost Circulation Materials
Lost circulation materials generally available:
Type Product name
Fibrous Materials BAROFIBRE, PLUG-GIT, HY-SEAL
Flake Material JELFLAKE, MICATEX
Granular Material STEELSEAL, BARACARB, WALL-NUT
Mixture Materials BARO-SEAL

Lost Circulation Checklist

To successfully fight lost circulation, it is important to be prepared in advance.
Research offset well data in the Baroid Technical Services (BTS) Database. Plan
for appropriate equipment, and sufficient materials. Ensure that drilling personnel
are aware of the drilling conditions that cause losses and what to do if losses
occur. Each individual well should have tailored procedures, with potential lost
circulation zones identified beforehand.
1. Look at offset well recaps/reports and lithology columns available
• Identify potential loss zones
• Review previous LCM treatments - success or failure?
• Evaluate previous LCM used
2. Draft a planned procedure for lost circulation
• Standardize procedures for action to be taken in the event of:
− Seepage Losses (< 1-10%)
− Partial Losses (10-50%)
− Severe Losses (50-100%)
− Complete Losses 100% / No returns )
3. Identify type, amount and storage place of all LCM on location
• Ensure materials are well marked and easily accessible
4. Discuss requirements of standby LCM treatments with rig and office
personnel
• Confirm compatibility with MWD and downhole motors, etc.
• Prepare LCM pills and agitate prior to drilling a potential thief zone
5. Identify all possible areas of surface loss
• Monitor mud loss/gain from processing equipment
• Check gains/losses with equipment operating and not operating.
6. Set up a communication network and instructions between:
• Drilling Foreman/Mud Engineer/Tool Pusher/Directional & MWD and
Rig Personnel
• Inform relevant personnel prior to LCM additions.