Primary funding is provided by

The SPE Foundation through member donations The SPE Foundation through member donations
and a contribution from Offshore Europe
The Society is grateful to those companies that allowtheir The Society is grateful to those companies that allow their
professionals to serve as lecturers
Additional s pport pro ided b AIME Additional support provided by AIME
Society of Petroleum Engineers
Distinguished Lecturer Program
www.spe.org/dl
How to Stabilize and Strengthen the
Wellbore during Drilling Operations Wellbore during Drilling Operations
Dr Fred Growcock Dr. Fred Growcock
Societyof PetroleumEngineers Society of Petroleum Engineers
Distinguished Lecturer Program
www.spe.org/dl
Presentation Outline
The Lost Circulation Problem
Strategy for Managing Lost Circulation
Wellbore Strengthening Wellbore Strengthening
Wellbore Stress Enhancement
Application Strategies on the Rig
Case History Case History
Summary
3
The Lost Circulation Problem: High-Risk Operations
e
i
g
h
t
Stable Wellbore
Fractured Wellbore
Pressure Gradi ent / Mud Densi ty
W
e
i
g
h
t
M
u
d

W
e
Stable Wellbore
Collapsed Wellbore
Weak zone (depleted)
Frac Gradient
Mud
M
u
d

W
Well Inclination
0 30 60 90
Deviated Wellbores
( p )
Weight
Pore
Pressure
Depleted Zones Depleted Zones
Deep Water
The Lost Circulation Problem
Estimated industry cost in the Gulf of Mexico:
$1 billion/yr. Worldwide: ~ $ 2 to 4 billion/yr. y y
On average, 10-20% of the total cost of drilling an
HTHP well is expended on mud losses (U.S.
Department of Energy) Department of Energy).
No consistent approach to manage lost circulation.
Nearly 200 products offered by 50 drilling fluid Nearly 200 products offered by 50 drilling fluid
companies to control lost circulation.
A comprehensive Lost Circulation mitigation and
prevention program is required. g
5
Managing Lost Circulation: A 4-Tiered Strategy
6
Tier I. Best Current or New
Accurate, precise Geomechanics Model, esp.
Pore Pressure / Fracture Gradient
Minimum and invariant Equivalent Circulating
Density (ECD)
Accurate hydraulics profile for pre-drilling & at well site
Good hole-cleaning practices g p
Optimized solids control equipment
Managed Pressure Drilling Managed Pressure Drilling
Casing While Drilling
Expandable Casing/Liner
7
Managing Lost Circulation: A 4-Tiered Strategy
8
Tier II. which Minimize Losses:
WBM:
Full pressure shielded from tip by
solids filter cake buildup.
OBM/SBM:
Full pressure at fracture tip.
based on Morita et al, SPE 20409
Tier II. which Minimize Losses:
High Low-Shear-Rate Viscosity (LSRV)
Reservoir Fluids Reservoir Fluids
Underbalanced Fluids
Aphron and Mixed Metal Fluids
Minimum and Invariant ECD
Soluble or Micronized Weighting Material
Temperature Insensitive Rheology Temperature-Insensitive Rheology
Wellbore Isolation
Silicate, Gilsonite Fluids
10
Managing Lost Circulation: A 4-Tiered Strategy
11
Tier IV. in Pills or Whole Mud
Contingency: losses in high permzones/fractures
Blends of materials of
Contingency: losses in high-perm zones/fractures
Optimum Bridging Agent Blend for Fluid
Blends of materials of
different sizes, shapes
and properties;
D10 T
D50 T
D90 T
F
0.8
0.9
1.0
Particle size distribution
matches distribution of
openings in rock
Brand
Mud
A=Pu
B=Pu
C=Sn
D=Om
0.6
0.7
i
z
e

D
i
s
t
r
i
b
u
t
i
o
n
openings in rock;
Used in squeeze or
sweep treatments;
0.3
0.4
0.5
C
u
m
u
l
a
t
i
v
e

P
a
r
t
i
c
l
e
-
S
sweep treatments;
May be used one time
or on regular basis
Calc
Avg 0
0.1
0.2
C
g
while drilling ahead.
12
Avg
Max
1x10
-2
1x10
-1
1x10
0
1x10
1
1x10
2
1x10
3
1x10
4
0
Particle Size (microns)
Managing Lost Circulation: A 4-Tiered Strategy
13
vs
Fl k Flakes
Most Fibers
Plates
Insoluble Salts
Plates
L i t
Marble
Synthetic
Graphite
Laminates
Hard,
Granular
Fibers
Swellable or
Reactive
Materials
Soft Granules
14
Strategies for Strengthening the Wellbore
Physical
Wellbore Isolation: Swellable or Reactive Materials
F t Ti I l ti (F t P ti R i t ) Fracture Tip Isolation (Fracture Propagation Resistance)
Chemical
Decrease clay swelling pressure (inhibitors such as K+ Decrease clay swelling pressure (inhibitors such as K+
and invert emulsions)
Thermal e a
Increase temp of drilling fluid above bottom-hole static
temp: stiff formations, high thermal expansion
Mechanical
Fracture Closure Stress
Hoop Stress Enhancement (Stress Cage)
15
Fracture Propagation Pressure (FPP)
OriginalFormationBreakdownPressure(FBP)
LeakOff
Pressure
(LOP)
FBPafterWellboreStrengthening
e
Fracture Propagation Pressure (FPP)
(LOP)
Fracture Gradient (FG)
P
r
e
s
s
u
r
e
Fracture Closure Pressure (FCP)
(=Minimum Horizontal Stress, S
hmin
)
P
Ti V l P d ( ) Timeor Volume Pumped (constant pumprate)
Fracture Closure Stress
High-fluid-loss treatment for existing fractures
A li d hi h fl id l ill h l d Applied as high-fluid-loss pills or whole mud
treatment (Drill-n-Stress)
Pill may be water-based in a non-aqueous
system
May follow with cross-linked polymer plugs or
cement
Fracture Closure Stress
As existing fracture is widened,
particles are forced deep within the fracture.
Liquid leaks from the slurry
through the fracture walls or tip.
18
Fracture Closure Stress
As the slurry deliquifies, it consolidates.
The residual solid plug supports the fracture and
isolates the tip isolates the tip.
19
Hoop Stress Enhancement
Wellbore is pre-fractured and sealed to prevent
subsequent fracturing
Mathematical models are used to design the :
calculate the required fracture width and particle size q p
distribution of
is added at moderate concentration while is added at moderate concentration while
drilling (involves solids control management):
Continuous addition is much more effective than pills p
The formation is pressured every stand to build hoop
stress or ECDis raised to desired level stress, or ECD is raised to desired level
Hoop Stress Enhancement
As fracture is widened, large particles are forced in
and wedged in the fracture mouth to create bridge
Smaller particles come in behind the bridge
and seal the openingg
21
Hoop Stress Enhancement
Trapped fluid filters
through permeable walls of fracture
The pressure drops and compressive p p p
forces are transferred to WSM
22
Hoop Stress EnhancementApplication Cycle
Suitability of Treatment Data Collection
Modeling of Fracture
Creation and Fillingg
Output:
-Fracture dimensions
-Formulation of Loss
Prevention Material
Lessons Learned
Fluids Program
-Type of treatment:
*Pills
*Continuous
Data Collected
-Handling WSM
-Fluid property management
-Monitoring tools
Slot Tester
Sieves
-Mud Pump restrictions
D h l t l t i ti
Program
Implementation
Data Collected
&
Analyzed
-Downhole tools restriction
-Lost circulation contingency
23
Design of Hoop Stress Enhancement
Fracture Width required to achieve desired
wellbore pressure elastic model:
Desired Equiv. Circ. Density, or Wellbore Pressure q y
Rock Properties Poissons Ratio, Youngs Modulus,
Minimum Horizontal Stress (or Fracture Gradient)
Well Geometry Depth, Inclination, Hole Size
Acceptable types of WSM p yp
WSM particle size distribution (PSD) and
concentration
24
Acceptable
Large, Tough and Granular Large, Tough and Granular
25
Unacceptable
26
Continuous Addition of to whole mud is best
For short intervals, bypass the shale shakers
For long intervals screen out the WSMwith the shakers For long intervals, screen out the WSM with the shakers
The most effective solution: an WSM Recovery System
Screens out drilled cuttings Screens out drilled cuttings
Recovers and
l WSM recycles WSM
Screens out fines
27
Screens out fines
Monitoring Hoop Stress Enhancement
Techniques to be used at the rigsite:
Permeability Plugging Tests y gg g
Wet Sieve Analysis
Sand kit determination
Techniques available at shore bases: Techniques available at shore bases:
Laser Light-Scattering Particle Size
Distribution
Fracture Sealing and Wellbore
Strengthening tests
28
eepwater Gulf of Mexico, Above and Below Salt eepwater Gulf of Mexico, Above and Below Salt
Case History Deepwater Gulf of Mexico
Major challenges
Mud losses> 15,000 bbl/well
on previous wells especially in
SALT SALT
on previous wells, especially in
intervals below the salt!
Wellbore stability
S l ti
SALT SALT
Solution
Strengthen five intervals
- One above the Salt
O i th S lt
Drilling ECD
exceeds min
Frac Gradient
- One in the Salt
- Three below the Salt
Shakers dressed with
14/20 mesh screens 14/20 mesh screens
[WSM] ~ 15 to 30 lb/bbl
WSMDesign
Si ed Marble - Sized Marble
- Granular Synthetic Carbons
Case History Deepwater Gulf of Mexico
No losses in 2900 ft sand section above salt
No losses in 7500 ft salt section, screened up
No losses in 9200 ft sand section below salt
(where majority of losses occurred in offset wells) (where majority of losses occurred in offset wells)
Savings
Total cost for the WSM~$ 0 7 MM Previous mud Total cost for the WSM~ $ 0.7 MM. Previous mud
losses ~ $ 2.7 MM. Net savings ~ $ 2.0 MM on
materials alone.
On subsequent 4 wells, similar net savings of ~ $ 2.0
MM on materials alone.
The 4-tier strategy for managing lost circulation
Summary
must be an integral part of well planning
31
Your Feedback is Important p
Enter your section in the DL Evaluation Contest by
completing the evaluation form for this presentation or completing the evaluation form for this presentation or
go online at:
http://www.spe.org/events/dl/dl_evaluation_contest.php
Society of Petroleum Engineers
Distinguished Lecturer Program
www.spe.org/dl
32