SPE/IADC-178165-MS

Lost Circulation Management in Naturally Fractured Reservoirs

Sharath Savari, Donald L. Whitfill, and Jonathan Walker, Halliburton

Copyright 2016, SPE/IADC Middle East Drilling Technology Conference and Exhibition

This paper was prepared for presentation at the SPE/IADC Middle East Drilling Technology Conference and Exhibition held in Abu Dhabi, UAE, 26 –28 January 2016.

This paper was selected for presentation by an SPE/IADC program committee following review of information contained in an abstract submitted by the author(s).
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Abstract
Managing severe-to-total lost circulation can be especially challenging in naturally fractured formations.
This situation becomes further complicated if it is a producing formation. Particulate lost circulation
materials (LCM) have been used to manage lost circulation for many years. However, current LCMs are
not efficient in terms of size and application methods to cure severe-to-total losses, such as highly
fractured reservoirs.
In the present paper, a novel acid-soluble combination in the form of an engineered composite LCM
solution (ECS) with a multi-modal particle size distribution (PSD) has the potential to manage severe-
to-total loss circulation situations in naturally fractured reservoir formations. The multi-modal PSD and
unique combination of particles will help manage any uncertainties in fracture sizes, and the larger
particles present will aid in plugging large fractures. The results of a laboratory investigation will be
presented, highlighting the potential benefits of this solution.
When managing severe-to-total losses in highly fractured reservoir formations, particulates alone may
not be effective, thus the LCM should preferably be acid soluble. The combination of a large multi-modal
PSD LCM containing a fibrous material along with platelet particles was designed as a candidate for
dealing with these extreme losses. The solution developed is capable of plugging laboratory-simulated
fracture sizes in the range of 5,000 ␮m. It was further demonstrated that supplementing with another larger
LCM platelet materials enhanced its capability to seal 0.5 in. (12.5 mm) in the lab. A significant
determination in the solution developed is up to 96% soluble in 15% HCl and organic acids. This paper
will discuss in detail the product concentration, testing methodology, and results. In addition, the strategy
to apply these materials in the field will be discussed.
The large PSD, acid-soluble LCM solution can help manage uncertainties in fracture sizes and allow
for curing severe-to-total losses in naturally fractured reservoir formations.

Introduction
Lost circulation remains a significant challenge to the oil and gas industry. If not addressed properly, it
could lead to potentially high non-productive time (NPT) during drilling. To an extent, lost circulation can
be managed using solutions in the form of Lost Circulation Materials (LCMs). LCMs are the additives that
are typically added to the drilling fluid, either to the entire active system or to a small volume of fluid
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(usually referred to as a pill). Operationally, whenever there is some prior experience of losses in a field
or when an event of loss circulation is expected, it is often recommended to have plans to either ⬙prevent⬙
(when possible) or ⬙remediate⬙. Depending on the lost circulation mechanics (or sources), a decision is
made to either to prevent or remediate. In addition, the selection of an LCM solution is also based on the
severity of lost circulation (that is, seepage, partial, severe, or total losses).
More often, the selection of LCMs depends on whether the solution is being applied in non-reservoirs
or reservoirs. In the case of non-reservoirs, it can be fairly stated that the range of LCMs is broad.
Particulates with large particle size distribution (PSD), filament fibers, reactive solutions (like gunks),
crosslinking polymers, and cement (if the situation demands) could be used in non-reservoir sections.
Depending on the severity of lost circulation, the decision of an LCM solution may be made without much
deliberation.
On the other hand, LCM solutions for a reservoir (or production zone) often have to be either
degradable, acid-soluble, or non-damaging. With such pre-requisites, the choice of LCMs in case of losses
in a reservoir can be very limited. Calcium-carbonate-based particles appear to be the primary component
of most LCM solutions for reservoirs because of their acid solubility. In dealing with seepage losses in
reservoirs, calcium-carbonate-based particles (of varied sizes) are often used as part of the fluid that
provides an effective bridging package. In the event of severe losses, the same calcium-carbonate particles
may be used, but may be of a larger PSD, along with an acid-soluble fibrous LCM (Darugar 2011; Droger
2014). In a few instances, these could be effective, and in other cases, they may not work. In situations
where large PSD calcium-carbonate particles are not working, a chemical-sealant solution is often
employed. Because the application will be in a production zone, a solids-free polymeric pill, or
non-damaging crosslinking system (Vasquez and Fowler 2013; Himes 1994), or a reservoir-friendly,
high-fluid-loss LCM (Sanders et al. 2010) may be needed. However, such chemical sealants may not be
effective in curing severe-to-total losses. Besides being technically inefficient, some chemical sealants
may not be easy to apply and may require specialized pumping techniques and equipment. These factors
may make the use of chemical sealants complicated and not operationally friendly. In situations where
particulate or chemical sealant LCMs are not effective in curing severe to total losses in a reservoir,
techniques, such as managed-pressure drilling and underbalanced drilling, are also being used.

Acid-Soluble, ⴖEngineered Composite Solutionⴖ (ECS)

The subject of this paper is a newly developed ECS lost circulation material, which is particulate-based
and acid soluble, for use in a reservoir to manage severe to total losses. In addition to this new ECS, a
supplemental LCM (which is also acid soluble) that may be used in combination to enhance the
effectiveness of the application is also discussed.
In the following sections, the properties of ECS, such as particle size distribution, acid solubility and
laboratory particle plugging data will be presented. In addition, the strategy on how this product is applied
in the field will be introduced.

Particle Size Distribution (PSD) of ECS

The basic concept of designing an ECS for lost circulation control is a ⬙multi-modal particle size
distribution.⬙ The description of multi-modality is provided by the authors in an earlier paper (Savari et
al. 2015), but it can be described as being a broad PSD with concentration peaks at a number of size
intervals. In the event of severe or total losses, the size of the flow paths (pores or fractures) is not
precisely known. Because of the multi-modal PSD, the ECS would have enough concentration of particles
at lower-size, mid-size, and larger-size ranges to manage any uncertainties in the pore/fracture size.
The acid-soluble ECS discussed in this paper is composed of all acid-soluble particulates. Its
composition also contains acid-soluble fibers. The PSD of the ECS is presented in Fig. 1.
SPE/IADC-178165-MS 3

Figure 1—Particle Size Distribution of Acid-Soluble ECS.

From Fig. 1, it can be noted that the PSD of this acid-soluble ECS is broad, which is evident from the
values of d10, d50, and d90. Multi-modality is also evident from the %Volume (or Distribution) curve in
the PSD plot.

Acid Solubility of ECS

Any solution presented to remediate severe to total losses in a production zone may require that the LCM
be acid soluble. The ECS presented in Fig. 1 was tested for its acid solubility in the laboratory in 15% HCl
and 10% formic acid. The results are presented in Table 1.

Table 1—Acid Solubility of ECS.

Type of acid % Solubility

15% HCl 96
10% Formic acid 96

Acid-Soluble, ⴖEngineered Supplemental Solutionⴖ

Along with the above ECS, an acid-soluble supplemental material is also proposed for use in combination
with the ECS. The combination is proposed whenever the ECS, on its own, is not as effective as needed.
The supplemental material is a calcium-carbonate-based flake material with sufficiently large PSD (Fig.
2) to aid the ECS in being more efficient in sealing larger fractures and vugs.
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Figure 2—Particle Size Distribution of Acid-Soluble, Engineered, Supplemental Solution.

Laboratory Performance Evaluation – Permeability Plugging Apparatus

(PPA) Tests
Evaluating LCMs on a PPA test is an industry-accepted practice. A PPA test does not exactly replicate
actual field conditions, but is a convenient and easy option to evaluate and compare different LCMs under
a set of test conditions. For more details on the exact test method using a PPA, refer to API-RP-13I. A
major difference is that instead of using aloxite (or ceramic) discs as filter media, slotted discs of varied
sizes are used. In addition, because the ECS and the supplemental materials have a large PSD, a modified
back-pressure receiver (termed LCM Evaluation Receiver; see Fig. 3) is used.

Figure 3—LCM Evaluation Receiver.

The present solution (ECS) was also tested on this PPA set up for its ability to plug different slotted
discs. In the event of severe-to-total lost circulation, there would most often be no information on the
SPE/IADC-178165-MS 5

pore/fracture sizes. Hence, it is recommended to have an ECS that has a broad and multi-modal PSD so
that it can remove uncertainty in the fracture sizes by having the ability to plug a wide range of apertures.
It is also recommended, as a good practice, to perform such lab tests (PPA) ahead of time on an in-house
developed variable-width slotted disc (Fig. 4) to provide evidence for potential solutions.

Figure 4 —Variable-Width Slotted Disc.

Figure 5—0.5-in. Vug Insert.

All PPA test data are provided in Fig. 6. The selected concentration of ECS and supplemental LCM
was added to a reservoir drilling fluid. PPA tests were performed at room temperature and at 1,000-psi
differential pressure. Fluid loss was reported at the end of a 30-minute test time.

Figure 6 —Permeability Plugging Apparatus (PPA) Test Data on ECS and its Combination with the Supplemental Solution.
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● 50 ppb of ECS, on its own, was successful in efficiently plugging up to a 3,000-micron slotted disc.
● The combination of the ECS and supplemental LCM was able to plug slotted discs up to 7,000
microns.
● The combination of the ECS and supplemental LCM was also able to plug a 0.5-inch vug insert
(Fig. 5).
Once again, as stated in the earlier sections, PPA test data may not actually replicate field conditions.
However, this kind of plugging data across varied slotted-disc sizes provides some confidence and an
indication of potential effectiveness.

Operational Considerations for the use of ECS

In regards to field applications, some points to consider are provided below.
● Because the ECS is primarily a combination of particulates and fibers (all acid soluble), it is
perceived to be operationally friendly to apply compared to crosslinking-type chemical sealants in
the production zones.
● Because all the components in the ECS are non-reactive, it can be mixed in any fluid.
● The ECS is recommended for application in the form of a pill for severe to total losses in
production zones.
● In the lab, up to 80 ppb of the ECS have been pumped (at 200 mL/min) through a 10/32-in. nozzle
(simulating a bit nozzle).
● 50 to 80 ppb is the recommended concentration for the ECS for use in severe-loss situations in a
reservoir that can be pumped through most BHAs.
● When the ECS is ineffective on its own, it is recommended that the larger-flake supplemental
material be added to the pill.
● When using the supplemental solution, the pill has to be pumped either open-ended or through a
treating sub (this is because of the large size of the supplemental solution).

Conclusion
● The newly developed ECS is expected to be an operationally friendly, easy-to-use, acid-soluble
solution for severe to total losses in production zones.
● The multi-modal feature of the ECS is expected to provide the flexibility of working in varied
pore/fracture sizes and, hence, be able to manage varied losses in production zones.
● The ECS being acid soluble (up to 96%) in 15% HCl and 10% formic acid is one of the primary
features for an LCM to remediate severe to total losses in production zones.
● An acid-soluble ECS is recommended for use in the form of a pill.
● A larger-flake supplemental material can be added to the acid-soluble ECS pill to enhance the
effectiveness of plugging and curing total losses.
● When using the supplemental solution, the pill must be pumped open-ended or through a treating
sub.

Acknowledgements
The authors would like to thank Halliburton operations personnel in providing valuable feedback for the
need of efficient LCMs for use in production zones that led to the development of this acid-soluble ECS.
The authors would also like to thank Halliburton management for giving the necessary permission and
encouragement to publish this work. Thanks are also extended to Jessica Paola Ramirez for her support
during the laboratory work and to Dr. Matthew Miller for his initial work on the project.
SPE/IADC-178165-MS 7

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