Lost circulation is a widespread problem in many formations in the United Arab Emirates, including Shallow Unconsolidated, Shallow Vuguler and Limestone. To minimize losses during drilling and cementing, several types of lost circulation solutions such as bridging agents and surface-mixed and downhole-mixed solutions have been used. Still, operators lose huge volumes of mud and cement slurry and expensive rig time. Consequently, many wells also require remedial operations, which can compromise well integrity. Loss-zone diagnosis and characterization helped to tailor the loss-circulation control solution for different requirements. Losses can occur due to unconsolidated formation (surface holes) or induced and natural fractures. Typical loss rates can vary between 150 to over 700 bbl/hr, particularly while drilling the 16-in. and 12 ¼-in. openhole sections. Thus, total losses in shallow vuguler formation require a different treatment than induced losses in shallow unconsolidated or limestone formation. Induced losses in limestone while drilling prevented increase in mud weights required to drill deeper reactive shale formation. A composite fiber-based system based on a novel four-step methodology was designed using advanced software analysis. Prior to the field trial a complete lab-scale and yard-scale testing was done to confirm superior effectiveness. In one of the pilot wells, multiple leakoff tests (LOTs) were performed in the Limestone formation to verify the minimum stress (1.40 SG), which did not change with subsequent LOTs. The formation was then treated with the reinforced composite mat based system, and the following formation LOT showed integrity buildup to 1.51 SG. It proved to be an easy to apply solution that can be mixed and pumped through a qualified bottomhole assembly (BHA). Zone and mechanism specific lost circulation control solutions are most effective in reducing nonproductive time (NPT). It was also demonstrated that fiber-based solutions work well for controlling losses and formation strengthening. The engineered composite fiber-blend system exhibits improved performance and robustness in terms of curing losses and even improves formation integrity.
This paper discusses the value of cement logs as the core input to analyze the cement quality and validate the improvements made to cementing designs and practices of the intermediate casing string in Extended-Reach Drilling (ERD) wells. The ERD wells are being drilled from artificial islands in a field offshore in the UAE. The primary cementing objectives are isolating the reservoirs from their sublayers and protecting the casing against possible future corrosion across an upper formation. Cementing challenges include higher angle deviation, higher mud weight requirements resulting from an anisotropic, unstable shale formation present above the reservoir section. Effective reservoir management requires sound zonal isolation to eliminate crossflow between different reservoir units. In combination with standard cement bond logs (CBL), ultrasonic technology has provided detailed information about cement quality and a qualitative indication of casing position in the borehole. These have also led to valuable insight into how continued cementing designs and practices improved zonal isolation. Improvements in cement quality seen as a result of enhanced casing centralization, optimized hydraulic model, modified cement rheology, displacement rate impact, among others, were confirmed with the cement log evaluation program. The paper will present the ultrasonic and standard CBL responses, which support the enhancements made to the cementing design and practices that yield the desired results. The cement quality has been improved in the ERD wells intermediate section through strategic modification in cementing practices. Cement evaluation logs have played a significant role in validating the cementing methods’ development. Consistently improved zonal isolation results have opened up the opportunity for future efficiency gains by eliminating routine CBL.
Lost circulation while drilling across vugular or naturally fractured limestone formations is a costly challenge and has financial impacts including nonproductive time and remedial operational expenses. Many fields in the UAE are encountering notorious lost circulation complications, which are difficult to control with conventional lost circulation solutions while drilling surface sections. Novel lightweight thixotropic cement has proven beneficial to take control of severe losses in these vugular and naturally fractured limestone formations. The main challenge while drilling across the surface section in UAE offshore field is the heavy or total loss of returns. Drilling performance is affected due to poor hole cleaning, a risk of stuck pipe, surface fluid handling problems, and well control risks. Conventional extended cement slurries have been widely used to cure losses while drilling but with limited success. A new lost circulation solution combines lightweight (10.5- lbm/galUS) high solids fraction cement (trimodal system) and a thixotropic agent, which develop fast gels with high compressive strength. Thus, it enables plugging of large voids and fractures to deliver the wellbore integrity required to continue drilling with enhanced performance and efficiency. Intensive laboratory qualification tests focusing on static gel strength and compressive strength development was performed to tailor the new solution. The results were promising with more than 100 lbf/100 ft2 of static gel strength in 10 minutes and compressive strength development of 1,000 psi within 24 hours at low surface temperature. In addition, a transition time (TT) on-off-on test demonstrated more rapid gel strength development when the shear is reduced and regained fluidity with reapplication of shear. In one of the wells, heavy losses were encountered while drilling across surface section. The lightweight thixotropic solution was pumped for the first time worldwide and it was shown that the innovative lost circulation solution was effective in significantly reducing the losses and enabled the operator to continue drilling to section TD. This case study demonstrates that this advanced system is effective in curing losses and reducing nonproductive time. The unique properties of faster rapid gel strength and high compressive strength make this solution effective for treating a wide range of lost circulation events while drilling. Furthermore, the advanced lightweight thixotropic cement lost circulation solution exhibits strong performance in curing heavy losses and establishing well integrity with reliability.
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