Advanced Light Weight Thixotropic Lost Circulation Cement Solution for Vugular and Natural Fractured Limestone Formations: UAE Offshore Case History

Abstract

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.