IADC/SPE 133735

Optimizing in Four Steps Composite Lost-Circulation Pills Without Knowing

Loss Zone Width
Slaheddine Kefi, SPE, Jesse C. Lee, Nikhil Dilip Shindgikar, SPE, Chrystel Brunet-Cambus, Benoit Vidick, SPE,
and Nelson Ivan Diaz, Schlumberger
Copyright 2010, IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition
This paper was prepared for presentation at the IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition held in Ho Chi Minh City, Vietnam, 13 November 2010.
This paper was selected for presentation by an IADC/SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not
been reviewed by the International Association of Drilling Contractors or the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the International Association of Drilling Contractors or the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this
paper without the written consent of the International Association of Drilling Contractors or the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an
abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of IADC/SPE copyright.

Abstract
A composite blend for controlling lost circulation has been developed on the base of a new four-step methodology. This blend
exhibits superior performance over conventional treatments and eliminates missing loss-zone diagnosis and characterization.
Fighting lost circulation is a costly and time-consuming process. Conventional lost-circulation treatments try minimizing
excess costs from rig time and fluid loss. In addition, they try avoiding the need for additional casing. However, these
treatments are often based on trial and error without any practical technique to properly diagnose and characterize the losszone.
The new methodology addresses these shortcomings. The methodology proceeds in four steps: Dispersing a composite lost
circulation material in a base fluid, Bridging the loss zone with fibers, Plugging the fiber networks, and Sustaining the plugs.
Each step is parameterized by criteria, which can be optimized to meet the performance requirements. The fibers must possess
certain form factor and exhibit specific physical properties to bridge open fractures after deploying through bottomhole
assembly and drill bits. The composite plug also must endure pressure fluctuation during drilling or cementing and must
tolerate erosion forces exerted by the fluid flow and downhole hardware. The four-step methodology provides an engineered
combination of sized granules, stiff and flexible fibers. This new composite system was validated in several field trials in
South America and Europe. In addition to the field trial results, this paper also describes the laboratory-scale and yard-scale
tests, which were used for developing the new system. These tests helped establish guidelines for deployment through
bottomhole assembly and drill bit.
These examples demonstrate that the novel composite blend system improves performance and robustness in curing losses
compared with conventional single-fiber systems.
Introduction
Lost circulation (LC) into natural fractures is typically troublesome to cure. The losses can happen at overbalance as low as
tens of psi. The location of natural fractures can spread through the entire geological interval being drilled.
Owing to the uncertainty of fracture locations, the most common solutions use a mixture of sized materials to physically
plug and seal the natural fractures wherever they are located in the flow path (Loeppke et al., 1990). The sized materials offer
another significant merit: they rely on physical plugging, and thus are largely independent of bottomhole conditions; in
particular, they do not depend on temperature. They can be effective for fractures spreading over the entire openhole interval
with possibly large temperature differences.
Several models have been proposed to optimize the size distribution for these granules to maximize their plugging and
sealing efficiency: Abrams model (Abrams, 1977), Ideal Packing Theory (Dick et al., 2000), Vickers model (Vickers et al.,
2006). Even though these algorithms vary in optimizing the particle-size distribution, they all agree that the optimized granule
size is a function of the loss-zone geometry (for example, the median granule size is equal to one third of the fracture width).
Oftentimes the size of the loss zone is not clearly characterized; then the basis for optimizing particle-size distribution
becomes a moving target.
The salient features of the conventionally sized material shall be preserved, while at the same time their short-comings
shall be eliminated. To this end, it is possible to develop a composite solution based on a novel four-step process, which

IADC/SPE 133735

includes dispersing a composite blend of fibers and granules, bridging across the loss zone, plugging the loss and sustaining
the plug during further operation.
The selected methodology optimizes the properties of the composite material that plugs the open fractures. The key
components in the composite solution are the engineered blend of fibers and an adapted granule package. The fiber blend is
designed to bridge various widths of open fractures, and the granule package is optimized to plug the permeability of the fiber
network. These two key components together form a stable and robust composite material that is capable of plugging open
fractures to cure losses and that remains effective until the trouble zone is cased off. The studies in this paper are limited to
water-based fluids.
New Four-step methodology
Initial laboratory observations showed that a combination of Lost Circulation Materials (LCM) and more particularly,
fibers and sized granules, gave a plugging composition independent of fracture geometry over a broad range of fracture widths
(Fig. 1).

Fig. 1Plugging Lost Circulation with a composite blend of fibers and granules.

This plugging could be observed as long as several key properties are achieved:
Both fibers and granules could readily disperse in the base fluid.
The fibers are stiff enough to bridge the opening.
The combined package could create an almost impermeable plug when concentrated.
This plug could sustain pressure differences and mechanical scraping.
Dispersion
This approach relies on homogeneous dispersion. The plugs reproducibility and efficiency are greatly improved with a full
separation of individual fiber or granule from aggregates and bundles and their homogeneous dispersion in the fluid volume.
Bridge
The fibers must not bend excessively or rupture while bridging the nature fractures to ensure synergy with the remaining
components in the LC solution. Therefore, there exists an optimal fiber-stiffness range. Above the maximum the fibers are too
stiff to be mixed and pumped and often become too brittle. Below the minimum the fibers bend too easily and are pushed
farther away into the formation without effectively bridging the open fractures. A simple mechanical model explains this
behavior for the bending of a structural beam supported on both sides (Fig. 2).

IADC/SPE 133735

Load w

Fracture width l
Fig. 2Fiber deflection across a fracture of width l.

The maximal deflection y of a fiber supported at both ends is inversely proportional to the fiber stiffness (Marghitu, 2001).
It can be estimated with respect to an applied uniform loading w (Durka and Al Nageim, 2003):
y=

5 wl 3
...............................................................(1)
.
384 E.I

where l is the distance between both ends, E is the fiber modulus of elastivity and I is the area moment of inertia
considering a cylindrical fiber of diameter d:
I=

d4
64

..................................................................(2)

If pressure load w and fracture width l are kept constant, then the stiffness of the cylindrical fiber can be related directly
to its diameter and elastic modulus.

w 6 Ed 4
............................................................(3)
=
y
5l 3

Hence, the fiber stiffness can be easily tuned by varying the fiber diameter and/or selecting different material. A relatively
stiff fiber, as opposed to flexible fibers typically used for LC, is required to effectively cure losses and more importantly, stay
effective after the placement.
Table 1 and Fig. 3 compare the stiffness calculated across a 3-mm opening for typical fibers already used as LCM. Some
of these values are hypothetical because all fibers could not be found with several millimeter length and the fiber length should
be higher than 3 mm to be supported at both ends in this specific example. The reported diameters correspond to the typical
diameter of commercially-available fibers. The stiffness is calculated by use of Eq. 3.
Animal hairs, wood, polymeric and steel fibers require the highest load for deflection provided the right sample is used
(because of material variation). For animal hairs, polymeric and steel fibers, this variation of diameter comes from the possible
selection of multiple vendors and sources. For wood fibers, this fiber-diameter variation is present for a given wood fiber
material. The material of choice would have been different if the selection criteria were based only on flexibility (elastic
modulus). For example, even though aramid or carbon fibers have a very high elastic modulus, their stiffness is average
because of their low diameter.
Table 1Description of LCM fibers (stiffness calculated for l = 3 mm).
Fiber Type

Elastic Modulus E
(GPa)

Typical diameter d
(m)

Calculated stiffness
(N/m)

Reference

Asbestos
Straw
Cotton
Wool
Aramid
Glass
Carbon
Animal hair
Bagasse
Wood
Polymeric
Steel
Animal hair

16
6
8
4
120
70
300
10
4.5
10
3
200
10

<1
15
16
20
15
20
15
100
400
10 to 1000
10 to 2000
10 to 700
20 to 2000

<0.000002
0.042
0.07
0.1
0.8
1.6
2.1
140
16 000
0.01 to 1 400 000
0.004 to 6 700 000
0.3 to 6 700 000
0.2 to 22 000 000

(Roggli and Brody, 1984)

(O'Dogherty et al., 1995)
(Kawabata et al., 2004)

(Shibata et al., 2006)

IADC/SPE 133735

Stiffness, N/m

100000000
10000000
1000000
100000
10000
1000
100
10
1
0.1
0.01
0.001
0.0001
0.00001
0.000001

Fiber type
Fig. 3Typical stiffness across a 3 mm opening of LCM fibers (dark green = impact of varied diameters).

For LC tests, we selected polymeric fibers with an average stiffness of 3000 N/m (S fibers). Steel fibers were not used to
ensure compatiblity with downhole drilling tools.
Plug
A given blend of fibers and granules must meet several requirements to create a concentrated impermeable plug:
Fiber concentration must be high enough so that fibers will entangle across the loss zone area, without being too
high to impair the fluid rheology.
For an optimal concentration, the fiber concentration shall stay lower than the limit between semi-dilute and
concentrated regimes, as defined in the literature of fiber and polymer suspensions (Herzhaft and Guazzelli, 1999).
In this regime, the relevant dimensionless number for rigid, cylindrical fibers is
2

L d
csd = N . ......................................(4)
2 2

where csd is proportional to the volume fraction of the disks, the diameter of which is equal to the fiber length L,
and N is the number of fibers per unit volume.
The limit between the semi-dilute regime with slightly entangled fibers and the concentrated regime with greatly
reduced fiber movement is determined for values of c2 approaching unity.
For the selected polymer fibers this concentration limit is around 15.7 g/L [5.5 lbm/bbl].

The granule concentration shall be so high that the granules fill enough holes in the concentrated fiber network.
In the context of these systems, this minimal concentration has been determined to be around 25% Solid Volume
Fraction (SVF).

The granule size is tuned to match holes in the fiber network.

For a given SVF and a given fiber system, the global size distribution of granules must be optimized. Most of the
presented laboratory tests of this paper are devoted to this optimization for a given set of granules and to adapting
variations of LCM particle-size distributions.

Sustain
Once the composite solution is pumped downhole, the plugs formed within the open fractures must remain stable and
sustain erosion, mechanical contact, surge and swab pressure fluctuation, and elevated differential pressure. Therefore, the
fiber component in the composite formulation must intermingle with other ingredients and must connect and secure the final
composite formed with the open fractures.
We selected gray very thin, flexible polymeric fibers (F fiber), blended with S fibers. F fibers show a high tendency to
penetrate the open fractures and wrap around other components, creating a composite plug that is stable and resilient. When

IADC/SPE 133735

the LCM blend is plugging a simulated fracture (slot on a disc), the ultra-flexible fibers tend to penetrate the slot, but at the
same time, grab the stiff fiber and then secure the final composite plug. Fig. 4 shows the bottom view of a 2-mm slot, where
some F fibers can be seen reaching below the slot.

Fig. 4Composite plug of S and F fibers on 2-mm slot.

Experimental studies
Dispersion
The first observed parameter is the influence of fiber dispersion in the base fluid. The dispersion of several fiber types in
water is evaluated by measuring the total volume of fibers dispersed with spatula stirring. The total volume was 250 mL each
time; the fiber quantity was adjusted to keep a constant csd concentration (Eq. 4). The nature of fiber sizing, their commercial
supply as single filament (staple fibers) or bundle of fibers, the temperature of dispersion, presence of co-solvents or additives
all greatly influence the quality of fiber dispersion (Fig. 5 shows several examples of dispersion).
Both selected fibers of the blend (S and F fibers) were tested in water and showed good dispersion properties.

Fig. 5Dispersion efficiency for three different fibers (same c2 concentration): bad dispersion (left),
medium dispersion (middle), good dispersion (right).

IADC/SPE 133735

Bridging and plugging experimental procedure

As usual in lost circulation experiments (Low et al., 2003), the laboratory plug tests used a modified 500 mL static fluid
loss cell (Fig. 6). A local nitrogen supply provided pressure up to 4.1 MPa [600 psi].

Fig. 6Modified fluid loss cell for LC plug tests.

Several repeat tests showed that some elements of this setup strongly influence plug-test reproducibility:
The bottom valve ensures that pressure is systematically applied in the same way at the very beginning of the test.
The grid support is leaving an empty space below the geometry to reduce additional friction pressure and
tortuosity that could artificially impact flow and plug behaviour.
This empty space is filled with water to eliminate any effect of rapid compression when the valve is opened.
A metal disk slightly smaller than the inside diameter of the cell is used as a piston on top of the fluid to suppress
any rapid fingering of nitrogen into the tested fluid.
The bottom valve, bottom cap and bottom line must have a large diameter to prevent any downstream plugging
that could affect the behaviour at the tested slot upstream: 1-in. [2.5-cm] stainless steel fittings are connected at
the bottom of the cell.
Metal grid inserts are used to simulate the open face of fractures. These tests used two different sets of slots (5- or 50-mm
depth) with a fixed length (46 mm) and various openings (from 1 to 5 mm) (Fig. 7).

Fig. 7Example of slots for LC plug tests (left: 2 mm slot, right: 5 mm slot).

IADC/SPE 133735

The base fluid was prepared by mixing 350 ml of water with bentonite in a high speed mixer for 25 minutes. After
checking bentonite hydration with rheology measurements, fine granules of the LCM blend were added to 300 mL of fluid and
mixed with the same mixer for 5 minutes. Medium, coarse granules and fibers of the LCM blend were added and stirred with a
spatula or paddle mixer for another 5 minutes until homogeneous dispersion is observed.
Once assembled, the cell is filled with water just below the slot (with the bottom valve closed), then with the prepared
slurry. After placing the piston on top of the fluid and closing the cell, the whole setup is set to the desired pressure (usually
500 psi [3.5 MPa]). To prevent splashing of fluid (in case of plug failure), a closed plastic box with a small top opening is
placed on a scale. The weight of spurt and filtrate is monitored as a function of time during the experiment.
This plug experiment was repeated three times for each formulation and test condition.
Three different types of behaviour are represented in further graphs with colors:
The system plugged the slot in the first minute of the test and held pressure variations with spurt volumes between
0 and 50 mL (Green).
The slot was plugged temporarily for several minutes and failed under increased pressure OR the test could not be
reliably repeated (Orange).
There was no plug or the plug failed rapidly under tests conditions (Red).
At the end of each test, the cell is depressurized, opened and the plug is examined visually.
Bridging and plugging test results
Several tests were performed with different water-dispersible fibers (as determined in the previous section), adjusting the
total granule concentration to 25% SVF (for example, 910 g/L [320 lbm/bbl] of calcium carbonate granules). The granule size
distribution was optimized for each fiber system as described in the next part of this section. As in the dispersion test, the fiber
concentration was also adjusted to a constant c2 concentration. Each system used fiber with lengths from 10 to 15 mm.
Fig. 8 shows the results for each granule + fiber system on different slot widths. The stiffness for a 3-mm opening
(Eq. 3) is also indicated for each system.
The performance variation with different fiber stiffness is clearly visible. Increasing fiber stiffness greatly improves plug
efficiency.
Plug tests with fibers and sized granules
(25% SVF, ambient temperature, 3.5 MPa [500 psi])
NO PLUG
RANDOM PLUG
PLUG

Slot width, mm

6
5
4
3
2
1
0
20 g/L [7 lbm/bbl],
glass fibers
(3 mN/m)

8.6 g/L [3 lbm/bbl],

polymer fibers
(0.1 mN/m)

8.6 g/L [3 lbm/bbl],

polymer fibers
(3 mN/m)

8.6 g/L [3 lbm/bbl],

S and F fibers
(3000 mN/m)

Fiber concentration, Fiber type (Stiffness)

Fig. 8Plug tests with different fibers in the presence of 25% SVF granules.

The blend of S and F fibers systematically plugged slot openings up to 5-mm width without changing the formulation from
one slot width to another.
When the source and composition of granules in the LCM blend is changing, it is necessary to adjust the total granule size
distribution for optimal results. For such an optimization, ternary blends are interesting because they provide enough
versatility to increase performance without adding too much difficulty for blending (four- or five-granule blends are more
difficult to prepare for a marginal performance improvement).

IADC/SPE 133735

When selecting different sizes for LCM granules, the following size categories produced consistent plugging efficiency:
Fine granules (median size up to 30 microns)
Medium granules (median size between 30 and 180 microns)
Coarse granules (median size between 180 and 750 microns)
Ultra-coarse granules (median size between 750 and 1500 microns) (ultra-coarse is preferred over coarse granules for
4- or 5-mm width slot)
With 8.6 g/L [3 lbm/bbl] of S and F fibers, three different types of calcium carbonate granules are tested varying the
relative volume proportion between them. Results are represented as ternary diagram (Fig. 9).
0
100%
10
90
20
80
30
70
40
60
50

CaCO3 M

50

CaCO3 XC

60
40
70
30
80
20
90
10
100%
0
0

10

20

30

40

50

60

70

80

90

100%

CaCO3 F
Fig. 9Relative proportions of CaCO3 granules for plugging compositions (green) (bordeline compositions
in orange).

The results show that the variation of plug efficiency is continuously changing with blend composition: it is possible to
define a green zone in the ternary diagram corresponding to efficient plugs..
All systems with less than 10 vol% fine granules were either failing or lead to very permeable plugs that did not control
flow.
This example helped define a target particle-size distribution and determine change of the green zone as function of the
relative granule concentration. In fact, for this defined optimized blend of fibers, it is possible to work out an optimal granule
composition, different for each set of granules used. Fig. 10 estimates the plugging efficiency by changing the ultra-coarse
calcium carbonate to ultra-coarse nut shells, the size distribution of which was measured in the laboratory.

IADC/SPE 133735

0
100%
10
90
20
80
30
70
40
60
50

CaCO3 M

50

Nut Shell

60
40
70
30
80
20
90
10
100%
0
0

10

20

30

40

50

60

70

80

90

100%

CaCO3 F
Fig. 10Relative proportions of CaCO3 fine, CaCO3 medium, and nut shell for plugging compositions
(green) (bordeline compositions in orange) (circles: experimental results).

The same graph displays tests with plugs (green circles) and no plug (red circles), confirming that the estimate predicts
plug tests as a function of relative volumic proportion of sized granules.
This result/estimate is very useful because it allows sourcing locally-available LCM granules and defining a target
formulation by just changing the proportion between them.
Plug tests were also performed at higher temperatures. In the selected composition, all LCM are chemically inert with
temperature; so radical changes are not expected in hotter conditions. The elastic moduli of the S and F fibers are slightly
decreasing by 20% between 25 and 120C [70 and 250F]. When applying this 20% change to the target size distribution, it is
possible to correctly predict the plug performance of different granule blends (Fig. 11).

10

IADC/SPE 133735
0

100%

100%

10

10

90

90

20

20

80

80

30

30

70

70

40

40

60

60

50

CaCO3 M

Sand

50

50

CaCO3 M

60

Sand

50

60

40

40

70

70

30

30

80

80

20

20

90

90

10

10

100%

100%

0
0

10

20

30

40

50

60

70

80

90

100%

0
0

10

CaCO3 F

20

30

40

50

60

70

80

90

100%

CaCO3 F

Fig. 11Relative proportions of CaCO3 fine, CaCO3 medium, and sand for plugging compositions (green) (bordeline
compositions in orange) at ambient temperature (left) and 120C [250F] (right) (circles: experimental results).

Sustaining erosion
A large scale flow loop is designed and is built to assess the resistance of various composite formulations to erosion. The
composite solution is prepared in a 1.6-m3 [10-bbl] mixing tank, then pumped through a flow cell containing a screen. The
composite materials plugged the screen. Q is the pump rate and Q2 is the fluid flow rate across the screen. Pressures in the
flow cell (P1) and inside the screen (P2) are monitored.

Fig. 12Setup of flow loop test to evaluate plug erosion.

After the screen plugging has taken place, Q is increased step-wise to simulate different degrees of wall shear stress. The
stability of the composite plugs formed on the screen is then evaluated. Test results showed that the addition of the flexible F
fibers considerably enhanced the erosion resistance of the composite solution, compared with conventional fiber-based
systems. This test methodology indicates that conventional fiber plugs are eroded from the screen when the flow is reaching
20- to 25-Pa wall shear stress. For the same conditions, the composite plug with S and F fiber and granule blends is still intact
at 35- to 40-Pa wall shear stress.
Compatibility with drillstring
Fiber-based LCM blends pose a high risk for some parts of the drillstring with narrow flow path (such as MWD tools and
drill bits). Several yard tests helped assess these premature plug risks and minimize jamming occurrence. The outcome of

IADC/SPE 133735

11

these yard tests led to new pumping guidelines. These tests focused on the mud-pulse-telemetry based MWD tools, because
they have been recognized as the drillstring asset with the highest jamming risk. Fig. 13 shows the setup of the yard test.

Fig. 13Schematic of yard test to assess jamming risk of MWD tool with LCM composite system.

The pressure drop across the tool, recorded during pumping, indicates the jamming tendency. Contrary to conventional
expectation, the composite solution could be pumped safely through even the smallest MWD tool (4 in.) without jamming. It
does not interfere with the telemetry during and after pumping of the LC pill.
Following tool development guidelines, the pressure drop is monitored across a 4-in. MWD tool with a pill comprising
25% SVF sized granules and increasing concentrations of S and F fiber blend (Fig. 14).
Fiber concentration, lbm/bbl
0

0.5

1.5

2.5

3.5

6
800
700
600

500
3

400
300

Pressure drop, psi

Pressure drop, MPa

200
1
100
0

0
0

4
6
Fiber concentration, g/L

10

Fig. 14Pressure drop across a 4-in. MWD tool with increasing S and F fiber concentrations.

The pressure drop is starting to significantly increase above 8.5-g/L [3-lbm/bbl] fiber concentration. The test was stopped
at 9.4 g/L [3.3 lbm/bbl] because of the onset of partial jamming (pressure drop close to 5.5 MPa [800 psi]).
In the same experimental setup, the MWD tool was replaced with a drill bit or float shoe. The risk of plugging the bit with
the LCM blend is evaluated with the same procedure (Table 2).
Table 2Pressure drop across drill-bit nozzles and float shoe with increasing S and F fiber concentrations.
Total Fiber Concentration
g/L [lbm/bbl]

0
7.1
7.7
9.4

[0]
[2.5]
[2.7]
[3.3]

Pressure
MPa [psi]
Drill-bit nozzle size
(8/32 in.)

(9/32 in.)

(10/32 in.)

5.7
5.7
5.7
6

3.9
4
4.2
4

2.8 [410]

[830]
[830]
[830]
[870]

[570]
[580]
[670]
[580]

Float shoe
(4.5 in.)
0.38
0.33
0.34
0.35

[55]
[48]
[49]
[51]

12

IADC/SPE 133735

In addition to the observations made while testing a 4-in. MWD, the composite plug did not jam the nozzles or the float
shoe AND no pressure drop increase is noticeable with increasing fiber concentration. As a matter of fact, the pressure stayed
fairly constant even up to 9.4-g/L [3.3-lbm/bbl] fiber concentration. This test result clearly proves that composite solution can
be pumped through typical drill-bit nozzles and float shoes,
Wellsite applications
Case History 1
For a land well in Europe, the composite-based solution was tested during the drilling operation to validate product
performance in terms of its ability to remain effective till the trouble zone is cased off. In addition to this test objective, the
placement technique was also assessed to maximize product performance.
The 12 in. vertical openhole section extends from approximately 900- to 2000-m [3,000- to 6,500-ft] depth. The
observed loss rate during drilling ranged from 30 to 45 m3/h [200-280 bbl/h]. The main challenges for this zone are long
openhole interval, no temperature log, no caliper log, and numerous loss zones. For an effective circulation-loss control the
composite-based solution must perform exactly as the four-step process, i.e. fibers must disperse properly; the pill in contact
with the loss zones must bridge and plug; and the resulting composite-plug must remain stable and sustain all subsequent well
activities.
The analysis of drilling reports identified two main loss zones at 1400 and 1500 m [4,600 and 4,900 ft] respectively.
Therefore, it was decided to place the pill by use of a balanced-plug technique. Once the pill was in contact with the loss
zones, squeeze pressure was applied to strengthen the properties of the composite plug. Operationally, a pill of 34-m3 [215bbl] volume and of 1430-kg/m3 [11.9 lbm/gal] density was placed through the drill bit (three 22/32-in. nozzles) to cover the
two identified zones. The drillstring was then pulled out of hole to the previous shoe. The blow-out preventer was
subsequently closed and 1.4-MPa [200-psi] squeeze pressure was applied slowly. The analysis of pressure profile recorded
during squeezing clearly indicates that the applied pressure both encouraged the interaction of pill and the loss zone and
strengthened the composite-plug. After the pill treatment, circulation was regained. The composite-plugs remained effective
until the zone was successfully cemented off one week later.
Case History 2
In this case, the composite solution was tested for total losses to gauge its performance limitation. For a well in South
America drilled with oil-based mud, total losses were observed for an openhole section at the depth of 5840 m [19,160 ft]. The
length of the open hole was approximately 64 m [210 ft]. The density of the oil-based mud was 1120 kg/m3 [9.3 lbm/gal].
Attempts to reduce the mud density to 1010 kg/m3 [8.4 lbm/gal] only resulted in kicks. The operator had estimated that the
mud density needed to be at 1150 kg/m3 [9.6 lbm/gal] to drill on safely.
After laboratory testing, the well was stabilized and the operator decided to pump the composite solution. The water-based
pill (density 1380 kg/m3 [11.5 lbm/gal]), in addition to the fibers and sized granules, was also formulated with surfactant to
ensure formation compatibility. The pill was then pumped through drill bit with three 22/32-in. nozzles. As in the previous
case history, 1.4-MPa [200-psi] annular pressure was applied to strengthen the composite-plug. After placement, the drillstring
was pulled out of hole to circulation point at 4900 m [16,100 ft], and full circulation was regained during circulation while the
mud density was increased stepwise to 1150 kg/m3 [9.6 lbm/gal]. The loss zone remained cured during subsequent drilling.
Mud density was then again increased to 1190 kg/m3 [9.9 lbm/gal]. The stability and effectiveness of the composite-plug was
still maintained and no losses were observed.
These two cases show that the composite solution is able to cure losses by forming composite materials that plug the open
fractures. These composite plugs exhibit satisfactory properties that can sustain erosion, downhole hardware scraping, pressure
fluctuation and pressure elevation across the loss zone.
Conclusions
To control lost circulation in natural fractures, it is possible to design a water-based pill including a composite blend of fibers
and granules whose formulation does not depend on the geometry of loss zones. This optimization is possible by closely
adapting four different aspects:
1. Dispersion of the fibers and granules in the base fluid to get an homogeneous composition,
2. Bridging of the same stiff fiber concentration across different fracture width,
3. Plugging of the fiber-granule concentrate by adapting granule size distribution and fiber network,
4. Sustained lost circulation control by using a blend of stiff and flexible fibers holding the plug in case of pressure
differences and mechanical scraping.
With experimental calibration in the laboratory, it is possible to select LCM and to define ranges of concentrations, fiber
stiffness, particle-size distributions that could increase rate of success of LCM use in the field.

IADC/SPE 133735

13

Acknowledgements
The authors would like to thank Schlumberger for its support and permission to publish this paper.
We would also like to thank our colleagues Kinapara Coulibaly, Gerard Daccord, Michel Ermel, Rodrigo Giron Rojas,
Sebastiano Tomassi, Lenin Omar Diaz Torres for their help with laboratory and field tests.
Nomenclature
csd
= dimensionless concentration of fibers for semi-dilute regime
d
= fiber diameter, m
l
= fracture width, m
w
= load, N
y
= fiber deflection, m
E
= fiber tensile elastic modulus, Pa
I
= fiber area moment, m4
L
= fiber length, m
LC
= lost circulation
LCM = lost-circulation materials
MWD = measurement while drilling
N
= number of fibers per unit volume
SVF = solid volume fraction, vol%

= fiber stiffness, N/m

References
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