BJ Fiber Additive Stopped Fluid Loss Problem
Case History
BJ Fiber Additive Stopped Fluid Loss Problem Successful cement job sealed thief zone to achieve full return
Benefits Stopped Saved
fluid loss
operating expenses
Challenges Well
in Offshore Nigeria
Severe
fluid losses (76 to 126 bbl/hr [12 to 20 m3/hr])
Baker Hughes solution and results Baker
Hughes BJ Fiber additive
Achieved
zonal isolation
In a well in offshore Nigeria, an operator planned to drill a 17½-in. hole section to a final depth of 3,746 ft (1142 m) and then run and cement 133/8-in. casing. At 770 ft (235 m), the well experienced minimal fluid loss, which the operator attributed to surface losses. As drilling continued, however, the losses increased, and the operator pumped 113 bbl (18 m3) of 14-ppg lost circulation material (LCM) in an unsuccessful attempt to stop the losses. Total loss occurred again at both 1,696 ft (517 m) and 2,493 ft (760 m), so additional mud and LCM were added. As drilling continued, the losses increased to as much as 126 bbl/hr, an average of 1,000 bbl (158 m3) of lost mud daily. This would cost the operator close to USD 100,000 after factoring in the cost of associated extended drilling periods.
To stop these losses, the operator pumped 128 bbl (20 m3) of a competitor’s LCM material. After letting the LCM material remain in the well for 6 hours, the operator continued drilling despite continued fluid losses in the formation. Since the Baker Hughes BJ Fiber™ additive had proven extremely effective in sealing thief zones in similar applications, the operator agreed to try it. At final depth, the rig crew started running the casing and experienced total fluid loss. When the casing was landed, Baker Hughes mixed and pumped a total of 516 bbl (82 m3) of 1.5 SG lead slurry and 123 bbl (19.6 m3) of 1.9 SG tail slurry onsite.
The BJ Fiber additive was added to the cement on the fly at 3 lbm/min (1.5 kg/min) and 2 lbm/min (0.75 kg/min), for a pump rate of 5 bbl/min and 4 bbl/min (1 m3/min) for the lead and tail slurries respectively. When Baker Hughes finished pumping the lead slurry (the cement slurry was still in the casing), there were very few returns, but there was a total loss of fluid. Pumping, however, continued as planned. When the cement slurry flowed back into the casing, the pressure gradient increased with an obvious gain in circulation volume. After the cement flowed from the casing, full returns were achieved and remained constant until the total displacement volume, 522 bbl (83 m3), was pumped and the plugs bumped with 1,200 psi (82 bar). The operator successfully sealed the thief zone and achieved full returns using Baker Hughes BJ Fiber additive in place of a competitive LCM.
www.bakerhughes.com Disclaimer of Liability: This information is provided for general information purposes only and is believed to be accurate as of the date hereof; however, Baker Hughes Incorporated and its affiliates do not make any warranties or representations of any kind regarding the information and disclaim all express and implied warranties or representations to the fullest extent permissible by law, including those of merchantability, fitness for a particular purpose or use, title, non-infringement, accuracy, correctness or completeness of the information provided herein. All information is furnished “as is” and without any license to distribute. The user agrees to assume all liabilities related to the use of or reliance on such information. BAKER HUGHES INCORPORATED AND ITS AFFILIATES SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, PUNITIVE, EXEMPLARY OR CONSEQUENTIAL DAMAGES FROM ANY CAUSE WHATSOEVER INCLUDING BUT NOT LIMITED TO ITS NEGLIGENCE. © 2012 Baker Hughes Incorporated. All rights reserved. 35485 8/2012
BJ Fiber Additive Stopped Fluid Loss Problem Successful cement job sealed thief zone to achieve full return
Benefits Stopped Saved
fluid loss
operating expenses
Challenges Well
in Offshore Nigeria
Severe
fluid losses (76 to 126 bbl/hr [12 to 20 m3/hr])
Baker Hughes solution and results Baker
Hughes BJ Fiber additive
Achieved
zonal isolation
In a well in offshore Nigeria, an operator planned to drill a 17½-in. hole section to a final depth of 3,746 ft (1142 m) and then run and cement 133/8-in. casing. At 770 ft (235 m), the well experienced minimal fluid loss, which the operator attributed to surface losses. As drilling continued, however, the losses increased, and the operator pumped 113 bbl (18 m3) of 14-ppg lost circulation material (LCM) in an unsuccessful attempt to stop the losses. Total loss occurred again at both 1,696 ft (517 m) and 2,493 ft (760 m), so additional mud and LCM were added. As drilling continued, the losses increased to as much as 126 bbl/hr, an average of 1,000 bbl (158 m3) of lost mud daily. This would cost the operator close to USD 100,000 after factoring in the cost of associated extended drilling periods.
To stop these losses, the operator pumped 128 bbl (20 m3) of a competitor’s LCM material. After letting the LCM material remain in the well for 6 hours, the operator continued drilling despite continued fluid losses in the formation. Since the Baker Hughes BJ Fiber™ additive had proven extremely effective in sealing thief zones in similar applications, the operator agreed to try it. At final depth, the rig crew started running the casing and experienced total fluid loss. When the casing was landed, Baker Hughes mixed and pumped a total of 516 bbl (82 m3) of 1.5 SG lead slurry and 123 bbl (19.6 m3) of 1.9 SG tail slurry onsite.
The BJ Fiber additive was added to the cement on the fly at 3 lbm/min (1.5 kg/min) and 2 lbm/min (0.75 kg/min), for a pump rate of 5 bbl/min and 4 bbl/min (1 m3/min) for the lead and tail slurries respectively. When Baker Hughes finished pumping the lead slurry (the cement slurry was still in the casing), there were very few returns, but there was a total loss of fluid. Pumping, however, continued as planned. When the cement slurry flowed back into the casing, the pressure gradient increased with an obvious gain in circulation volume. After the cement flowed from the casing, full returns were achieved and remained constant until the total displacement volume, 522 bbl (83 m3), was pumped and the plugs bumped with 1,200 psi (82 bar). The operator successfully sealed the thief zone and achieved full returns using Baker Hughes BJ Fiber additive in place of a competitive LCM.
www.bakerhughes.com Disclaimer of Liability: This information is provided for general information purposes only and is believed to be accurate as of the date hereof; however, Baker Hughes Incorporated and its affiliates do not make any warranties or representations of any kind regarding the information and disclaim all express and implied warranties or representations to the fullest extent permissible by law, including those of merchantability, fitness for a particular purpose or use, title, non-infringement, accuracy, correctness or completeness of the information provided herein. All information is furnished “as is” and without any license to distribute. The user agrees to assume all liabilities related to the use of or reliance on such information. BAKER HUGHES INCORPORATED AND ITS AFFILIATES SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, PUNITIVE, EXEMPLARY OR CONSEQUENTIAL DAMAGES FROM ANY CAUSE WHATSOEVER INCLUDING BUT NOT LIMITED TO ITS NEGLIGENCE. © 2012 Baker Hughes Incorporated. All rights reserved. 35485 8/2012
