A new laboratory work procedure has been developed to evaluate and test the performance and effectiveness of chemical-sealant-based loss circulation materials (CS-LCMs), which are often used in cases of severe-to-total losses. These unconventional testing methods should be useful tools to evaluate the integrity of loss circulation material (LCM) products under downhole conditions in terms of differential pressure buildup and how quickly such LCMs can arrest lost circulation.

Evaluation and testing of LCMs in the laboratory before field application are crucial. Conventionally, the plugging capacity of particulate LCMs is tested against various-sized slotted discs using a permeability plugging apparatus (PPA), and integrity is tested in terms of sealing capacity and fluid loss value. Testing the performance of CS-LCMs required another means that included plugging extra-large vugs and building a significant differential pressure that could sustain the drilling fluid column. Pumpability of CS-LCMs and mechanical strength performance over time were evaluated using a high-pressure/high-temperature (HP/HT) consistometer, ultrasonic cement analyzer (UCA), and modified PPA following this fit-for-purpose procedure.

Extensive laboratory testing revealed that the new testing method was highly compatible with almost all types of chemical-based LCMs, including resin, gunk squeeze, and thixotropic slurries. The effectiveness and performance of several commercially available CS-LCMs were measured using different vug sizes (i.e., up to tens of millimeters). Thickening time of LCMs were observed pumpable [i.e., <70 Bearden units of consistency (Bc)], even after hours of conditioning at bottomhole circulating temperatures (BHCTs). As per API routine practice, tested slurry is deemed unpumpable if Bc exceeds 70. However, the thickening time of gunk squeeze LCMs were observed to be significantly high in a short interval of time once aqueous and nonaqueous streams mixed together. Gunk-based LCMs build high differential pressures and compressive strength over the same periods of curing time at bottomhole static temperature (BHST) and pressure compared to thixotropic-based LCMs.

Appropriate laboratory testing and evaluation of chemical-based LCMs under downhole conditions are highly recommended before field trail/application. This new testing/evaluation method should help minimize operational risk and nonproductive time (NPT) at the rig site.

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