Turbo-Chem International, INC. Case History
- Chevron USA: La. Offshore
- EXCO Resources: Caddo Parish, La.
- Penn Virginia: Gonzales County, TX
- OXY: Reeves Cty, TX
- EXCO Resources: Nacogdoches Cty, TX Premium Seal® / Turbo-Phalt™
- Cobalt International : Garden Banks 959 LA Offshore Premium Seal® / SYN-Seal®
- Dynamic : Green Canyon LA Offshore Premium Seal® / SYN-Seal® / EZ Squeeze®
- Texakoma: Roberts Cty, TX EZ Squeeze® & SwelLCM®
Chevron USA: La. Offshore
- Well: OCS-G 1316 DA-10 ST-2
- Rig: Ensco 68
- Total Depth: 5,655’
- Problem Interval: 3,190’
- Mud Weight/Type: 10.7 Synthetic Base Mud
Problem Encountered Operator is losing 18-22 bbls. /hr. to the hole. Milling 10’ of new formation and attempting to get a 13 ppg Shoe test with no success @ 3,174’. Prior Application Background material and pumping 45 ppb sweeps of Calcium Carbonate , Gseal and Ultra Seal with no success
Product Application Pumped a 25 bbl pill containing 40 ppb First Response. TCI recommended pumping 20 bbl First Response pills @ 40 ppb sweeps while drilling to control losses.
Results The operator was able to drill to 5,674’ controlling losses by pumping 40 ppb First Response™ sweeps. The operator was able to circulate the hole clean. *While back-reaming out of the hole, the operator decided to eliminate First Response™ sweeps and revert back to Calcium Carbonate Fine/Medium/Coarse, Gseal Plus and Ultra Seal for background LCM and Sweeps (45 ppb). Hole started taking mud at 32 bbls./hr and continued to take mud at this rate for 24 hrs. The operator continued to add background material and pumping 45 ppb sweeps of Calcium Carbonate , Gseal and Ultra Seal with no success. The operator decided to run 7⅝ casing.
EXCO Resources: Caddo Parish, La.
- Well: Red Oak Timber
- Rig: Patterson 212
- Total Depth: 12,100
- Problem Interval: 12,100/li>
- Mud Weight/Type: Oil Base Mud
The operator lost returns 300’ outside of the shoe.. While drilling ahead the losses increased to 30 bbls. / hr. Mud weight was cut back and losses slowed to 10 bbls. / hr. but the formation started caving in.
Strata’s Frac Attack was pumped and briefly slowed losses (Resulting FIT = EMW 15.8 ppg)
TCI Engineer mixed a 100 bbl. pill containing 50 ppb First Response™. The pill was spotted at 12,100’ then POOH above the pill. 15 bbls was lost while pulling. The pumps were staged up in 10 spm increments. Staged up to 65 spm and the well took 5 bbls. Shut the pumps down and monitored the well for 30 minutes
The pumps were again staged up with no losses. Circulated for 2 hrs. while monitoring the well. Shut the pumps down and closed the annulus. Pressure was increased to 1800 psi (Resulting FIT = 17.8 ppg EMW). Washed and reamed back to bottom with no further losses.
Penn Virginia: Gonzales County, TX
- Well: Miller Unit 2-H
- Rig: Pioneer 8
- Total Depth: NA
- Problem Interval: Wilcox Formation
- Mud Weight/Type: 13.1 Oil Base Mud
The operator lost full returns while drilling ahead in the Wilcox Formation.
CI Engineer mixed a 45 ppb First Response™ pill and spotted it over the theft zone while tripping in the hole. When the operator tagged bottom they continued to drill ahead. Their losses were reduced from 20 to 40 bbls/hr. to only losing 10 – 20 bbls/hr. TCI advised the operator to continue treating the hole with First Response™ sweeps. After 5 to 6 sweeps the operator was no longer losing mud to the formation. A 45 ppb First Response™ pill was spotted on bottom before running casing. The operator was then able to run cement with no losses during the cement job
Turbo-Chem was able to solve Penn Virginia’s massive lost circulation problem without numerous , redundant pills and/or High Solid Squeezes. Penn Virginia was so impressed with First Response™ that they will soon require First Response™ to be placed on all rigs for contingency and remediation purposes.
OXY: Reeves Cty, TX
- Well: Collie B 35
- Rig: HP 347
- Total Depth: 6,242’
- Problem Interval: 4,800’-5,400’
- Mud Weight/Type: 8.9 Water Base Mud
While drilling ahead, returns were lost @ 4,800’-5,400’. It was decided to give Turbo-Chem and opportunity to assist in regaining circulation. Previously, the operator was going to drill to TD with no returns .
TCI Engineer arrived on location. The rig was currently drilling with full returns from the casing shoe (5,126’). Upon reaching 5,126’ , the rig lost full returns. The operator continued to drill from 5,126’ – 5,400’ with no returns. Turbo-Chem recommended and started mixing a 50 ppb pill in 100 bbls. of the 8.9 ppg System Water Base Mud. POOH from 5,400’ to 4,417’. There were no First Response™ returns while picking up the pill. Picked up 90 bbls of the pill and chased it with 62 bbls. of system First Response First Response™ Water Base Mud to spot it outside of the bit. After 25 bbls of the system mud was pumped behind the pill, the rig First Response™ started to see returns. Returns were seen while pumping the entire 62 bbls of Water Base Mud. POOH to 3,900’ and waited 2 hours to let the heal and stabilize the hole. After the 2 hour wait, the rig started slowly circulate at 30 strokes with full First Response™ returns. The pumps were increased by 10 strokes every 10 minutes until the drilling pump capacity of 300 gallons/minute were reached. Circulated at full drill rate for 30 minutes with no losses to the formation. The operator shut the pumps off and TIH to 4,700’. After circulating again for 30 minutes at drill rate for 30 minutes there were no losses.
The operator then reached 5,400’ (TD) with full returns. While drilling ahead to 5,647’ returns were again lost. Turbo-Chem pumped a sweep consisting of 15 ppb First Response™ and regained circulation , but had some seepage. The First Response™ sweeps were then increased to 25 ppb. After 20 bbls of the sweep came around the formation, the flow increased and full returns were regained. TCI recommended that the operator pump 20 bbls of the First Response™ pill every other joint. The operator followed the recommendation and drilled to TD (6,242’) with full returns. Upon reaching TD , the operator spotted 25 bbls of First Response™ on bottom prior to POOH to run their casing.
EXCO Resources: Nacogdoches Cty, TX
Premium Seal® / Turbo-Phalt™
- Well: Walker Suh #1H
- Rig: Patterson 209
- Total Depth: 10,512’
- Problem Interval: 10,045’
- Mud Weight/Type: 10.9-11.5 Water Base Mud
Accidental 140 bbl addition of water from the reserve pit to the active system. Cut mud weight and well took a kick at 10,030’. Shut well in at 10,078’ to circulate out gas. Increased mud weight to 11.5 ppg. Lost partial returns at 10,450’ and then lost full returns at 10,512’.
Baker Hughes LCM additions:
10,030’- 0.5 ppg MilCarb + 0.25 ppb Mica Added to the active system.(still losing mud)
10,078’- 1.5 ppb MilCarb + 1 ppb Mica+ 1 ppb ChekLoss added to the active system
50 bbl pill consisting of 20 ppb MilCarb + 5 ppb Mica+ 5 ppb ChekLoss (30 ppb Total)
10,450’- Pumped a 35 bbl Pill consisting of 40 ppb Baker Hughes LCM (Lost partial returns)
10,512’- Lost full returns and pumped 80 bbl Baker Hughes Pill consisting of 65 ppb Baker LCM in annulus.
Added 20 ppb of LCM (MilCarb, Mica, ChekLoss and MilSeal to active system) . Operator attempted to back ream from 8,415’-7,720 noticed stuck pipe tendencies.
Treated the active system with 10 ppb Premium Seal Fine®, 5 ppb Turbo-Phalt™ and 10 ppb Premium Seal Regular® while sweeping the hole every 100’ with a 20 bbl sweep consisting of 10 ppb Premium Seal Fine®, 10 ppb Premium Seal Regular® and 5 ppb Turbo-Phalt™
While pumping Turbo-Chem sweeps alone with no Baker Hughes product added, the losses were under control. On September 6th, we were informed that Baker Hughes began adding their product to the sweep regimen’ and returns were lost again. Baker Hughes also cut back the Turbo-Chem sweeps to 20 bbls every 300’ rather than every 100’ of new hole. Gas began showing again soon after. The company man informed TCI that they had POOH for a bit trip and may have knocked the “scab” off the formation that was sealing the loss zone and that a fault covering 400’ may be causing additional losses. While trying to keep gas under control TCI recommended pumping Premium Seal Regular® with SYN-Seal® and the operator was able to increase his mud weight with no losses from 11.9-12.0 ppg without experiencing total losses and keeping the gas under control
Cobalt International : Garden Banks 959 LA Offshore Premium Seal® / SYN-Seal®/
- Well: OCS-G 30876 #1
- Rig: Ensco 8503
- Total Depth: 30,712’
- Problem Interval: 25,000’
- Mud Weight/Type: 14.8-15.8 Synthetic Base Mud
Problem Encountered Operator is expecting losses from +/- 25,000’ till TD.
Prior Application Tiger Bullets, G-Seal, VinSeal M, Calcium Carbonate.
Product Application The active system was treated with 10 ppb SYN-Seal®. Sweeps were built containing 20 ppb SYN-Seal® and 10 ppb Premium Seal Regular®. No other LCM was added.
Results The operator was able to drill to 27,690’ with no losses. At 27,690’ the operator drilled into a shale section and began to notice losses. A 40 bbl pill containing 30 ppb SYN-Seal® was pumped and drilling the pump rate was slowed. Losses were immediately stopped. The operator was now able to drill to 30,712’ with no further losses and identify a liner point. This well was drilled successfully to TD.
Dynamic : Green Canyon LA Offshore Premium Seal® / SYN-Seal®/ EZ Squeeze®
- Well: OCS-G 05889 A-20
- Rig: HP 206
- Total Depth: 7,576’
- Problem Interval: 5,000’-7,000’
- Mud Weight/Type: 10.5-11.5 Synthetic Base Mud
Operator feels that losses are self-induced by the driller not following protocol (not breaking circulation while TIH after 3 days of down time, mud was cold and lost right into the loss zone). Lost 150 bbls and kept drilling ahead. Pumping at full drill rate and losing 10 bbls. / hr. Cut mud weight back to 10.5 from 11.5 ppg.
Baroid sweeps containing Baracarb, BaroFibre and Steel Seal.
The active system was treated with 10 ppb SYN-Seal® and 20 ppb Premium Seal® and adding 6 sacks of EZ Squeeze® per hour. Pumping 10 bbls sweeps every 30’ containing 15 ppb EZ Squeeze®, 15 ppb Premium Seal® and 10 ppb SYN-Seal®.
The operator was able to drill to 7,652’ with no losses and now able to raise mud weight from 10.5 ppg to 11.5 ppg at this depth.
Texakoma: Roberts Cty, TX
EZ Squeeze® & SwelLCM®
- Well: North McMordie 10-1
- Rig: Titan 3
- Total Depth: 4,988’
- Problem Interval: 4,988’
- Mud Weight/Type: 8.7 Oil Base Mud
The operator lost full returns at 4,988’. Rather than waste time pumping more cotton seed hulls, and based on the past successes with SwelLCM and EZ Squeeze®, the operator notified Turbo-Chem of the losses and asked for help in remediating.
The operator was unsuccessful in stopping losses by running 35 ppb cotton seed hulls in sweeps.
The operator mixed and pumped a 50 bbl SwelLCM pill followed by 3 bbls of system mud to flush the rig surface pipe. The operator then pumped a 100 bbl un-weighted EZ Squeeze® pill. The pumps were kicked on and when the entire pill was in place, it was allowed to sit and react downhole. The operator then pumped 5 bbls at a time, waiting 30 minutes in b/w and monitored the pressure. The operator then circulated through the fill line and backside for 2 hours followed by circulation through the bit for 1 hour with total returns.
The resulting squeeze was able to hold 600 psi for 4 hours. The operator was now able to stage back in the hole 5 stands at a time circulation bottoms up each time, eventually making it back to bottom while pumping Turbo-Chem’s Premium Seal Regular® and Turbo-Phalt™ in sweeps without any seepage or mud losses. The operator had made 500’ of new hole with no losses at the time when TCI’s Engineer was released.