BJ PolyFX: Lost Circulation Sealant Guide
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Aquiles CarreraBJ PolyFX: Lost Circulation Sealant Guide
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Aquiles CarreraCommon questions
Powered by AIBJ PolyFX is designed to provide a permanent seal in environments with a pH above 8. However, if it comes into contact with low pH fluids, such as 15% HCl, the seal will break. This pH sensitivity allows the gelatinous mass to provide effective sealing while minimizing the risk of formation damage, as it will dissolve when exposed to acidic conditions, allowing for the continuation of other well operations without obstruction .
BJ PolyFX interacts with hydrochloric acid by breaking down when contacted by low pH solutions like 15% HCl. This interaction is intentionally designed so that the PolyFX seal can dissolve if exposed to acidic environments, which is crucial for avoiding permanent blockages in the wellbore post-treatment. This property allows BJ PolyFX to be used confidently in various drilling environments where post-application acid treatments may be required to stimulate the well or address other formation issues .
Determining the exact location of losses and the appropriate injection rate are critical factors in the BJ PolyFX treatment as they inform the strategic placement and effectiveness of the sealant. Accurate identification of the loss location allows for precise delivery of PolyFX in the affected interval, maximizing the sealing effect. Similarly, establishing the correct injection rate ensures that the sealant is applied under optimal conditions, mitigating risk of inadequate coverage or excessive pressure that could compromise well integrity or the seal's durability .
In cases of severe losses during BJ PolyFX application, procedural adjustments are essential. Pumping down the annulus is not advised if significant backflow is expected, but the annulus should be shut to prevent polymer escape. Additionally, monitoring pressure closely and adjusting pump rates accordingly—such as reducing the rate to prevent pressure spikes—ensures that the polymer stays localized to the loss zone. Maintaining a squeeze pressure of 100 psi for 30 minutes can help stabilize the seal. If losses persist, evaluating the rate and considering a second treatment may be necessary .
Optimizing the application of BJ PolyFX involves integrating multiple factors into its system design, including wellbore architecture, type, location, and rate of losses, fluid dynamics, BHA, and bottom-hole pressure. By appropriately assessing these factors, the system design can be customized to meet the unique demands of each lost circulation scenario, thereby enhancing the potential success of the treatment. The coupling of setting characteristics with the proper placement procedure ensures that the seal is both effective and durable, minimizing the risk of future fluid losses .
The appropriate volume of BJ PolyFX for a lost circulation scenario is determined by considering the loss rate, the capacity of the hole, and the length of the interval to be sealed. The volume is calculated as three times the capacity of the hole across the loss interval plus five percent of the losses in barrels per hour. For instance, for an 8.5" hole with a 50' loss interval and 300 bph losses, the calculation is [(0.0702 bbl/ft x 50') x 3] + [300 bph x 0.05], resulting in 25.5 barrels necessary to address the situation .
Pressure monitoring is vital during the BJ PolyFX application to ensure the stability and effectiveness of the seal being applied. It is important to monitor pressures, particularly those less than 1000 psi, on the annulus as the polymer pill is pumped. If the annular pressure begins to increase, the pump rate should be halved while continuing to clear the work string of the polymer pill. This careful control helps manage pressure variances and ensures that the polymer remains within the target zone without unintended migration .
The pre-flush and post-flush operations are critical for optimizing BJ PolyFX application. The pre-flush involves introducing a blend of catalyst (XLW-60) and surfactant (NE-118) in fresh water to the system, which prepares the zone for effective sealing by the polymer. Post-flush serves to ensure further spread and activation. By adjusting these operations, specifically adding catalyst and surfactant directly to the polymer suspension, the process can be simplified and directly activated by water-based drilling fluids, potentially increasing the efficacy of the seal in certain conditions .
BJ PolyFX contains hydratable polymers and, when contacted by water or water-based drilling fluids, forms a gelatinous mass. This reaction occurs instantaneously and continues to form a rigid gel within 1-3 minutes of mixing, helping to seal losses within natural or induced fractures. The reaction speed depends on the concentration of the catalyst leached during the mixing process. This mechanism helps PolyFX create a permanent seal in fluid environments with pH above 8, addressing lost circulation zones effectively .
The mixing procedure for BJ PolyFX involves several critical steps to ensure successful deployment. Mixing should be performed in a cement batch mixer or rig-slugging pit, which must be inspected and cleaned to ensure proper agitation. During mixing, water contact with PolyFX must be avoided by purging lines with diesel or hydrocarbon-based fluids. Slowly mix 171.4 pounds of polymer blend per barrel of diesel, ensuring to add OB-1 for dispersion and limit bridging material to 10-20 lbs/bbl if OB-1 is not available. It is important to prevent water from contacting the polymer suspension prior to its placement in the loss zone .