Case study
Early detection of salt creep prevents stuck pipe and minimizes NPT
Published: April 3, 2025
Location: Gulf of Mexico, Mexico
Products used: Exebenus Spotter, Stuck Pipe Agent, Vibration Agent
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Exebenus Spotter’s real-time monitoring and ML-driven diagnostics warned the operator of salt creep and mechanical sticking in a zone between 4,300 and 4,503 meters. For more than 16 hours, the solution provided an objective assessment of deteriorating hole conditions, allowing timely intervention before the stuck pipe risk became critical.
By delivering predictive insights, Exebenus Spotter distinguished between stick-slip and true mechanical sticking. This proactive approach not only prevented a stuck pipe incident but also optimized operational decision-making, reduced nonproductive time (NPT), and reinforced the value of continuous wellbore monitoring in challenging formations.
Summary of case study for a quick browse:
Challenge
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Risk of stuck pipe due to wellbore instability caused by salt creep or the presence of salt stringers in the formation.
Objective
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The monitoring team deployed the Exebenus Spotter Stuck Pipe Agent and Vibration Agent to detect early warnings and provide timely alarms, enabling proactive measures to prevent stuck pipe.
Results
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Early warnings from the Stuck Pipe Agent, supported by the Vibration Agent, indicated that salt creep was gradually increasing the risk of stuck pipe. Based on this insight, the rig team executed a wiper trip, successfully preventing stuck pipe and reducing NPT.
Challenge
Addressing wellbore instability due to salt fingers in the formation
The operator anticipated a high risk of stuck pipe in an exploration well due to salt creep, which causes wellbore instability. As the salt moves into the wellbore, the hole diameter is reduced, causing pack-off and increasing static friction. Additionally, as evidenced by the Vibration Agent, the salt prevents free rotation of the pipe, also off-bottom. This leads to an increased risk of stalling pipe, further compromising well integrity and drilling efficiency.
Objective
Deploying Exebenus Spotter for early detection and proactive intervention
To mitigate these risks, the operator’s monitoring team deployed the Exebenus Spotter Stuck Pipe Agent to identify stuck pipe risks from fluid friction, ECD anomalies, and excessive static and dynamic drag using predictive machine learning. Rapid transitions between salt and other rock formations can cause significant torque fluctuations, increasing the risk of mechanical sticking.
While operating off-bottom, the Vibration Agent detected a risk of stick-slip. This indicated that the torque oscillations were caused by salt clinging to the BHA/pipe, rather than stick-slip during drilling. The Vibration Agent reinforced the stuck pipe warnings, confirming that the high torque oscillations were due to salt accumulation and highlighting the high risk of pipe stalling.
Results
Early detection and timely response prevent costly downtime
More than 16 hours before the decision to perform a wiper trip, the Hole Cleaning Agent detected early pack-off risks, while the Mechanical Sticking Agent and Vibration Agent indicated an increasing risk of stalling—both signaling deteriorating well conditions and a tightening hole. The Exebenus Spotter system identified the stuck pipe risk as being caused by salt fingers higher up in the well than initially anticipated—an interpretation later confirmed by the mudlogger.
With these early warnings, the rig team had time to validate the situation and take mitigating actions. They executed a wiper trip, pulling back 500 meters from TD, which successfully reopened the hole and prevented the casing from getting stuck—avoiding costly downtime.
This case highlights the critical value of Exebenus Spotter’s real-time insights in preventing operational disruptions.
While drilling the 28-degree 10 5/8” x 12 1/4” section, the Stuck Pipe Agent triggered multiple torque (A) and fluid friction alerts (B), while the Vibration Agent detected significant stick-slip (C) conditions during reaming off-bottom. These warnings occurred above a salt layer expected at approximately 4500 meter, suggesting salt fingers creeping into the formation—a ‘dirty formation’ scenario. In response, the operator performed a wiper trip from 4473 meter back to 4000 meter to reopen the wellbore. This preventive action (D) successfully mitigated the risk of a stuck pipe incident.
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The Exebenus Spotter agents provided an objective assessment of deteriorating hole conditions for over 16 hours, enabling intervention before risks reached an unacceptable level.