Bottom Hole Assembly Fabric Deployment for Lost Circulation

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Solution Overview

Problem

Lost circulation during drilling in subterranean formations poses a significant challenge due to drilling fluids flowing into natural or induced fractures, leading to financial losses and potential well control issues.

Innovation Solution

A bottom hole assembly is used to deploy lost circulation fabric along wellbore walls, utilizing differential pressure to set the fabric and prevent fluid loss, with a compact design that includes a spiral spring release mechanism and actuation systems to minimize formation damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional forces are applied to set the barrier material, then the barrier can be securely placed, but formation damage is more likely to occur

Engineering Contradiction:

Improvebarrier placement reliabilityVSAvoidformation damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention converts the harmful effect of formation pressure into a beneficial force by allowing differential pressure to automatically set the fabric barrier against the formation wall, eliminating the need for additional damaging forces while ensuring reliable barrier placement

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The barrier material self-sets using the natural differential pressure that already exists across the loss zone, requiring no external actuation or additional forces, thereby preventing formation damage while achieving secure barrier placement

Inventive Principle:

Principle #25Self-service

2Device complexity

If a compact bottom hole assembly is used, then the deployment is simpler and more reliable, but the area of fabric that can be deployed is limited

Engineering Contradiction:

Improvebottom hole assembly complexityVSAvoidfabric deployment area

Core Design Contradiction:

Device complexityVSArea of moving object

Solution Approach 1:

The spool assembly is designed to rotate and unwind dynamically as the compact bottom hole assembly moves through the wellbore, enabling continuous deployment of large fabric area from a compact initial configuration without increasing device complexity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The fabric is rolled into compact spools that are nested within the bottom hole assembly, allowing large areas of fabric to be stored in a small volume and deployed progressively as the assembly moves downhole

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If the fabric is deployed using conventional methods, then it can cover the loss zone, but the non-productive time increases due to costly LCMs and complex procedures

Engineering Contradiction:

Improveloss zone sealing effectivenessVSAvoidnon-productive time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention replaces complex mechanical LCM deployment systems with a simpler fabric barrier system that uses differential pressure for automatic setting, eliminating costly LCM materials and reducing non-productive time while maintaining effective loss zone sealing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental parameter of barrier material from particulate LCM to continuous fabric, enabling faster deployment and setting without complex procedures, thereby reducing non-productive time while achieving reliable loss zone sealing

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach effectively mitigates lost circulation in formations with varying porosities and fracture sizes, reducing the need for costly LCMs and minimizing non-productive time, while maintaining well control and reducing the risk of formation damage.

Implementation Method 1

a spring ring comprising a spring disposed around the body, the spring having an inner surface, the spring having a compressed position in which the inner surface of the spring abuts the outer surface of the body and a relaxed position in which the inner surface of the spring is spaced from the outer surface of the body

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The surface roughness of the lost circulation fabric can be enhanced provides sufficient friction for the lost circulation fabric to grasp on the formation and withstand the differential pressure

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 3

During the deployment, differential pressure around the loss zone is utilized to press the lost circulation fabric on the formation

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS11454071B2Deploying material to limit losses of drilling fluid in a wellbore

Publication Date: 2022.09.27 SAUDI ARABIAN OIL CO

AI summary

Bottom hole assemblies for deploying sheets of material in a wellbore include: a body configured for attachment to a drill pipe; a spool ring attached to the body; a spring ring; and rolls of fabric.