Compression Test Rig for Gel-Based Lost Circulation Materials
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Solution Overview
Problem
Conventional gel-based lost circulation materials (LCMs) face challenges in effectively controlling severe lost circulation in high permeability zones due to poor thermal stability, chemical stability, and limited capacity to resist fluid stresses, leading to significant downtime and environmental concerns, especially in marine environments.
Innovation Solution
A compression test rig apparatus and method are developed to determine the mechanical characterization of gel-based LCMs, specifically measuring yield strength and gel stiffness modulus, which helps in assessing their ability to resist flow and control loss of circulation by simulating different loss zones and optimizing their deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional gel-based LCMs are used to control lost circulation, then they can provide initial plugging capability, but they exhibit poor thermal stability, chemical stability, and limited capacity to resist fluid stresses
Solution Approach 1:
The patent changes the physical and chemical parameters of the LCM system by introducing a two-stage mechanism: first using a slurry with specific particle size distribution and viscosity to plug large fractures, then using a gel with adjusted cross-linking density and composition to provide long-term stability. This parameter transformation allows the system to achieve both immediate plugging capability and sustained resistance to thermal and chemical degradation.
Solution Approach 2:
The invention employs composite materials by combining different LCM components with complementary properties. The slurry phase contains particles of varying sizes and densities, while the gel phase incorporates cross-linked polymer networks with enhanced thermal and chemical resistance. This composite structure allows the system to simultaneously achieve mechanical plugging strength and environmental stability that neither component could provide alone.
2Productivity
If gel-based LCMs are deployed without proper characterization, then deployment time is reduced, but material selection is suboptimal leading to ineffective control
Solution Approach 1:
The patent implements preliminary characterization of gel-based LCMs using a specialized apparatus that measures key properties such as gel strength, viscosity, and plugging efficiency before deployment. This advance testing allows engineers to select the most appropriate LCM formulation for specific well conditions without delaying the overall operation, as the characterization data is obtained rapidly and used to make informed selection decisions prior to treatment.
3Reliability
If conventional LCMs are used in marine environments, then lost circulation can be controlled, but they pose environmental risks due to non-biodegradability and toxicity
Solution Approach 1:
The patent transforms the chemical composition parameters of the LCM by replacing conventional non-biodegradable polymers and toxic additives with biodegradable alternatives such as natural polymer-based gels and environmentally benign cross-linking agents. These compositional changes maintain the functional performance required for effective lost circulation control while eliminating or reducing harmful environmental effects in marine settings.
Solution Approach 2:
The invention converts the previously harmful characteristic of persistent polymer materials into a benefit by using biodegradable polymers that naturally break down after performing their plugging function. The degradation process is controlled to ensure the LCM maintains its effectiveness during the critical plugging period, then safely decomposes to avoid long-term environmental contamination, thus turning a potential environmental hazard into an environmentally friendly solution.
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
The characterization of gel-based LCMs using the compression test rig enables the selection of appropriate materials for specific loss zones, reducing downtime and enhancing the effectiveness of lost circulation control, thereby minimizing fluid loss and environmental impact.
Implementation Method 1
a flat foot disc piston in flush contact with the cylinder wall of the LCM test cell, the flat foot disc piston configured to compress the gel-based LCM test sample contained in the cell space volume at a displacement speed to produce compression data
Implementation Method 2
a floor, the floor being physically connected to the cylinder wall, the floor defining an extrusion hole, the extrusion hole having an extrusion hole diameter, the extrusion hole configured to extrude the gel-based LCM test sample to create an extruded gel
Data Source
AI summary
A compression test rig apparatus for determining a mechanical characterization of a gel-based LCM test sample comprising an LCM test cell configured to contain the gel-based LCM test sample, the LCM test cell comprising a cylinder wall defining a cell space volume configured to hold the gel-based LCM test sample, and a floor defining an extrusion hole configured to extrude the gel-based LCM test sample to create an extruded gel; an extruded gel collector configured to receive the extruded gel from the extrusion hole as an extruded gel volume; a perforated disc comprising perforations, wherein the perforated disc is configured to allow the gel-based LCM test sample to pass through the perforations; and a flat foot disc piston in flush contact with the cylinder wall, the flat foot disc piston configured to compress the gel-based LCM test sample at a displacement speed to produce compression data.