Deformable Lost Circulation Material Plug for Wellbore Sealing
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Solution Overview
Problem
Lost circulation in subterranean formations during oil or gas well drilling, where drilling fluid flows into the formation instead of returning to the surface, poses risks including loss of drilling fluid and potential blowouts, necessitating effective remediation methods.
Innovation Solution
A deformable lost circulation material (LCM) system where a first solid LCM is charged with a specific electrical charge and flowed into a wellbore, followed by a second oppositely charged LCM, which accumulates to form a plug. A plasticizer is then introduced to make the plug malleable and adhesive, sealing the loss zone by flowing through the wellbore to further secure the seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solid LCM is used to seal the loss zone, then the plug structure is formed, but the plug cannot conform to irregular fracture surfaces and propagating cracks
Solution Approach 1:
The LCM is designed to transition from a rigid solid state during transport to a deformable state at the loss zone through chemical activation. The solid LCM particles are initially rigid for easy handling and transport, then upon contact with drilling fluid or chemical agents, they soften and become moldable to conform to irregular fracture surfaces and propagating cracks, finally hardening to form a permanent seal.
Solution Approach 2:
The invention changes the physical parameters of the LCM by controlling its temperature and chemical state. The LCM is heated or chemically treated to become deformable and adhesive, allowing it to conform to the loss zone geometry. After sealing, it cools or undergoes further chemical transformation to become rigid and permanent, thus adapting its properties to different stages of the sealing process.
2Quantity of substance
If LCM is transported through the wellbore, then the material reaches the loss zone, but premature accumulation occurs before reaching the target area
Solution Approach 1:
The LCM is prepared in advance with specific properties that prevent premature accumulation during transport. The material is kept in a stable, non-adhesive state during wellbore traversal, then activated at the loss zone to become adhesive and accumulate only at the target location, ensuring precise placement.
Solution Approach 2:
The invention uses an intermediary mechanism such as a chemical coating or surface treatment on the LCM particles that prevents premature adhesion during transport. This intermediary layer is removed or activated at the loss zone, allowing the LCM to accumulate only at the desired location.
3Strength
If the LCM plug is made rigid for structural stability, then the plug maintains its shape, but it cannot adapt to irregular fracture surfaces
Solution Approach 1:
The LCM exhibits dynamic mechanical properties, transitioning from a rigid state during transport to a deformable state at the loss zone. The material softens upon contact with drilling fluid or chemical agents, allowing it to flow and conform to irregular fracture surfaces, then hardens to form a structurally stable permanent plug.
Solution Approach 2:
The LCM behaves like a flexible material during the sealing process, allowing it to mold around irregular fracture surfaces and propagating cracks. After conforming to the geometry, it transforms into a rigid structure that maintains its shape and provides long-term structural stability for the seal.
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 system effectively remedies lost circulation by forming a form-fitting plug that conforms to the loss zone, preventing fluid flow from the wellbore into the subterranean formation, even in cases of inaccurately estimated porosity and permeability or propagating fractures, thereby ensuring safe drilling operations.
Implementation Method 1
The plasticizer causes the charged second solid lost circulation material to become deformable and adhesive in response to contacting the charged second solid lost circulation material
Implementation Method 2
A second solid lost circulation material is charged with a second electrical charge that is opposite the first electrical charge. The charged second solid lost circulation material is allowed to come in contact with and accumulate onto the charged first solid lost circulation material
Data Source
AI summary
A solid lost circulation material is flowed into a wellbore formed in a subterranean formation to a loss zone. After flowing the solid lost circulation material into the wellbore, a plasticizer is flowed into the wellbore to the loss zone. The plasticizer is allowed to come in contact with the solid lost circulation material at the loss zone. The plasticizer causes the solid lost circulation material to become deformable and adhesive in response to contacting the solid lost circulation material. The solid lost circulation material contacted by the plasticizer forms a malleable plug that seals the loss zone. After malleable plug seals the loss zone, a fluid is circulated through the wellbore to further seal the plug against the loss zone to block fluid flow from the wellbore into the loss zone.