Foam Rubber Filtration Bridge for Subterranean Fracture Sealing
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Solution Overview
Problem
Existing methods for sealing fractures, voids, and pores in subterranean formations during drilling operations are unreliable due to varying downhole conditions, leading to lost circulation problems and fluid leakage.
Innovation Solution
A composition comprising a filtration material with interconnected foam rubber elements and a carrying fluid, which forms a filtration bridge to restrict fluid flow and allows solid material to accumulate and block the openings, creating a reliable seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fibrous, pelleted, or particulate lost circulation materials are used to seal fractures and voids, then the sealing process is simple, but the seal reliability is poor due to varying downhole conditions
Solution Approach 1:
The patent uses a composite sealing composition comprising multiple components: a carrying fluid, filtration material (such as foam rubber or sponge), and solid material (such as cement or barite). This composite structure allows each component to perform its specific function - the carrying fluid transports the materials, the filtration material forms a filter bridge that controls fluid flow, and the solid material accumulates to create the final seal. This multi-component composite approach significantly improves seal reliability compared to single-material systems.
Solution Approach 2:
The patent employs porous filtration material with interconnected cells that allow fluid flow through the material while trapping solid particles. The porous structure enables the filtration material to form a filter bridge that controls fluid flow paths, allowing the solid material to accumulate in controlled manner and form a reliable seal. The porosity is crucial for both fluid flow control and solid particle accumulation.
2Strength
If the filtration material is made larger to build a thick seal inside larger voids, then the sealing strength increases, but the material cannot be delivered through piping and bit nozzles
Solution Approach 1:
The filtration material is segmented into small individual elements or cells that can be transported through piping and bit nozzles. These small segments accumulate inside the voids and fractures to form a thick seal. The segmentation allows the material to be delivered in a manageable form while still achieving the required seal thickness and strength once accumulated in the target zone.
Solution Approach 2:
The filtration material is designed to be dynamic in nature - it can compress and expand to conform to the shape of the voids and fractures. This dynamic behavior allows the material to adapt to varying downhole conditions and maintain an effective seal. The material can be compressed during delivery and then expand once inside the voids to achieve the required seal thickness.
3Ease of operation
If the filtration material is made flexible to deliver through bit nozzles, then the deliverability improves, but the material may not form a thick enough seal in larger voids
Solution Approach 1:
The filtration material is designed with dynamic properties that allow it to compress during delivery through bit nozzles and then expand once inside the voids. This dynamic behavior enables the material to be delivered in a compact form while still achieving the required seal thickness. The material can change its volume state based on the environmental conditions.
Solution Approach 2:
The filtration material is segmented into small elements that can be delivered through bit nozzles and then accumulate to form a thick seal. The segmentation allows the material to be delivered in a manageable form while still achieving the required seal thickness once accumulated in the target zone.
4Reliability
If solid material is used to block fluid flow paths directly, then the sealing is effective, but the material cannot be delivered through the same piping system
Solution Approach 1:
The carrying fluid acts as an intermediary that transports both the filtration material and solid material through the piping system. The carrying fluid allows the solid material to be delivered to the wellbore without direct contact with the piping, preventing clogging. Once inside the voids, the carrying fluid allows the solid material to accumulate and form the seal while maintaining deliverability through the existing piping system.
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 solution effectively reduces fluid loss by forming a strong, thick seal within subterranean openings, even in varying conditions, ensuring efficient circulation and preventing lost circulation zones during drilling operations.
Implementation Method 1
The multitude of foam rubber elements may be elastic to compress and expand to thereby conform to any subterranean openings
Implementation Method 2
The foam rubber elements may comprise a plurality of cells that permit fluid flow therethrough and define the plurality of fluid flow paths through the filtration material
Data Source
AI summary
A region of a borehole with one or more openings to be sealed off, such as one or more fractures, voids, and or pores, may or may not be sealed off around a tubular string with a borehole seal such as a packer or plug. A carrying fluid may be utilized to transport a filtration material into the opening to create a bridge, which at least partially seals the opening, but still provides a flow path that permits fluid flow therethrough. A solid material and/or settable material may then utilize the fluid flow subsequently or be simultaneously spotted with or behind the filtration material to thereby form compositions which effectively seals off the flow path into the one or more openings.