Hook and Latch Sphere Lost Circulation Material
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Solution Overview
Problem
Existing lost circulation materials (LCMs) lack optimal shapes and mechanical properties to effectively form bridges or plugs in fractures and openings, leading to inadequate sealing and potential premature swelling, which can cause plugging of drilling equipment or failure to seal lost circulation zones.
Innovation Solution
The development of a lost circulation material comprising spheres with radially distributed hooks and latches that interlock to form structures, allowing for improved plug formation and accumulation of additional LCMs for enhanced sealing without relying on swelling, using a carrier fluid to introduce these spheres into the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If naturally-occurring or shaped materials are used as LCM, then the material is readily available and easy to manufacture, but the LCM lacks optimal shapes for forming bridges or plugs in fractures and channels
Solution Approach 1:
The LCM is segmented into multiple spherical particles, each equipped with hooks and latches that can interlock with adjacent spheres. This segmentation allows each sphere to be individually manufactured with consistent geometry while the collective assembly forms complex bridge and plug structures in fractures and channels.
Solution Approach 2:
The LCM uses spherical particles instead of irregular naturally-occurring shapes. The spherical geometry provides uniform flow characteristics and predictable packing behavior, while the radially distributed hooks and latches on each sphere enable reliable interlocking to form stable bridges and plugs in lost circulation zones.
2Ease of manufacture
If naturally-occurring or shaped materials are used as LCM, then the material is easy to obtain, but the LCM suffers from insufficient mechanical strength, chemical resistance, thermal stability, and biological degradation
Solution Approach 1:
The LCM employs composite spherical particles combining a robust base material with attached hook and latch components. This composite structure provides superior mechanical strength, chemical resistance, and thermal stability compared to natural materials, while the modular design allows for optimized material selection to resist biological degradation.
3Reliability
If swellable LCM is used, then the LCM can expand to seal fractures, but there is a risk of premature swelling which could plug a bottom hole assembly or drill pipe
Solution Approach 1:
The harmful swelling property is extracted from the LCM design. Instead of using swellable materials that risk premature expansion, the invention employs non-swelling spherical particles with mechanical interlocking features. The sealing function is achieved through the hooks and latches that physically block fracture pathways rather than through volumetric expansion.
4Reliability
If swellable LCM is used, then the LCM can expand to block lost circulation zones, but there is a risk of late swelling such that the LCM is swept away before use
Solution Approach 1:
The LCM spheres are pre-positioned in the drilling fluid and ready for immediate deployment. The hooks and latches are pre-configured for interlocking, eliminating the time delay associated with swelling activation. When the spheres reach the lost circulation zone, they immediately engage with formation features or adjacent spheres to form seals, preventing being swept away by continued fluid flow.
5Device complexity
If traditional LCM shapes are used, then the material is simple in design, but the LCM cannot effectively form bridges or plugs to achieve desired lost circulation performance
Solution Approach 1:
The LCM is divided into modular spherical units with standardized hooks and latches. This segmentation maintains manufacturing simplicity while enabling the spheres to self-assemble into effective bridge and plug structures through mechanical interlocking, significantly improving lost circulation control performance.
Solution Approach 2:
The spherical LCM with hooks and latches serves multiple functions: it blocks fracture pathways, forms bridges across channels, accumulates to create seals, and maintains structural integrity under downhole conditions. This multi-functionality achieves superior lost circulation performance without proportionally increasing design complexity.
Data Source
AI summary
A lost circulation material (LCM) that includes spheres having radially distributed hooks and latches to facilitate engagement (such as interlocking) of the spheres is provided. Each sphere has a plurality of hooks and a plurality of latches to engage latches and hooks respectively of adjacent spheres. Each hook may include two hook arms, and each latch may define an aperture to receive a hook arm. The spheres may form plugs in channels, fractures, and other openings in a lost circulation zone. Additionally or alternatively, the spheres may form a bridge on which other LCMs may accumulate to seal openings in a lost circulation zone. Methods of preventing lost circulation using the spheres are also provided.