Interlocking Particulates for Subterranean Fluid Loss Sealing
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Solution Overview
Problem
Traditional fluid loss control materials (FLCMs) often fail to effectively seal fluid loss zones in subterranean formations due to insufficient contact and stress resistance, leading to fluid loss and operational challenges in hydrocarbon well operations.
Innovation Solution
The use of interlocking notched and protruding particulates with specific shapes and perimeter values that form an interlocking network, providing enhanced contact stresses and sealing capabilities to prevent fluid loss, with the interlocking network exhibiting contact stresses between components in the range of 5 MPa to 5000 MPa.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional spherical FLCMs are used, then the treatment fluid can be pumped into the wellbore, but the FLCMs form insufficient contact among one another to withstand stresses within the subterranean formation
Solution Approach 1:
The FLCM is divided into multiple interlocking components (protruding particulates and notched particulates) that assemble to form a structured network, providing both mechanical strength and pumpability
Solution Approach 2:
The FLCM uses asymmetric shapes with complementary protrusions and notches instead of symmetric spherical shapes, enabling interlocking contact that resists formation stresses while maintaining pumpability
2Reliability
If traditional FLCMs are used, then they can be introduced into the wellbore, but they fail to interact with one another to sufficiently prevent treatment fluids from leaking-off into a formation
Solution Approach 1:
The complementary asymmetric shapes of protruding and notched particulates create interlocking contacts that reliably prevent fluid leakage, with the complexity built into the geometric design rather than requiring complex assembly procedures
Solution Approach 2:
Multiple interlocking components merge to form a unified interlocking network that provides enhanced sealing effectiveness, combining the functions of multiple particulates into a coordinated sealing system
3Loss of substance
If traditional FLCMs are used, then they can be placed in the formation, but the presence of interstitial spaces between aggregated individual FLCMs results in a widening of the interstitial spaces as fluid flows through, thereby compounding the fluid loss problem
Solution Approach 1:
The asymmetric interlocking shapes eliminate interstitial spaces by creating complementary contacts between particulates, preventing fluid bypass and space widening while maintaining stable contact under flow conditions
Solution Approach 2:
The interlocking components maintain curved surfaces that conform to one another, creating tight seals that prevent fluid loss while distributing stresses evenly across the contact surfaces
Data Source
AI summary
The present invention provides for methods of treating a fluid loss zone in a wellbore in a subterranean formation including providing interlocking notched particulates having an outer face comprising at least one notch therethrough; wherein the at least one notch has a shape and an inner perimeter value; providing interlocking protruding particulates having an outer perimeter portion that protrudes in an approximate equivalent to the shape and value of the inner perimeter of the at least one notch; introducing the interlocking protruding particulates and the interlocking notched particulates into the wellbore in the subterranean formation; interlocking the interlocking protruding particulates and the interlocking notched particulates through the at least one notch to form an interlocking network of at least one interlocking protruding particulate and at least one interlocking notched particulate; sealing at least a portion of the fluid loss zone.