Lost Circulation Fabric Deployment in Wellbores

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Solution Overview

Problem

Lost circulation during drilling in subterranean formations poses significant challenges due to drilling fluids flowing into natural or induced fractures, leading to financial losses and potential well control issues.

Innovation Solution

A bottom hole assembly is used to deploy lost circulation fabric along wellbore walls in loss zones, utilizing differential pressure to set the fabric and prevent fluid loss, with a compact design that includes a spiral spring release mechanism and actuation systems to ensure effective sealing without formation damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional forces are applied to set the barrier in the loss zone, then the barrier can be securely positioned, but formation damage may occur

Engineering Contradiction:

Improvebarrier positioning reliabilityVSAvoidformation damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of differential pressure (which normally causes fluid loss into the formation) into a beneficial force that sets the barrier. The differential pressure across the loss zone naturally presses the flexible barrier against the wellbore wall, securing it without requiring additional mechanical forces that could damage the formation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The barrier sets itself utilizing the existing differential pressure conditions in the wellbore. The system requires no external actuation or additional forcing mechanisms - the natural pressure difference between the wellbore and formation automatically positions and secures the barrier against the wellbore wall in the loss zone.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If a compact bottom hole assembly is used to deploy fabric, then the assembly is easier to operate and handle, but deploying a large area of fabric becomes more challenging

Engineering Contradiction:

Improvebottom hole assembly handlingVSAvoidfabric deployment area

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The patent transitions from deploying fabric in a single dimension (linear extrusion) to deploying it in multiple dimensions. The flexible barrier expands radially outward from the bottom hole assembly in the radial dimension while also extending axially, creating a two-dimensional deployment pattern that covers a large surface area on the wellbore wall despite the compact size of the deploying assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent uses a flexible barrier that can be stored in a compact, rolled, or folded configuration within the small bottom hole assembly. Once deployed, the flexible material expands and conforms to the wellbore wall, utilizing its flexibility to cover a large area while maintaining a compact storage form factor during handling and transportation.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If traditional mechanical methods are used to seal loss zones, then sealing can be achieved, but the process becomes complex and risky

Engineering Contradiction:

Improvesealing effectivenessVSAvoidsealing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical sealing systems (such as expandable packers, mechanical bridges, or cementing operations) with a simpler flexible barrier that is set by differential pressure. This substitution eliminates the need for complex mechanical actuation systems, multiple deployment steps, and extensive operational procedures, thereby reducing both device complexity and operational risk while maintaining sealing effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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

This approach effectively mitigates lost circulation in formations with varying porosities and large fracture sizes, reducing non-productive time and material costs, while avoiding the complexities and risks associated with traditional mechanical methods.

Implementation Method 1

During the deployment, differential pressure around the loss zone is utilized to press the lost circulation fabric on the formation

Methodology Applied

Scientific EffectDifferential pressure: Pressure Gradient

Implementation Method 2

The surface roughness of the lost circulation fabric can be enhanced provides sufficient friction for the lost circulation fabric to grasp on the formation and withstand the differential pressure

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11286733B2Deploying material to limit losses of drilling fluid in a wellbore

Publication Date: 2022.03.29 SAUDI ARABIAN OIL CO

AI summary

Bottom hole assemblies for deploying fabric can include: a body configured to be attached to a drill pipe; a control tube disposed inside the body at a position controlled by engagement of a cam with a continuous guide path; a set tube, the set tube and the body together defining a pressure chamber with the body defining an inlet port extending between the interior cavity and pressure chamber, the set tube movable between a rolling position and a reaming position; a reamer assembly with at least one first articulated arm with extending between first attachment point on the body and the set tube; and a roller assembly with: at least one second articulated arm extending between the set tube and a second attachment point on the body; and a roller positioned at a joint of each second articulated arm.