Lost Circulation Fabric Deployment in Drilling BHA
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Solution Overview
Problem
Lost circulation during drilling in subterranean formations poses significant challenges due to drilling fluids flowing into fractures, leading to financial losses and potential well control issues.
Innovation Solution
A bottom hole assembly deploys lost circulation fabric along wellbore walls using differential pressure to prevent fluid loss, featuring a compact design with a spiral spring release mechanism and actuation systems to securely anchor the fabric without additional forces on the formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional forces are applied to set the barrier on the formation, then the barrier can be securely anchored, but formation damage may occur
Solution Approach 1:
The lost circulation fabric utilizes the existing differential pressure between the wellbore and formation to set itself against the formation wall, eliminating the need for additional external forces. The fabric's own operational conditions (differential pressure) become the setting mechanism, achieving secure anchoring without harmful additional forces on the formation.
Solution Approach 2:
The differential pressure that causes drilling fluid loss into the formation is converted into a beneficial force that presses the lost circulation fabric against the formation wall. The same pressure gradient that creates the problem (fluid loss) becomes the solution mechanism for securing the barrier.
2Volume of moving object
If a compact bottom hole assembly is used to deploy large area of fabric, then the device size is reduced, but the deployment complexity increases
Solution Approach 1:
The lost circulation fabric is rolled or compressed onto a spool assembly within the bottom hole assembly, allowing a large area of fabric to be stored in a compact form. The fabric is nested within the BHA structure, enabling compact deployment while maintaining large coverage area capability.
Solution Approach 2:
The bottom hole assembly incorporates movable and deployable components including articulated arms that can extend and retract, and a spool assembly that can unwind and redeploy the fabric. This dynamic design allows the compact BHA to expand its functional capability during deployment operations.
3Reliability
If large-grain LCM is used to seal fractures, then the loss zone can be plugged, but the formation may be damaged
Solution Approach 1:
The invention uses a flexible lost circulation fabric (thin film) instead of large-grain LCM to seal the loss zone. The fabric conforms to the formation wall and fracture surfaces, providing an effective seal without the mechanical damage that would result from forcing large particles into the formation.
Solution Approach 2:
The lost circulation fabric appears to be a composite material structure that combines filtration capability with mechanical strength, allowing it to seal fractures effectively while remaining flexible and non-damaging to the formation. The fabric's composite nature enables it to function as both a seal and a protective barrier.
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 various porosities and fracture sizes, reducing formation damage and operational costs by avoiding the use of large-grain LCM and complex expandable tubular systems.
Implementation Method 1
This approach uses differential pressure around the loss zone to set the lost circulation fabric, reducing the likelihood of formation damage by avoiding the use of additional forces on and interactions with the formation.
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.
Implementation Method 3
This invention represents a new approach of combating the severe lost circulation using lost circulation fabric with a compact bottom hole assembly and a reliable spiral spring release mechanism.
Data Source
AI summary
Bottom hole assemblies with a combined roller-underreamer assembly can include: a body configured to be attached to a drill pipe; an uphole ring attached to the body; a downhole ring attached to the body between the uphole ring and the downhole end of the body; a sliding ring mounted around the body between the uphole ring and the downhole ring; a set tube slidably mounted around the body between the uphole ring and the sliding ring; a reamer assembly with at least one first articulated arm with extending between the uphole ring and the downhole end of the set tube; and a roller assembly with: at least one second articulated arm extending between the uphole end of the set tube and the sliding ring; and a rolling positioned at a joint of each second articulated arm.