Lost Circulation Fabric for Wellbore Fluid Loss Control

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Solution Overview

Problem

Lost circulation during drilling operations leads to significant non-productive time and increased costs due to the seepage of drilling fluid into highly permeable, fractured, and porous formations, causing potential drilling hazards like kick, blowout, and borehole collapse.

Innovation Solution

A lost circulation fabric (LCF) system comprising a sheet of a first lost circulation material and particles of a second lost circulation material is deployed in the wellbore to reduce fluid loss, where the LCF is applied to cover fractures and high porosity areas, and a slurry of particles is circulated to form a filter cake that impedes fluid leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If drilling fluid is circulated through highly permeable, fractured, or porous formations, then drilling operations can proceed, but significant fluid loss occurs into the formation

Engineering Contradiction:

Improvedrilling operation continuityVSAvoiddrilling fluid loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The wellbore is divided into lost circulation zones and non-lost circulation zones. The fabric is deployed selectively only in the lost circulation zones, allowing drilling to continue in other areas while preventing fluid loss in specific problematic sections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A lost circulation fabric acts as an intermediary barrier between the wellbore and the formation. This fabric intercepts drilling fluid before it can enter the formation, preventing fluid loss while allowing the drilling operation to continue.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If drilling fluid pressure is increased to maintain well control, then well control and borehole stability are improved, but fluid loss into fractures and porous formations increases

Engineering Contradiction:

Improvewell control and borehole stabilityVSAvoiddrilling fluid loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The lost circulation fabric serves as a mediator that allows high pressure to be applied for well control and borehole stability while preventing the pressure-driven fluid loss into fractures and porous formations. The fabric blocks the flow path before fluid can enter the formation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fabric is deployed in advance in lost circulation zones to prevent fluid loss before it occurs. This preliminary action allows drilling fluid pressure to be increased for well control without the subsequent harmful effect of fluid loss into the formation.

Inventive Principle:

Principle #9Preliminary anti-action

3Loss of substance

If conventional lost circulation materials are used, then some fluid loss can be prevented, but severe fluid loss continues and drilling time is lost

Engineering Contradiction:

Improvedrilling fluid loss reductionVSAvoiddrilling time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The wellbore is segmented into lost circulation zones and non-lost circulation zones. The fabric is deployed selectively only in the lost circulation zones, allowing drilling to continue in other areas while preventing fluid loss in specific problematic sections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #24Intermediary (Mediator)

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 LCF system effectively reduces or stops fluid loss in severe circulation zones, maintaining well control and preventing catastrophic events by forming a bridging structure that traps particles and limits fluid flow, as demonstrated by laboratory tests showing reduced fluid loss when using the LCF in combination with a lost circulation slurry.

Implementation Method 1

Methodology Applied

Scientific EffectPhysical barrier filtration: Filter (physical)

Implementation Method 2

a slurry of particles is circulated to form a filter cake that impedes fluid leakage

Methodology Applied

Scientific EffectFilter cake formation: Deposition (physical)

Data Source

PatentUS11434708B2Lost circulation fabric, method, and deployment systems

Publication Date: 2022.09.06 SAUDI ARABIAN OIL CO

AI summary

A lost circulation system and a method for reducing losses of drilling fluid in a lost circulation zone of a wellbore are described. The lost circulation system includes a sheet of lost circulation material and particles of a lost circulation material. The sheet of lost circulation material has a maximum thickness of 1 millimeter, a length of one foot to one thousand feet, and a width of one inch to twenty inches. The method for reducing losses of drilling fluid in a lost circulation zone of a wellbore includes identifying the lost circulation zone, deploying a sheet of a first lost circulation material in the wellbore at the lost circulation zone, and circulating a slurry containing particles of the lost circulation material through the wellbore.