Lost Circulation Shape Deployment for Subterranean Sealing

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Solution Overview

Problem

Conventional lost circulation materials are ineffective in sealing cavities with widths larger than 4-6 millimeters in subterranean wells, leading to excessive fluid loss, well control issues, and potential abandonment of wells.

Innovation Solution

The deployment of an optimized combination of lost circulation shapes and materials, determined by geophysical data, which are designed to be neutrally buoyant and trap the material within cavities, forming a plug to seal the formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional lost circulation materials are deployed, then sealing of small cavities (4-6 mm) is effective, but sealing of larger cavities becomes ineffective

Engineering Contradiction:

Improvesealing effectivenessVSAvoidcavity size range

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The lost circulation material is segmented into multiple size fractions, with larger particles (e.g., 8-16 mesh) deployed first to fill large cavities, followed by smaller particles (e.g., 20-40 mesh) to seal smaller cavities. This segmentation allows the material to adapt to different cavity sizes sequentially, resolving the contradiction between effectiveness for small cavities and adaptability to large cavities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The particle size parameter of the lost circulation material is changed dynamically during deployment. The system transitions from deploying larger particles to smaller particles as the treatment progresses, allowing the material to effectively seal cavities across a wide size range from small to large, thereby improving both sealing effectiveness and adaptability.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If larger cavities are treated with conventional materials, then more material is required, but sealing effectiveness decreases

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmaterial volume

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The material is segmented into size fractions that are deployed in a specific sequence. Larger particles fill the bulk volume of large cavities first, reducing the total quantity of fine material needed. Smaller particles then seal the remaining smaller cavities and gaps, achieving effective sealing with optimized material quantity distribution.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Larger particles are deployed as a preliminary action to fill large cavities and create a structural framework before smaller particles are introduced. This preliminary filling action reduces the volume that subsequent smaller particles must traverse, improving sealing effectiveness while reducing overall material consumption.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If conventional lost circulation materials are used, then simple deployment is possible, but excessive fluid loss occurs in large cavities

Engineering Contradiction:

Improvedeployment simplicityVSAvoidfluid loss

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The material system is segmented into multiple size fractions deployed in sequence through the same circulation system. This maintains ease of operation by using standard deployment equipment while the segmented material structure prevents excessive fluid loss by blocking cavities of various sizes more effectively than uniform small particles alone.

Inventive Principle:

Principle #1Segmentation

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 seals larger cavities, reducing fluid loss and maintaining well stability, allowing for continued drilling operations without the need for secondary remedial actions or specialized equipment.

Implementation Method 1

The lost circulation shape is a hollow perforated geometric shape that can fill with wetting fluid and have a generally neutral buoyancy in the drilling fluid. Due to this generally neutral buoyancy the lost circulation shape can move downhole freely with the drilling fluid

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 2

The lost circulation shape can act as a trap for the conventional lost circulation material and allow for accumulation and bridging of the lost circulation material onto the lost circulation shape. This will result in eventual plugging of the formation.

Methodology Applied

Scientific EffectBridging:

Data Source

PatentUS11371301B2Lost circulation shape deployment

Publication Date: 2022.06.28 SAUDI ARABIAN OIL CO

AI summary

Methods and systems for sealing a lost circulation zone associated with a subterranean include determining geophysical data of the lost circulation zone. An available range of lost circulation shape data and an available range of lost circulation material data is provided. The geophysical data, the available range of lost circulation shape data, and the available range of lost circulation material data are part of a fixed data set. An initial lost circulation mix is determined from the fixed data set. An initial drill string downhole flow rate and an initial annulus uphole flow rate are determined and an initial loss volume is calculated. The initial lost circulation mix is delivered into the subterranean well. A revised drill string downhole flow rate and a revised annulus uphole flow rate are determined and a revised loss volume is calculated.