Sequential Reactive Pills and Thixotropic Cement for Lost Circulation

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Solution Overview

Problem

The balanced plug method for addressing lost circulation in subterranean formations is limited by precise placement requirements, potential misplacement leading to ineffective sealing, and materials that may degrade over time, failing to provide a long-term solution.

Innovation Solution

A method involving a series of viscous, reactive pills comprising calcium chloride and sodium silicate solutions followed by progressively thixotropic cements is used to treat lost circulation zones, forming a robust seal by introducing multiple cement slurries with increasing setting properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the balanced plug method is used to address lost circulation, then fluid loss is reduced by creating pressure balance, but the method requires precise placement and formulation which increases operational complexity and time

Engineering Contradiction:
Improvesealing effectivenessVSAvoidplacement precision requirements
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The treatment is divided into multiple sequential stages: first placing a balanced plug to establish pressure control, then sequentially placing additional plugs with increasing thixotropy. Each plug serves a specific function in the sequence, breaking down the complex task into manageable segments that build upon each other to achieve complete sealing.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The balanced plug is placed first to establish pressure balance and control fluid loss before subsequent plugs are placed. This preliminary action creates a stable foundation that enables successful placement of additional materials and ensures the wellbore is stabilized before further treatment steps.

Inventive Principle:
Principle #10Preliminary action

2Reliability

If the balanced plug method is used, then immediate fluid loss control is achieved, but the sealing materials may degrade over time reducing long-term reliability

Engineering Contradiction:
Improveimmediate sealingVSAvoidlong-term seal durability
Core Design Contradiction:
ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The thixotropy parameter of the cement plugs is progressively increased from the first plug to subsequent plugs. Each plug has higher thixotropy than the previous one, creating a gradient of gel strength that ensures long-term durability. The final plugs provide robust, permanent sealing that compensates for potential degradation of earlier materials.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The treatment uses a composite approach combining multiple cement-based materials with different properties. Each plug contains cement slurry with specific thixotropic agents and additives tailored to its functional role, creating a composite system where materials work together to provide both immediate control and long-term sealing durability.

Inventive Principle:
Principle #40Composite materials

3Duration of action of stationary object

If multiple cement plugs with increasing thixotropy are placed sequentially, then long-term sealing durability is improved, but the process time and operational complexity increase

Engineering Contradiction:
Improveseal durabilityVSAvoidtreatment process time
Core Design Contradiction:
Duration of action of stationary objectVSLoss of time

Solution Approach 1:

The treatment maintains continuous useful action by keeping the wellbore filled with drilling fluid throughout the process, preventing collapse and maintaining pressure control. Each plug is placed and allowed to set continuously without interrupting the overall treatment objective, enabling efficient progression through multiple plugs without unnecessary downtime.

Inventive Principle:
Principle #20Continuity of useful action

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 lost circulation zones, reducing fluid flow by forming a durable, self-supporting gel structure that mitigates fluid loss, improving wellbore stability and operational safety.

Implementation Method 1

allowing the first fluid pill to interact with the second fluid pill to form a solid within the at least one lost circulation zone

Methodology Applied
Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

allowing the first fluid pill to interact with the second fluid pill to form a solid within the at least one lost circulation zone

Methodology Applied
Scientific EffectPrecipitation: Precipitation

Implementation Method 3

introducing a second cement having a higher thixotropy than the first cement into the subterranean formation

Methodology Applied
Scientific EffectThixotropy: Thixotropy

Implementation Method 4

Lost circulation typically occurs when the drilling fluid encounters a formation with high permeability or natural fractures

Methodology Applied
Scientific EffectPermeation: Permeation

Data Source

PatentUS12460120B1Methods for curing lost circulation in subterranean formations
Publication Date: 2025.11.04 SAUDI ARABIAN OIL CO

AI summary

Methods comprise introducing a first fluid pill and a second fluid pill into a subterranean formation containing at least one lost circulation zone via a wellbore; allowing the first fluid pill to interact with the second fluid pill to form a solid within the at least one lost circulation zone; introducing a first cement into the subterranean formation; allowing at least a portion of the first cement to solidify within the at least one lost circulation zone; consecutively reintroducing the first fluid pill and the second fluid pill into the subterranean formation; introducing a plurality of cements having progressively higher thixotropies; and allowing the plurality of cements to solidify within the at least one lost circulation zone.