This disclosure relates to preventing lost circulation in wellbores during drilling operations.
Lost circulation occurs when drilling fluid such as drilling mud flows into one or more fractures of geological formations instead of returning up the annulus of the wellbore. Lost circulation can cause mud waste, dry drilling, and other downhole problems. Preventing lost circulation can save time and resources by keeping the drilling mud from leaving through formation fractures.
Implementations of the present disclosure include a method that includes drilling, with a drill string configured to flow drilling fluid, a wellbore, where at a downhole location the drilling fluid is lost through a formation fracture. The method also includes deploying, through the drill string, a plugging assembly to the downhole location of the wellbore. The plugging assembly includes a flexible fiber sheet releasably coupled to a pumpable dart such that when the plugging assembly reaches the downhole location, the flexible fiber sheet is released from the dart to flow, with the drilling fluid, to the formation fracture to at least partially overlay the formation fracture. The method also includes adding, to the drilling fluid, lost circulation material configured to accumulate on a portion of the flexible fiber sheet to at least partially fluidically plug the formation fracture.
In some implementations, the flexible fiber sheet is wrapped and configured to unwrap at the downhole location. Adding the lost circulation material includes adding the lost circulation material such that the lost circulation material reaches the downhole location after the flexible sheet is released from the pumpable dart.
In some implementations, the flexible fiber sheet is configured to form a bridge at the formation fracture for lost circulation material to pile on the flexible fiber sheet and form a fluid plug. Adding the lost circulation material includes adding the lost circulation material such that the lost circulation material reaches the downhole location after the flexible sheet forms a bridge at the formation fracture.
In some implementations, adding the lost circulation material includes adding the lost circulation material to the drilling fluid and circulating the drilling fluid in and out of the wellbore.
In some implementations, the flexible fiber sheet is releasably coupled to the pumpable dart with a gel dissolvable in the drilling fluid at the downhole location, and where the flexible fiber sheet is configured to separate from the pumpable dart when the dissolvable gel is dissolved in the drilling fluid. Adding the lost circulation material includes adding the lost circulation material such that the lost circulation material reaches the downhole location after the gel is dissolved and the flexible sheet is disengaged from the pumpable dart.
In some implementations, the flexible fiber sheet is folded about a pin of the pumpable dart to engage with the dart. Adding the lost circulation material includes adding the lost circulation material such that the lost circulation material reaches the downhole location after the flexible fiber sheet is unfolded from the pin and disengaged from the dart.
In some implementations, the dissolvable gel is disposed inside a pill that covers the plugging assembly. The pill includes fluid configured to prevent the dissolvable gel from completely dissolving before exciting the drill string, the pill configured to be lost at the downhole location to expose the plugging assembly to the drilling fluid. Adding the lost circulation material includes adding the lost circulation material such that the lost circulation material reaches the downhole location after the gel is dissolved and the flexible sheet is disengaged from the pumpable dart.
In some implementations, the fluid of the pill includes an inhibited fluid polymer. Adding the lost circulation material includes adding the lost circulation material such that the lost circulation material reaches the downhole location after the inhibited fluid polymer is lost at the downhole location and the gel is dissolved.
In some implementations, deploying the plugging assembly includes disposing, inside a surface pumping head, the plugging assembly, and flowing, though a first portion of the pumping head downstream of the plugging assembly, a first portion of the pill. Deploying the pumping assembly also includes moving the plugging assembly away from the surface pumping head toward the first portion of the pill, flowing, through a second portion of the pumping head upstream of the plugging assembly, a second portion of the pill to cover the plugging assembly, and pumping, with the drilling fluid, the pumping assembly with the first and second portions of the pill.
In some implementations, the flexible fiber sheet includes pores to allow part of the drilling fluid to pass through the flexible fiber sheet into the formation fracture when the flexible fiber sheet is at the formation fracture, and where adding the lost circulation material includes adding the lost circulation material such that the lost circulation material flows, with the drilling fluid, to the flexible fiber sheet to accumulate on the flexible fiber sheet and form a fluid plug.
Implementations of the present disclosure also include a wellbore plugging assembly that includes a dart configured to be pumped through a drill string disposed at the wellbore, the dart configured to leave the drill string at or near a downhole location where drilling fluid is lost through a formation fracture. The assembly also includes a flexible fiber sheet releasably coupled to the dart such that when the wellbore plugging assembly reaches the downhole location, the flexible fiber sheet is released from the dart to flow, with the drilling fluid, to the formation fracture to at least partially overlay the formation fracture. The flexible fiber sheet is configured to form a bridge at the formation fracture for lost circulation material to accumulate on a portion of the flexible fiber sheet to at least partially fluidically plug the formation fracture.
In some implementations, the flexible fiber sheet is wrapped to form a longitudinally continuous strip. The flexible fiber sheet is configured to unwrap at the downhole location upon leaving the drill string and being exposed to the drilling fluid, before reaching the formation fracture.
In some implementations, the flexible fiber sheet includes pores to allow part of the drilling fluid to pass through the flexible fiber sheet into the formation fracture when the flexible fiber sheet is at the formation fracture, such that the lost circulation material flows, with the drilling fluid, to the flexible fiber sheet to accumulate on the flexible fiber sheet and form a fluid plug.
In some implementations, the flexible fiber sheet is releasably coupled to the dart with a gel dissolvable in the drilling fluid at the downhole location, and where the flexible fiber sheet is configured to separate from the pumpable dart when the dissolvable gel is dissolved in the drilling fluid.
In some implementations, the flexible fiber sheet is folded about a pin of the pumpable dart to engage with the dart.
In some implementations, the dissolvable gel is disposed inside a pill that covers the plugging assembly, the pill including fluid configured to prevent the dissolvable gel from completely dissolving before exciting the drill string, the pill configured to be lost at the downhole location to expose the plugging assembly to the drilling fluid.
In some implementations, the fluid of the pill includes an inhibited fluid polymer configured to be lost at the downhole location to expose the dissolvable gel to the drilling fluid.
Implementations of the present disclosure include a fluid loss plugging system that includes a dart, the dart configured to be pumped through a drill string disposed at a wellbore, the dart configured to leave the drill string at or near a downhole location where drilling fluid is lost through a formation fracture. The system also includes a flexible fiber sheet releasably coupled to the dart such that when the plugging assembly reaches the downhole location, the flexible fiber sheet is released from the dart to flow, with the drilling fluid, to the formation fracture to at least partially overlay the formation fracture. The system also includes lost circulation material, the lost circulation material configured to flow through the drill string to the downhole location and to the formation fracture to accumulate on a portion of the flexible fiber sheet to at least partially fluidically plug the formation fracture.
In some implementations, the flexible fiber sheet is wrapped or twisted to form a longitudinally continuous strip, the flexible fiber sheet configured to unwrap or untwist at the downhole location upon leaving the drill string and being exposed to the drilling fluid, before reaching the formation fracture.
In some implementations, the flexible fiber sheet is releasably coupled to the dart with a gel dissolvable in the drilling fluid at the downhole location such that the flexible fiber sheet separates from the pumpable dart when the dissolvable gel is dissolved in the drilling fluid.
During the drilling of a wellbore 114, lost circulation or loss of circulation can occur when drilling fluid 160 (for example, drilling mud) enters a naturally fractured formation or an induced fracture. The present disclosure relates to a wellbore plugging assembly 100 and methods for preventing drilling fluid 160 from leaving the wellbore through fractures (for example, large fractures) of the formation. The plugging assembly 100 is used to create a bridge at the formation fracture or fractures for lost circulation material (for example, organic or synthetic particles) to pile up and form a fluid plug. Such a pile of lost circulation material can and stop or reduce the losses in large formation fractures.
Implementations of the present disclosure may realize one or more of the following advantages. For example, the well system can save time and resources by preventing drilling mud from leaving the wellbore through large fractures of the formations. The present disclosure features a system that is compatible with multiple types of wellbore fluids (for example, water-based-mud, oil-based-mud, brine, or cement slurry). Additionally, the system can be used to stop losses before running the casing which enhances the cementing operation of wellbore casing to increase the life of the well and prevent any behind casing communication. The system can also be quickly deployed without the need of specialized personnel.
The flexible fiber sheet 102 can be a fine fiber mesh, having a fine crisscross pattern of fiberglass threads like silk. The flexible fiber sheet 102 can provide high shear resistance to withstand fluidic pressure and form a proper bridge for lost circulation material to accumulate and form a fluid plug at the formation fracture. The sheet 102 forms a base at the formation fracture for any fluid-loss control material (LCM) or loss circulation material such as a granular material to build up and form a plug. The flexible fiber sheet 102 is wrapped, twisted, or wrung to form a longitudinally continuous strip or rope 111. The wrapped flexible fiber sheet 102 can be glued or adhered to itself with a dissolvable adhesive or gel 113 (shown in
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Although the following detailed description contains many specific details for purposes of illustration, it is understood that one of ordinary skill in the art will appreciate that many examples, variations and alterations to the following details are within the scope and spirit of the disclosure. Accordingly, the exemplary implementations described in the present disclosure and provided in the appended figures are set forth without any loss of generality, and without imposing limitations on the claimed implementations.
Although the present implementations have been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the disclosure. Accordingly, the scope of the present disclosure should be determined by the following claims and their appropriate legal equivalents.
The singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
Ranges may be expressed in the present disclosure as from about one particular value, or to about another particular value or a combination of them. When such a range is expressed, it is to be understood that another implementation is from the one particular value or to the other particular value, along with all combinations within said range or a combination of them.
As used in the present disclosure and in the appended claims, the words “comprise,” “has,” and “include” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps.
As used in the present disclosure, terms such as “first” and “second” are arbitrarily assigned and are merely intended to differentiate between two or more components of an apparatus. It is to be understood that the words “first” and “second” serve no other purpose and are not part of the name or description of the component, nor do they necessarily define a relative location or position of the component. Furthermore, it is to be understood that that the mere use of the term “first” and “second” does not require that there be any “third” component, although that possibility is contemplated under the scope of the present disclosure.