Laboratory study of plugging mechanism and seal integrity in fractured formations using a new blend of lost circulation materials

Abstract

AbstractThe problem of lost circulation occurred long during the drilling operation. Through induced and natural fractures, huge drilling fluid losses lead to higher operating expenses during the drilling. Historically, this problem was addressed with the help of the Lost Circulation Materials (LCMs). These materials are added to the drilling fluid to seal the fractures and increase fracture initiation or propagation pressure. Therefore, understanding the mechanisms of fracture sealing and the performance of the lost circulation materials is critical if the problem of lost circulation is to be mitigated effectively. Despite extensive advances in the last couple of decades, lost circulation materials used today still have disadvantages, such as damaging production zones, failing to seal large fractures, or plugging drilling tools. Here, we propose a new blend of smart expandable lost circulation material (LCM) to remotely control the expanding force and functionality of the injected LCM. This paper aimed to assess the performance of the selected LCMs (Mica, Wheat Straw, Oak Shell, and Sugarcane Bagasse Fiber or Canes) in water-based drilling fluids. The particle bridging of LCMs was investigated using particle bridging experiments in the laboratory. Moreover, we determined the particle size distribution of D50. The cell utilized in the sealing experiments had 1000- and 3000 micron fractures to mimic different size fractures in the formation. Fracture widths are predicted based on well-log data and adaptation of existing models in the desired oil field. The concentrations of LCMs in Mica, Wheat Straw, Oak Shell, and Sugarcane Bagasse Fiber (Canes) were (25, 50, and 80 ppb), (1.5, 2, 2.5 ppb), (3, 6, and 10 ppb), and (1.5, 2, 2.5 ppb), respectively. The results indicate that a combination of LCMs outperforms individual LCMs. When used individually, Oak Shells performed the highest, followed by Mica and Sugarcane Bagasse Fiber mixtures. Also, the Wheat Straw blend served the weakest lost circulation treatments. Finally, the combination applied in this investigation successfully sealed fractures up to 3 mm in diameter in the targeted oil field, which traditional LCM would be unable to do. Due to the abundance and low cost of these materials in the study area, they can be used to ensure successful plugging. Graphical Abstract