Additive Manufactured Shapes used to Cure Total Lost Circulation Events

Abstract

Abstract Lost circulation is a major cause of drilling non-productive time. Lost circulation events can range from seepage, partial, severe and total losses. An extensive range of Lost Circulation Materials (LCM) are available and commonly used to cure seepage and partial losses. However, severe and total losses are not curable using standard LCM solutions and alternative time consuming and expensive remedial solutions are required. A supplement to conventional LCM has been designed to extend standard LCM loss curing capability to cope with severe total loss circulation events. Conventional LCM limitations are reported to be formation fracture widths up to 4-6 mm in size. Formation fractures greater than this limit will become problematic to cure using conventional LCM, the fractures are too large for LCM to collect, bridge and create an efficient pressure seal between the formation and well bore. When conventional Lost Circulation cure solutions prove ineffective, more costly solutions involving tripping and specific remedial treatments have to be utilized. An Additive Manufactured shape used as a supplement to standard LCM has been designed and tested has be shown to increase the loss curing capabilities of the standard LCM to larger formation fractures typical of Total Lost Circulation events. The Additive Manufactured Lost Circulation Shape when used with existing and readily available LCM product has been shown to extend the plugging range of a LCM from the typical 4mm - 6mm to larger total loss fractures of 20mm to 40mm. The Lost Circulation Supplement deployed with standard LCM will extend the loss curing capability of existing standard LCM's. By extending the curing capabilities of standard LCM costly and time-consuming tripping and alternative Lost Circulation remedial solutions can be avoided.