An optimal design for millimeter-wide facture plugging zone

Lost circulation control in millimeter-wide fractures has been a challenge in well drilling all the time. Low pressure-bearing capacity of a plugging zone will result in excessive consumption of lost circulation materials (LCMs) and extra down time. In this study, laboratory experiments were conducted on the plugging of millimeter-wide fractures to evaluate the plugging effects of different types of LCM including rigid granules, elastic particles and fiber. Maximum plugging pressure, total loss volume before sealing and plugging time were taken as the evaluation index of the LCM plugging effect. According to the experimental results, the synergistic plugging mechanisms of different LCM combinations were also analyzed. Experimental results showed that the total loss volume of the plugging zone formed by rigid and elastic particle combination was generally greater than 400 mL, and the maximum plugging pressure of the plugging zone formed by elastic particle and fiber combination was generally less than 6 MPa. In contrast, the plugging zone formed by the combination of the three types of LCMs has the maximum plugging pressure of up to 13 MPa and total loss volume before sealing of 75 mL. In the synergistic plugging process, rigid granules form a frame with high pressure-bearing capacity in the narrower parts of the fractures; elastic particles generate elastic force through elastic deformation to increase the friction between a fracture and a plugging zone to make the plugging zone more stable; fibers filling in the pore space between the particles increase the tightness and integrity of the plugging zone. The experimental results can provide guidance for the optimal design of LCMs used in the field.