Numerical Study on Lost Circulation Mechanism in Complex Fracture Network Coupled Wellbore and Its Application in Lost-Circulation Zone Diagnosis

Deep and ultra-deep drilling operations commonly encounter fractured and fracture-vuggy formations, where weak wellbore strength and well-developed fracture networks lead to frequent lost circulation, presenting a key challenge to safe and efficient drilling. Existing diagnostic practices mostly rely on drilling fluid loss dynamic models of single fractures or simplified discrete fractures to invert fracture geometry, which cannot capture the spatiotemporal evolution of loss in complex fracture networks, resulting in limited inversion accuracy and a lack of quantitative, fracture-network-based loss-dynamics support for bridge-plugging design. In this study, a geologically realistic wellbore–fracture-network coupled loss dynamic model is constructed to overcome the limitations of single- or simplified-fracture descriptions. Within a unified computational fluid dynamics (CFD) framework, solid–liquid two-phase flow and Herschel–Bulkley rheology are incorporated to quantitatively characterise fracture connectivity. This approach reveals how instantaneous and steady losses are controlled by key geometrical factors, thereby providing a computable physical basis for loss-zone inversion and bridge-plugging design. Validation against experiments shows a maximum relative error of 7.26% in pressure and loss rate, indicating that the model can reasonably reproduce actual loss behaviour. Different encounter positions and node types lead to systematic variations in loss intensity and flow partitioning. Compared with a single fracture, a fracture network significantly amplifies loss intensity through branch-induced capacity enhancement, superposition of shortest paths, and shortening of loss paths. In a typical network, the shortest path accounts for only about 20% of the total length, but contributes 40–55% of the total loss, while extending branch length from 300 mm to 1500 mm reduces the steady loss rate by 40–60%. Correlation analysis shows that the instantaneous loss rate is mainly controlled by the maximum width and height of fractures connected to the wellbore, whereas the steady loss rate has a correlation coefficient of about 0.7 with minimum width and effective path length, and decreases monotonically with the number of connected fractures under a fixed total width, indicating that the shortest path and bottleneck width are the key geometrical factors governing long-term loss in complex fracture networks. This work refines the understanding of fractured-loss dynamics and proposes the concept of coupling hydraulic deviation codes with deep learning to build a mapping model from mud-logging curves to fracture geometrical parameters, thereby providing support for lost-circulation diagnosis and bridge-plugging optimisation in complex fractured formations.

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Journal
Processes
Published
2025-12-31
DOI
https://doi.org/10.3390/pr14010143
Primary Topic
Drilling and Well Engineering
Type
article
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article

Numerical Study on Lost Circulation Mechanism in Complex Fracture Network Coupled Wellbore and Its Application in Lost-Circulation Zone Diagnosis

Chong Lin, Yili Kang, Zhichao Xie, Lijun You et al.
Processes
Drilling and Well Engineering
article

Numerical Study on Lost Circulation Mechanism in Complex Fracture Network Coupled Wellbore and Its Application in Lost-Circulation Zone Diagnosis

Chong Lin, Yili Kang, Zhichao Xie, Lijun You, Feifei Zhang, Chengyuan Xu
article en

Abstract

Deep and ultra-deep drilling operations commonly encounter fractured and fracture-vuggy formations, where weak wellbore strength and well-developed fracture networks lead to frequent lost circulation, presenting a key challenge to safe and efficient drilling. Existing diagnostic practices mostly rely on drilling fluid loss dynamic models of single fractures or simplified discrete fractures to invert fracture geometry, which cannot capture the spatiotemporal evolution of loss in complex fracture networks, resulting in limited inversion accuracy and a lack of quantitative, fracture-network-based loss-dynamics support for bridge-plugging design. In this study, a geologically realistic wellbore–fracture-network coupled loss dynamic model is constructed to overcome the limitations of single- or simplified-fracture descriptions. Within a unified computational fluid dynamics (CFD) framework, solid–liquid two-phase flow and Herschel–Bulkley rheology are incorporated to quantitatively characterise fracture connectivity. This approach reveals how instantaneous and steady losses are controlled by key geometrical factors, thereby providing a computable physical basis for loss-zone inversion and bridge-plugging design. Validation against experiments shows a maximum relative error of 7.26% in pressure and loss rate, indicating that the model can reasonably reproduce actual loss behaviour. Different encounter positions and node types lead to systematic variations in loss intensity and flow partitioning. Compared with a single fracture, a fracture network significantly amplifies loss intensity through branch-induced capacity enhancement, superposition of shortest paths, and shortening of loss paths. In a typical network, the shortest path accounts for only about 20% of the total length, but contributes 40–55% of the total loss, while extending branch length from 300 mm to 1500 mm reduces the steady loss rate by 40–60%. Correlation analysis shows that the instantaneous loss rate is mainly controlled by the maximum width and height of fractures connected to the wellbore, whereas the steady loss rate has a correlation coefficient of about 0.7 with minimum width and effective path length, and decreases monotonically with the number of connected fractures under a fixed total width, indicating that the shortest path and bottleneck width are the key geometrical factors governing long-term loss in complex fracture networks. This work refines the understanding of fractured-loss dynamics and proposes the concept of coupling hydraulic deviation codes with deep learning to build a mapping model from mud-logging curves to fracture geometrical parameters, thereby providing support for lost-circulation diagnosis and bridge-plugging optimisation in complex fractured formations.

ProcessesVol. 14(1)
Southwest Petroleum University (CN), Yangtze University (CN), State Key Laboratory of Oil and Gas Reservoir Geology and Exploitation (CN), Zhongshan Hospital (CN)
Openalex Percentile: Top 35%
Drilling and Well Engineering
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