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Lost circulation is one of the important problems that restricts the speed and efficiency of oil and gas drilling and production. In this study, a resin plugging system was successfully developed for lost circulation formation. The resin plugging system showed excellent performance under high temperature and pressure conditions. The experimental results showed that the compressive strength of the resin plugging material can reach 9.23 MPa after curing, which is significantly higher than that of the traditional polymer gel material. The resin material can achieve effective curing in the temperature range of 60 °C to 100 °C, and the curing time decreases with the increase of temperature and only needs 3.46 h at 140 °C. The microstructure results showed that the resin material can form a chain or three-dimensional network structure after curing, which can effectively increase the toughness and strength of the cured plugging layer. Infrared and thermogravimetric analysis further confirmed the thermal stability of the chemical bonds in the material, and the initial decomposition temperature was about 241 °C, indicating that it had good thermal stability at about 300 °C. In addition, the effects of curing temperature, salinity, and drilling fluid pollution on the properties of the resin plugging agent were also investigated. The results showed that curing agent dosage and curing temperature are the key factors affecting curing time, while salinity and drilling fluid pollution affect the curing strength and overall properties of the materials. After adding 20% KCl polysulfonate drilling fluid, the compressive strength of the consolidated body decreased to 4.55 MPa. This study can provide an efficient and reliable plugging solution for malignant loss formation.

Thermosetting resins have good temperature resistance and high strength and have been widely used as plugging agents in oil fields. However, the current resin materials have high costs, and unmodified thermosetting resins are brittle or have deteriorated properties such as flame retardancy after curing to form a crosslinked network structure. In this study, the resin was modified via physical blending. The curing strength and temperature resistance were used as the main indicators. The resin matrix, curing agent, rheology modifier, and filling materials were modified and formulated optimally to form a high-strength resin gel plugging system. The resin gel system exhibited good fluidity and pumpability. When the shear rate was 200 s−1 at 25 °C, the initial viscosity was 300–400 mPa·s. The viscosity gradually decreased with increasing shear rate, and the apparent viscosity had good long-term stability at room temperature. A contamination test of different types of drilling fluids on the resin gel system showed that this system had good anti-contamination capability and could maintain a high curing strength even after being contaminated. At the same time, the system exhibited good plugging capability. A wedge-shaped fracture with an inlet size of 7 mm and an outlet size of 5 mm was plugged at 12.84 MPa for 10 min without leakage. A sand-filling pipe (with a diameter of 3.8 cm and pipe length of 30 cm) connected to the pipeline with a 6 mm outlet was subjected to a constant pressure of 11.29 MPa and plugged for 8 min before breaking through. Therefore, it exhibited good capability for plugging fissures and cavities. The resin gel leakage-plugging system has significant potential to realize effective plugging of the deep large-fracture leakage layer.

Lost circulation is a common and complicated situation in drilling engineering. Serious lost circulation may lead to pressure drop in the well, affect normal drilling operations, and even cause wellbore instability, formation fluid flooding into the wellbore, and blowout. Therefore, appropriate preventive and treatment measures need to be taken to ensure the safe and smooth operation of drilling operations. So, it is necessary to conduct in-depth research on the development and performance of the plugging materials. In this study, urea formaldehyde resin with high temperature resistance and strength was used as the main raw material, and the curing conditions were optimized and adjusted by adding a variety of additives. The curing time, compressive strength, temperature resistance, and other key performance indexes of the resin plugging agent were studied, and a resin plugging agent system with excellent plugging performance was prepared. The formula is as follows: 25% urea formaldehyde resin +1% betaine +1% silane coupling agent KH-570 + 3% ammonium chloride +1% hexamethylenetetramine +1% sodium carboxymethyl cellulose. The optimal curing temperature is between 60 and 80 °C, with a controllable curing time of 1–3 h. Experimental studies examined the rheological and curing properties of the resin plugging agent system. The results showed that the viscosity of the high-strength curable resin system before curing remained stable with increasing shear rates. Additionally, the storage modulus and loss modulus of the resin solutions increased with shear stress, with the loss modulus being greater than the storage modulus, indicating a viscous fluid. The study also investigated the effect of different salt ion concentrations on the curing effect of the resin plugging system. The results showed that formation water containing Na+ at concentrations between 500 mg/L and 10,000 mg/L increased the resin’s curing strength and reduced curing time. However, excessively high concentrations at lower temperatures reduced the curing strength. Formation water containing Ca2+ increased the curing time of the resin plugging system and significantly impacted the curing strength, reducing it to some extent. Moreover, the high-strength curable resin plugging agent system can effectively stay in various fracture types (parallel, wedge-shaped) and different fracture sizes, forming a high-strength consolidation under certain temperature conditions for effective plugging. In wedge-shaped fractures with a width of 10 mm, the breakthrough pressure of the high-strength curable resin plugging agent system reached 8.1 MPa. As the fracture width decreases, the breakthrough pressure increases, reaching 9.98 MPa in wedge-shaped fractures with an outlet fracture width of 3 mm, forming a high-strength plugging layer. This research provides new ideas and methods for solving drilling fluid loss in fractured loss zones and has certain application and promotion value.

A common problem associated with conventional gel breakers is that they can cause a premature reduction in gel viscosity at high temperatures. To address this, a urea-formaldehyde (UF) resin and sulfamic acid (SA) encapsulated polymer gel breaker was prepared via in situ polymerization with UF as the capsule coat and SA as the capsule core; this breaker was able to withstand temperatures of up to 120–140 °C. The encapsulated breaker was characterized using scanning electron microscopy (SEM), infrared spectroscopy (FT-IR), and thermogravimetric (TG) analysis. Meanwhile, the dispersing effects of various emulsifiers on the capsule core, and the encapsulation rate and electrical conductivity of the encapsulated breaker were tested. The gel-breaking performance of the encapsulated breaker was evaluated at different temperatures and dose conditions via simulated core experiments. The results confirm the successful encapsulation of SA in UF and also highlight the slow-release properties of the encapsulated breaker. From experimentation, the optimal preparation conditions were determined to be a molar ratio between urea and formaldehyde (nurea:nformaldehyde) of 1:1.8 for the capsule coat, a pH of 8, a temperature of 75 °C, and the utilization of Span 80/SDBS as the compound emulsifier; the resulting encapsulated breaker exhibited significantly improved gel-breaking performance (gel breaking delayed for 9 days at 130 °C). The optimum preparation conditions determined in the study can be used in industrial production, and there are no potential safety and environmental concerns.

Polymer gels are widely used in oil–gas drilling and production engineering for the purposes of conformance control, water shutoff, fracturing, lost circulation control, etc. Here, the progress in research on three kinds of polymer gels, including the in situ crosslinked polymer gel, the pre-crosslinked polymer gel and the physically crosslinked polymer gel, are systematically reviewed in terms of the gel compositions, crosslinking principles and properties. Moreover, the advantages and disadvantages of the three kinds of polymer gels are also comparatively discussed. The types, characteristics and action mechanisms of the polymer gels used in oil-gas drilling and production engineering are systematically analyzed. Depending on the crosslinking mechanism, in situ crosslinked polymer gels can be divided into free-radical-based monomer crosslinked gels, ionic-bond-based metal cross-linked gels and covalent-bond-based organic crosslinked gels. Surface crosslinked polymer gels are divided into two types based on their size and gel particle preparation method, including pre-crosslinked gel particles and polymer gel microspheres. Physically crosslinked polymer gels are mainly divided into hydrogen-bonded gels, hydrophobic association gels and electrostatic interaction gels depending on the application conditions of the oil–gas drilling and production engineering processes. In the field of oil–gas drilling engineering, the polymer gels are mainly used as drilling fluids, plugging agents and lost circulation materials, and polymer gels are an important material that are utilized for profile control, water shutoff, chemical flooding and fracturing. Finally, the research potential of polymer gels in oil–gas drilling and production engineering is proposed. The temperature resistance, salinity resistance, gelation strength and environmental friendliness of polymer gels should be further improved in order to meet the future technical requirements of oil–gas drilling and production.

Polymer gels with suitable viscoelasticity and deformability have been widely used for formation plugging and lost circulation control, profile control, and water shutoff. This article systematically reviews the research progress on the preparation principle, temperature resistance, salt resistance, and mechanical properties of the ground and in situ crosslinked polymer gels for oil-gas drilling and production engineering. Then, it comparatively analyzes the applicable conditions of the two types of polymer gel. To expand the application range of polymer gels in response to the harsh formation environments (e.g., high temperature and high salinity), we reviewed strategies for increasing the high temperature resistance, high salt resistance, and rheological/mechanical strengths of polymer gels. This article provides theoretical and technical references for developing and optimizing polymer gels suitable for oil-gas drilling and production.

Lost circulation in fractured formation is the first major technical problem that restricts improvements in the quality and efficiency of oil and gas drilling engineering. Improving the success rate of one-time lost circulation control is an urgent demand to ensure “safe, efficient and economic” drilling in oilfields all over the world. In view of the current situation, where drilling fluid loss occurs and the plugging mechanism of fractured formation is not perfect, this paper systematically summarizes the drilling fluid loss mechanism and model of fractured formation. The mechanism and the main influencing factors to improve the formation’s pressure-bearing capacity, based on stress cage theory, fracture closure stress theory, fracture extension stress theory and chemical strengthening wellbore theory, are analyzed in detail. The properties and interaction mechanism of various types of lost circulation materials, such as bridging, high water loss, curable, liquid absorption and expansion and flexible gel, are introduced. The characteristics and distribution of drilling fluid loss in fractured formation are also clarified. Furthermore, it is proposed that lost circulation control technology for fractured formation should focus on the development of big data and intelligence, and adaptive and efficient intelligent lost circulation material should be continuously developed, which lays a theoretical foundation for improving the success rate of lost circulation control in fractured formation.

Polymer gel lost circulation control technology is a common and effective technique to control fractured lost circulation. The performance of a lost circulation control agent is the key to the success of lost circulation control techniques. In this study, rheological tests were used to study the physical and chemical properties of a shear thixotropic polymer gel system, such as anti-dilution, high temperature resistance and high salt resistance. The results showed that the shear thixotropic polymer gel system had the ability of anti-dilution, and the gel could be formed under a mixture of 3 times volume of heavy salt water and 3/7 volume white oil, and could keep the structure and morphology stable. Secondly, the gel formation time of shear thixotropic polymer gel system could be controlled and had good injection performance under the condition of 140 °C and different initiator concentrations. Meanwhile, the shear thixotropic polymer gel system had the ability of high temperature and high salt resistance, and the gel formation effect was good in salt water. When the scanning frequency was 4 Hz and the temperature was 140 °C, the storage modulus (G′) of the gel was 4700 Pa. The gel was dominated by elasticity and had excellent mechanical properties. By scanning electron microscope observation, it was found that the shear thixotropic polymer gel system had a stable three-dimensional reticular space skeleton under the condition of high salt, indicating that it had excellent ability to tolerate high salt. Therefore, the shear thixotropic polymer gel had high temperature and high salt resistance, dilution resistance and good shear responsiveness. It is believed that the results presented in this work are of importance for extending real-life applications of shear thixotropic polymer gel systems.