A New Method for Simulating Fractures and Evaluating Drilling Plugging Effectiveness Based on 3D Printing

doi:10.12388/j.issn.1673-2677.2026.01.007

Xinjiang Oil & Gas ›› 2026, Vol. 22 ›› Issue (1): 58-67.DOI: 10.12388/j.issn.1673-2677.2026.01.007

• OIL AND GAS DEVELOPMENT • Previous Articles Next Articles

A New Method for Simulating Fractures and Evaluating Drilling Plugging Effectiveness Based on 3D Printing

YANG Liuqing¹，WANG Haibo²，LIU Zhimin³，ZENG Xin⁴，LIU Ming³

1. CNPC Chuanqing Drilling Engineering Co.，Ltd.，Chengdu 610056，Sichuan，China；2. Research Institute of Petroleum Engineering Technology Co.，Ltd.，Sinopec，Changping 102206，Beijing，China；3. Drilling Fluid Technical Service Company，CNPC Chuanqing Drilling Engineering Co.，Ltd.，Chengdu 610051，Sichuan，China；4. Downhole Service Company，CNPC Chuanqing Drilling Engineering Co.，Ltd.，Chengdu 610052，Sichuan，China

Received:2025-07-28 Revised:2025-12-15 Accepted:2025-12-18 Online:2026-03-10 Published:2026-03-10

运用3D打印技术模拟裂缝及评估钻井堵漏效果新方法

杨柳青¹，王海波²，刘智敏³，曾欣⁴，刘明³

1.中国石油集团川庆钻探工程有限公司，四川成都 610056；2.中石化石油工程技术研究院有限公司，北京昌平 102206；3.中国石油集团川庆钻探工程有限公司钻井液技术服务公司，四川成都 610051；4.中国石油集团川庆钻探工程有限公司井下作业公司，四川成都 610052

通讯作者: 王海波（2000-），2025年毕业于西南石油大学材料工程专业，硕士，助理工程师，目前从事钻井液处理剂研发与现场应用工作。（E-mail）207189600@qq.com
作者简介:杨柳青（1973-），2005年毕业于伊利诺伊大学香槟分校机械工程专业，博士，中国石油集团川庆钻探工程有限公司企业首席专家，目前从事钻完井工程研究与智能制造相关工作。（E-mail）yangliuq_sc@cnpc.com.cn
基金资助:
国家自然科学基金面上项目“深井、超深井水基钻井液失水造壁性与流变性调控机理研究”（52274008）。

Abstract

Abstract: Lost circulation is a critical technical challenge in drilling engineering. Current laboratory simulations of fracture-induced lost circulation primarily rely on traditional methods such as steel plate fractures，metal sheets，and sand beds，which fail to adequately replicate complex characteristics of actual thief zones，including the fracture orientation，tortuosity，and surface roughness. As a result，the field application success rate of plugging materials under complex geological conditions is still generally low. This paper proposes an innovative method that integrates realistic fracture simulation of thief zones with 3D printing technology through 3D imaging reconstruction. Actual rock samples of thief zones are scanned to establish digital core models，and 3D printing is applied to creating simulated cores，which significantly improves the fidelity and compatibility to real fracture structures. On this basis，a customized high temperature high pressure dynamic circulation plugging apparatus is used to conduct systematic pressure bearing experiments of multi-scale composite fractures. The sealing performance of various plugging formulations are compared and analyzed between 3D printed cores and traditional steel plate fractures，and a new methodology applicable to realistic fracture simulation and plugging evaluation is constructed. Field testing has validated that the optimized plugging formulation presents a one-time success rate of 83%，significantly enhancing the operational feasibility and economic viability of plugging operations. This method provides effective technical support for the efficient and precise sealing of complex formation fractures and contributes substantially to improved drilling efficiency and security of oil and gas resource recovery.

Key words: fracture-induced lost circulation, 3D printing, simulated core, plugging evaluation, drilling

摘要： 井漏是钻井工程的关键技术难题。当前实验室模拟裂缝性漏失主要依赖钢板缝、金属薄片及砂床等传统方法，难以充分还原真实漏失地层中裂缝的走向、迂曲程度及表面粗糙度等复杂特征，导致堵漏材料在复杂地层条件下的现场应用成功率普遍偏低。提出一种将漏层真实裂缝模拟与3D打印技术相结合的创新方法，通过三维成像重构技术扫描实际漏层岩样，建立数字岩心模型，并应用3D打印技术制作模拟岩心，显著提高了对地层裂缝真实结构的还原度与契合度。在此基础上，采用特制的高温高压动态循环堵漏评价装置，开展多尺度复合缝的系统性承压实验，对比分析了多种堵漏配方在3D打印模拟岩心与传统钢板缝中的封堵性能差异，构建一套适用于真实裂缝模拟与堵漏评价的新方法。经现场试验验证，优化后的堵漏配方一次性堵漏成功率提升至83%，显著增强了堵漏作业的可行性与经济性。研究成果为实现复杂地层裂缝性漏失的高效与精准封堵提供了有效技术支撑，对提升钻井工程效率及油气资源开采保障能力具有重要意义。

关键词: 裂缝性漏失, 3D打印, 模拟岩心, 堵漏评价, 钻井

CLC Number:

TE282

YANG Liuqing, WANG Haibo, LIU Zhimin, ZENG Xin, LIU Ming. A New Method for Simulating Fractures and Evaluating Drilling Plugging Effectiveness Based on 3D Printing[J]. Xinjiang Oil & Gas, 2026, 22(1): 58-67.

杨柳青, 王海波, 刘智敏, 曾欣, 刘明. 运用3D打印技术模拟裂缝及评估钻井堵漏效果新方法[J]. 新疆石油天然气, 2026, 22(1): 58-67.

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A New Method for Simulating Fractures and Evaluating Drilling Plugging Effectiveness Based on 3D Printing

运用3D打印技术模拟裂缝及评估钻井堵漏效果新方法

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