Research on visual fracture evaluation instrument based on digital twin system and plugging fluid

Abstract:

To address the problems of existing plugging evaluation instruments， such as cumbersome manual operation， poor data stability， insufficient safety， and low field plugging success rate， a visualized fracture evaluation instrument based on a digital twin system was developed， along with a wide-temperature range filtration-type composite structure plugging fluid. The instrument integrates a 3D visualization control interface， a physical perception tracking system， and an experimental management platform. It achieves a data acquisition accuracy of ±0.5%FS， a transmission rate of 1~5 Mbps， a system stability of >99.5%， and a maximum pressure capacity of 5 MPa. Capable of simulating 1~5 mm fractures， it enables remote operation and visual observation of the plugging process， thereby significantly improving experimental safety. Based on this instrument， the wide-temperature range filtration-type composite structure plugging fluid was developed； by optimizing the dosages of the main agent and suspending agent， plugging formulations adaptable to different fracture widths were formulated. Experimental results show that the plugging fluid can effectively seal 1~3 mm fractures， with a consolidated strength of ≥8 MPa and a drillability grade of 2~3. Field applications in 24 wells demonstrate a one-time plugging success rate of 87.5%， with normal circulation restored and no leakage after operations. The results indicate that the instrument and plugging fluid significantly enhance the safety and efficiency of plugging evaluation， providing an intelligent solution for the effective treatment of fractured loss zones.