Casing Leak Repair Tool With Dual Packers for Single-Trip Cementing
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Solution Overview
Problem
Conventional methods for repairing casing leaks in wellbore casing strings require multiple trips into the well, which are time-consuming and increase the risk of wellbore incidents like kicks and blowouts.
Innovation Solution
A curing casing leak tool (CCLT) comprising an upper isolation packer, lower isolation packer, lower ball valve, upper ball valve, and drillable tubulars is used to seal off the leak location and deploy cement to repair it in a single trip, utilizing pressure tests to determine the leak's depth and employing drillable materials for removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to repair casing leaks, then the leak can be repaired, but multiple trips into the well are required which increases time consumption and risk of wellbore incidents
Solution Approach 1:
The patent combines multiple repair operations (pressure testing, leak localization, cement injection, and tool retrieval) into a single integrated tool assembly that can be deployed in one trip. The curing casing leak tool integrates a packer, pressure test mechanism, cement injection system, and drillable components, allowing all functions to be performed during a single well intervention operation.
Solution Approach 2:
The tool performs pressure testing and leak localization before cement injection during the same trip. The packer is deployed and pressure tests are conducted to identify the exact leak location prior to cementing, ensuring that the repair process is optimized and completed in one operation rather than requiring separate diagnostic and repair trips.
2Reliability
If conventional methods are used to repair casing leaks, then the leak can be repaired, but multiple trips into the well are required which increases the risk of wellbore incidents
Solution Approach 1:
The patent combines multiple repair operations (pressure testing, leak localization, cement injection, and tool retrieval) into a single integrated tool assembly that can be deployed in one trip. The curing casing leak tool integrates a packer, pressure test mechanism, cement injection system, and drillable components, allowing all functions to be performed during a single well intervention operation.
Solution Approach 2:
The tool performs pressure testing and leak localization before cement injection during the same trip. The packer is deployed and pressure tests are conducted to identify the exact leak location prior to cementing, ensuring that the repair process is optimized and completed in one operation rather than requiring separate diagnostic and repair trips.
3Loss of time
If a single trip repair method is used, then time is reduced and risk is minimized, but the tool complexity increases
Solution Approach 1:
The tool assembly is divided into distinct functional modules: a packer module for isolation, a pressure test module for diagnostics, a cement injection module for repair, and drillable tubular sections for deployment and retrieval. Each module performs a specific function, and the modular design allows the complex tool to be assembled, deployed, and retrieved systematically in a single trip.
Solution Approach 2:
The tool incorporates drillable tubulars and a drillable packer that are designed to be left in the wellbore after cement injection. These components are intentionally made disposable and drillable, allowing the functional parts of the tool to remain in place while being removed by subsequent drilling operations, simplifying the retrieval process.
4Productivity
If a single trip repair method is used, then productivity is improved, but the device complexity increases
Solution Approach 1:
The tool assembly is divided into distinct functional modules: a packer module for isolation, a pressure test module for diagnostics, a cement injection module for repair, and drillable tubular sections for deployment and retrieval. Each module performs a specific function, and the modular design allows the complex tool to be assembled, deployed, and retrieved systematically in a single trip.
Solution Approach 2:
The tool assembly is designed to perform multiple functions (isolation, pressure testing, leak localization, cement injection, and self-retrieval via drilling) within a single integrated system. This multi-functionality allows the tool to complete an entire repair workflow in one trip, significantly improving productivity despite the increased complexity of the device.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The CCLT effectively repairs casing leaks in a single trip, reducing the risk of wellbore incidents and ensuring the integrity of the well by isolating the leak area and injecting cement to seal it, thus preventing fluid migration and pressure control issues.
Implementation Method 1
The upper isolation packer is located up hole from the location of the leak and is configured to seal against an inner surface of the tubular. The lower isolation packer is located downhole from the location of the leak and is configured to seal against the inner surface of the tubular.
Implementation Method 2
The lower ball valve is located downhole from the lower isolation packer and is configured to allow the upper isolation packer and the lower isolation packer to seal against the inner surface of the tubular. The upper ball valve is located between the upper isolation packer and the lower isolation packer and is configured to deploy cement into the leak to repair the leak.
Implementation Method 3
The upper ball valve is located between the upper isolation packer and the lower isolation packer and is configured to deploy cement into the leak to repair the leak.
Data Source
AI summary
A system includes a plug and a tool. The plug is configured to perform one or more pressure tests within the tubular to determine a location of the leak. The tool includes an upper isolation packer, a lower isolation packer, a lower ball valve, an upper ball valve, and drillable tubulars. The upper isolation packer is located up hole from the location of the leak and is configured to seal against an inner surface of the tubular. The lower isolation packer is located downhole from the location of the leak and is configured to seal against the inner surface of the tubular. The lower ball valve is configured to allow the upper isolation packer and the lower isolation packer to seal against the inner surface of the tubular. The upper ball valve is configured to deploy cement into the leak to repair the leak.