Casing Patch Deployment via Wedge Expansion
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Solution Overview
Problem
Unintentional holes or defects in casing strings within wellbores lead to leaks and fluid loss, necessitating effective sealing solutions during wellbore operations.
Innovation Solution
A casing patch assembly with upper and lower wedge portions and a radially expandable patch, deployable using a power rod and deployment device, creates metal-to-metal and elastomeric seals within the casing string to address defects and perforations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a casing patch is deployed to seal defects in the casing string, then wellbore integrity and sealing performance are improved, but the device complexity and deployment difficulty increase
Solution Approach 1:
The casing patch assembly is divided into multiple functional segments including a setting kit with upper wedge portion, a lower wedge portion, and a expandable patch element. Each segment performs a specific function: the upper wedge provides sealing and positioning, the lower wedge provides support and additional sealing, and the patch element provides the primary seal. This segmentation allows for simpler individual components that are easier to manufacture and deploy while achieving reliable wellbore integrity when assembled.
Solution Approach 2:
The setting kit and upper wedge portion are pre-assembled and configured before deployment into the casing string. The power rod is pre-attached to the setting kit, and the entire assembly is conveyed to the target location in a compact, pre-configured state. This preliminary assembly simplifies the deployment process by eliminating the need for complex downhole assembly operations and reduces the complexity of the deployment device required.
2Reliability
If a radially expandable patch is used to seal defects, then sealing effectiveness is improved, but the manufacturing precision and deployment control requirements increase
Solution Approach 1:
The casing patch transitions from a compact, low-profile configuration during conveyance to an expanded, high-profile configuration during operation. The patch element is designed to radially expand after deployment, transforming its shape and size to provide effective sealing against the casing wall. This dynamic transformation allows the patch to achieve high sealing effectiveness while being deployed in a compact form that is easier to manufacture and handle with standard equipment.
Solution Approach 2:
The upper and lower wedge portions serve as intermediary elements that facilitate the controlled expansion of the patch element. These wedges are positioned radially outward of the patch and provide a mechanical interface between the deployment device and the patch element. The wedges guide and control the expansion process, ensuring that the patch expands uniformly and achieves proper sealing without requiring extremely precise manufacturing tolerances on the patch element itself.
3Reliability
If a power rod and mandrel system is used to deploy the patch, then deployment reliability is improved, but the device complexity and operational difficulty increase
Solution Approach 1:
The deployment system is designed to be self-actuating through the interaction of its components. The power rod, when actuated, automatically drives the mandrel, which in turn positions the upper and lower wedge portions. The wedges then automatically expand the patch element against the casing wall through their radial positioning and mechanical interaction. This self-service mechanism reduces the need for complex control systems and manual intervention, improving ease of operation while maintaining deployment reliability.
Solution Approach 2:
The deployment mechanism replaces complex hydraulic or electronic control systems with a purely mechanical actuation system. The power rod and mandrel provide direct mechanical force transmission to position the wedges and expand the patch. This mechanical substitution simplifies the overall system by eliminating the need for downhole power sources, control electronics, or hydraulic fluid systems, thereby improving ease of operation while maintaining reliable deployment through robust mechanical components.
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 solution effectively seals leaks and defects, enhances wellbore integrity, and allows for gas lift operations and tool location profiles, improving wellbore performance and fluid production.
Implementation Method 1
an upper wedge portion operatively coupled to the setting kit and defining an upper ramp portion, a lower wedge portion arranged at a downhole end and defining a lower ramp portion... radially expanding a distal end of the casing patch as the distal end slidingly traverses the lower wedge portion, and radially expanding a proximal end of the casing patch as the proximal end slidingly traverses the upper wedge portion
Data Source
AI summary
Disclosed are systems and methods for deploying a casing patch in a wellbore. One casing patch assembly includes a setting kit arranged at an uphole end, an upper wedge portion operatively coupled to the setting kit and defining an upper ramp portion, a lower wedge portion arranged at a downhole end and defining a lower ramp portion, and a casing patch axially interposing the upper and lower wedge portions and having a proximal end configured to radially expand upon slidably engaging the upper ramp portion and a distal end configured to radially expand upon slidably engaging the lower ramp portion.