Wellbore Casing Repair Tool with Segmented Sealing Elements
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Solution Overview
Problem
Existing wellbore casing repair methods for low-pressure hydrocarbon wells are costly and inefficient, particularly due to the need for heavy lifting equipment and the difficulty in achieving a reliable seal, which poses safety risks from toxic or flammable gases during repair operations.
Innovation Solution
A wellbore tool with a rod and multiple sealing elements that provides a gas-tight seal within the wellbore casing, allowing for safe repair without bulky equipment, using a non-flammable fluid to isolate hazardous gases and enabling easy assembly, disassembly, and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wellbore casing repair methods are used, then reliable sealing can be achieved, but heavy lifting equipment is required and the process becomes costly and inefficient
Solution Approach 1:
The sealing system is divided into multiple discrete sealing elements that can be individually positioned along the rod. Each sealing element can independently contact the casing inner wall, providing distributed sealing points that achieve reliable sealing without requiring complex heavy equipment. The segmented approach allows the sealing function to be distributed along the length of the tool.
Solution Approach 2:
A non-flammable fluid is introduced as an intermediary substance between the hazardous gases and the repair environment. This fluid creates a barrier that isolates toxic or flammable gases from the repair zone, enabling safe repair operations without requiring complex safety equipment while maintaining sealing reliability.
2Object-affected harmful factors
If traditional repair equipment is used, then safety can be maintained, but the cost and time required for repair increases
Solution Approach 1:
The sealing elements are pre-positioned on the rod before insertion into the wellbore casing. The rod with attached sealing elements is inserted as a complete assembly, and the sealing elements are subsequently deployed against the casing inner wall. This preliminary preparation eliminates the need for complex on-site equipment assembly and reduces repair time while maintaining safety through effective hazardous gas isolation.
Solution Approach 2:
The wellbore tool is designed as a simple, inexpensive device that can be quickly deployed and removed. The sealing elements and rod structure use straightforward materials and construction methods, making the tool cost-effective compared to traditional heavy equipment. The tool is designed for single-use or limited-use scenarios where rapid deployment and removal are more valuable than long-term durability.
3Reliability
If heavy lifting equipment is used, then reliable repair can be performed, but the equipment is bulky and difficult to transport
Solution Approach 1:
The essential sealing and repair functions are extracted from the complex heavy lifting equipment and concentrated into a simple rod with sealing elements. By removing the unnecessary heavy components and retaining only the core functional elements (rod, sealing elements, and non-flammable fluid), the tool achieves repair reliability without the burden of bulky transport equipment.
Solution Approach 2:
The sealing elements utilize flexible sealing structures that can conform to the inner wall of the wellbore casing. These flexible sealing components replace rigid heavy-duty sealing mechanisms, providing reliable sealing through elastic deformation and pressure distribution rather than mechanical force from heavy equipment.
4Reliability
If complex sealing systems are used, then gas-tight sealing can be achieved, but the system becomes difficult to assemble and disassemble
Solution Approach 1:
The sealing system is segmented into multiple independent sealing elements that can be individually attached to the rod. Each sealing element functions independently, and if one fails or needs replacement, only that specific element needs to be addressed rather than the entire sealing system. This segmentation simplifies assembly and disassembly while maintaining gas-tight sealing through the collective action of multiple sealing points.
Solution Approach 2:
Instead of assembling a complex sealing system around the rod, the sealing elements are attached to the rod in a simplified manner and then deployed by expanding or inflating them against the casing inner wall. The inversion of the assembly sequence—attaching simple components first and creating the sealing action second—simplifies the overall assembly process while ensuring reliable gas-tight sealing.
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
Enables safe, cost-effective, and efficient repair of wellbore casings by isolating hazardous gases, reducing the need for heavy machinery, and facilitating quick installation and removal, while being easily configurable for different casing diameters and easy maintenance.
Implementation Method 1
Each sealing element is configured to provide a gas-tight seal between the sealing element and an inner wall of the wellbore casing
Data Source
AI summary
A wellbore tool includes a rod with a plurality of rod sections. The rod is configured to be placed within a wellbore casing of a low-pressure hydrocarbon well. A plurality of sealing elements are positioned at a downhole end of the rod. Each sealing element is configured to provide a gas-tight seal between the sealing element and an inner wall of the wellbore casing. A handle positioned at an uphole end of the rod provides a hand grip for a user of the wellbore tool.