Downhole Temperature-Activated Bypass for Well Plugging
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Solution Overview
Problem
Existing downhole plug and abandonment methods for wells with annuli or annular spaces are complicated and costly, as they require large rigs to remove production casing and risk damage to other completion barriers.
Innovation Solution
A downhole system featuring a temperature-activated bypass assembly with a bypass channel and an obstruction part, allowing fluid communication between volumes when the obstruction part is heated above a predetermined temperature, enabling melted metal to flow through the bypass channel and plug the well without damaging other completion barriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large rig is shipped to pull the production casing out of the well to properly plug the well, then the well can be plugged safely, but the operation becomes expensive and complex
Solution Approach 1:
The invention extracts the problematic production casing through a bypass channel created by melting through the barrier, rather than requiring mechanical removal by a large rig. The thermite charge melts the casing material, allowing it to be extracted through the bypass channel, thus eliminating the need for complex rig operations while maintaining safe plugging.
Solution Approach 2:
The invention replaces the mechanical rig-based casing removal system with a thermal field (thermite charge) that melts through the barrier and casing. This substitution of mechanical extraction with thermal melting simplifies the operation and eliminates the need for expensive large rigs while achieving the same plugging objective.
2Ease of operation
If pyrotechnics or explosives are used to remove tubing for access to the annular space, then access is achieved, but other completion barriers may be damaged
Solution Approach 1:
The invention applies local quality by concentrating the thermal energy precisely at the barrier and production casing location through the bypass channel. The thermite charge is positioned to melt only the specific materials that need removal, while the controlled nature of the thermal field prevents damage to surrounding completion barriers, unlike the uncontrolled shock waves from explosives.
Solution Approach 2:
The bypass channel acts as an intermediary that directs the thermal field from the thermite charge to the production casing. This controlled pathway ensures that the thermal energy is applied precisely where needed to melt and remove the casing, while preventing the uncontrolled propagation of energy that could damage other completion barriers.
3Reliability
If cement is used to fill the annular space to plug the well, then plugging is achieved, but cement cannot completely fill the annular space creating blowout risk
Solution Approach 1:
The invention performs preliminary action by removing the production casing through the bypass channel before introducing cement into the annular space. This preliminary removal of the casing eliminates the barrier that prevents complete cement filling, allowing subsequent cement placement to achieve reliable plugging without the complexity of trying to fill around the casing.
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
This solution allows for efficient and safe plug and abandonment of wells with annuli or annular spaces, reducing the need for large rigs and minimizing the risk of damage to other completion barriers, thereby lowering costs and ensuring environmental safety.
Implementation Method 1
the obstruction part is heated above a predetermined temperature so that the bypass channel is opened for fluid communication
Implementation Method 2
the risk that such heat would damage other parts of the completion unintentionally is eliminated... when heat is applied above the melting point of the obstruction part, the barrier melts
Data Source
AI summary
The present invention relates to a downhole system for providing plug and abandonment of a well having a top, comprising a first well tubular metal structure arranged in a borehole, a barrier arranged inside or around the first well tubular metal structure, isolating a first volume from a second volume, the barrier having a top face facing the first volume and a bottom face facing the second volume, wherein the barrier has a temperature-activated bypass assembly comprising a bypass channel and an obstruction part, the bypass channel extending from the top face to the bottom face for providing fluid communication between the first volume and the second volume when the obstruction part is removed by being heated. The invention also relates to a downhole method for providing plug and abandonment of a downhole system.