Downhole Casing Patch With Expandable Wedges for Metal Sealing
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Solution Overview
Problem
Existing downhole casing repair methods are inadequate for creating a reliable seal and controlling fluid production in hydrocarbon wells, particularly when casings have imperfections or damage, as they often require power supply from the surface and do not effectively manage fluid communication.
Innovation Solution
A deployable downhole casing patch system with expandable wedges and a power unit that creates a metal-to-metal seal with the wellbore casing, including a port for fluid communication and a profile for tool placement, allowing for independent power operation and adjustable fluid passage based on hydrocarbon well parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing downhole casing repair methods are used, then casing damage can be addressed, but reliable sealing and fluid communication cannot be achieved without surface power supply
Solution Approach 1:
The casing patch system incorporates a self-contained power unit with a battery that provides power independently of surface supply. The system includes an expandable wedge mechanism that can be deployed and activated downhole without requiring continuous power transmission from the surface, enabling self-sufficient operation for sealing and fluid communication functions.
Solution Approach 2:
The power unit is segmented into discrete components including a battery, motor, and control system that can be independently packaged and deployed. This segmentation allows the power source to be self-contained within the downhole tool, eliminating the need for continuous surface power supply while maintaining all necessary functions for reliable sealing.
2Reliability
If expandable wedges are used to create metal-to-metal seal, then sealing performance is improved, but device complexity increases
Solution Approach 1:
The wedge assembly is designed as a dynamic, expandable mechanism that transitions from a compact deployed state to an expanded sealing state. The wedge can be selectively activated to expand against the casing wall, creating a metal-to-metal seal only when needed, thereby providing reliable sealing without permanently increasing device complexity.
Solution Approach 2:
The expandable wedge mechanism is nested within the casing patch structure, allowing the sealing function to be integrated into the existing patch geometry. The wedge can be contained within the patch body and deployed outward only when sealing is required, minimizing the increase in overall device complexity while maintaining effective sealing capability.
3Manufacturing precision
If locating profile is added to constrain downhole tool, then tool positioning accuracy is improved, but manufacturing complexity increases
Solution Approach 1:
The locating profile is implemented as a localized feature on the inner surface of the casing patch, rather than requiring complex machining of the entire patch. The profile can be added as a discrete element that provides tool constraint only where needed, minimizing the impact on overall manufacturing complexity while achieving the required positioning accuracy.
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 reliable sealing of casing imperfections without surface power, facilitating controlled fluid production and communication, and allowing for the placement of downhole tools, thereby enhancing wellbore stability and production efficiency.
Implementation Method 1
each of the first end and second end comprising an expandable wedge that is deformable into a wellbore casing
Implementation Method 2
a power unit comprising a connection for a conveyance from a terranean surface through a wellbore, the power unit providing power independent of the conveyance
Data Source
AI summary
A casing patch includes a tubular that comprises a first end and a second end opposite the first end, each of the first end and second end comprising an expandable wedge that is deformable into a wellbore casing; and a locating profile formed onto an inner surface of the tubular between the first and second ends.