Downhole Drill-Inject Plug Tool Casing Repair

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Solution Overview

Problem

Casing annular leaks in wells, often caused by poor cement, corrosion, or damage, require time-consuming repair processes that may reduce the well's internal diameter and involve multiple operations for sealing perforations.

Innovation Solution

A drill bit assembly with a frangible drive shaft, conical swage, and seal plug allows for simultaneous perforation, fluid injection, and sealing of the casing in a single operation, using a thread cutting surface and self-cutting thread to create a permanent seal with minimal diameter reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional expandable solution is used to seal perforation, then sealing is achieved, but internal diameter of casing is reduced and operation becomes time-consuming

Engineering Contradiction:

Improvesealing effectivenessVSAvoidoperation time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The seal plug is divided into distinct functional segments: a threaded portion for engagement with the perforation hole wall, a conical swage portion for radial expansion, and a drive shaft for rotation and retrieval. This segmentation allows each component to perform its specific function efficiently, enabling sealing without time-consuming operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of expanding a solution across the hole from the inside, the invention uses a pre-formed seal plug that is inserted into the hole and then radially expanded outward against the hole wall using the conical swage. This inverted approach achieves sealing more quickly and without reducing the internal diameter.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If multiple operations are used for sealing perforation, then sealing is achieved, but operational complexity increases

Engineering Contradiction:

Improvesealing effectivenessVSAvoidnumber of operations

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges multiple functions into a single integrated tool: the drill bit creates the perforation hole, the seal plug is inserted and threaded into the same hole, and the conical swage expands the seal plug to seal the hole all within one operational sequence. This consolidation eliminates the need for separate sealing operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The seal plug serves multiple functions: it acts as a barrier to prevent leakage, provides a threading surface for engagement with the hole wall, and contains the conical swage for radial expansion. This multi-functionality allows a single tool to perform what would traditionally require multiple specialized operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If expandable solution is applied to inner surface of casing, then sealing is achieved, but internal diameter is reduced

Engineering Contradiction:

Improvesealing effectivenessVSAvoidinternal diameter

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The sealing function is extracted from the casing's internal volume and transferred to a separate seal plug that interfaces with the perforation hole wall. This allows sealing to occur at the hole location without requiring the expandable solution to occupy the internal diameter of the casing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The seal plug acts as an intermediary element between the perforation hole and the casing interior. It provides the sealing interface at the hole wall while its expanded portion blocks the hole without requiring the casing's internal diameter to be reduced, as the seal plug occupies the hole space rather than the casing lumen.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method enables efficient repair of casing annular leaks with a single tool, providing a permanent seal and minimizing diameter reduction, thus extending the well's operational life without the need for subsequent patching.

Implementation Method 1

engaging an outer surface of the conical swage with an inner surface of the seal plug and radially expanding the seal plug as the conical swage is retracted through the hole wall

Methodology Applied

Scientific EffectMechanical expansion: Mechanical Force

Implementation Method 2

thread cutting surface formed on an outer surface of the drill bit... outer surface of the seal plug having a self-cutting thread

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11332997B2Downhole drill-inject and plug tool

Publication Date: 2022.05.17 SAUDI ARABIAN OIL CO

AI summary

An apparatus includes a drill bit having a frangible drive shaft, a thread cutting surface formed on an outer surface of the drill bit, a conical swage formed on the drill bit, the conical swage having a conical shape, and a seal plug coupled to the drill bit, the seal plug removable from the drill bit. A method includes penetrating an inner surface and an outer surface of the casing with a drill point of the drill bit thereby forming a hole, threadingly engaging the seal plug with the hole wall, disengaging the seal plug from a drive shaft of the drill bit assembly, retracting the drill bit assembly through the seal plug, and engaging an outer surface of a conical swage with an inner surface of the seal plug and radially expanding the seal plug as the conical swage is retracted through the hole wall, thereby sealing the hole.