Eutectic Alloy Deployment Tool for Lost Circulation Sealing
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Solution Overview
Problem
Existing methods for addressing lost circulation during well drilling are inadequate, particularly in cases of total loss-of-circulation, as they fail to accurately and efficiently deposit eutectic metal alloys at targeted locations within the well.
Innovation Solution
A deployment tool equipped with eutectic metal alloy pellets, a heating element, and a crucible is used to melt and deposit the eutectic alloy precisely at lost circulation zones, allowing for the formation of a patch that seals the fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If eutectic metal alloy is transported with carrier fluid to the loss zone, then the alloy can reach the targeted location, but the alloy drifts away deep into the fractures long before it solidifies
Solution Approach 1:
The patent removes the carrier fluid from the delivery system and instead uses a dry mechanical delivery system that transports solid eutectic metal alloy pellets directly to the loss zone. This extraction of the carrier fluid eliminates the time delay and imprecision associated with fluid transport, allowing the alloy to be delivered directly and solidify immediately upon contact with the cooler formation.
Solution Approach 2:
The patent replaces the chemical/fluid-based delivery system with a mechanical delivery system that uses a deployment tool with a heater element. The solid alloy pellets are mechanically transported and then melted by the heater element directly at the deployment location, providing precise control over placement and immediate solidification when the heater is deactivated.
2Quantity of substance
If existing mechanical delivery system is used to deposit eutectic metal alloy, then the alloy can be delivered to the loss zone, but the alloy cannot be placed accurately and close enough to a heat source for adequate melting
Solution Approach 1:
The patent combines the delivery mechanism and heating function into a single integrated deployment tool. The heater element is embedded within the tool body, and the alloy pellets are delivered directly into contact with or near the heater element. This merging ensures that the alloy is always placed close enough to the heat source for adequate melting while maintaining precise placement control.
Solution Approach 2:
The deployment tool acts as an intermediary device that bridges the gap between alloy delivery and heat source placement. The tool contains both the alloy pellets and the heater element, and mechanically positions them in precise relationship to each other, ensuring accurate placement and adequate heating without requiring separate delivery and heating operations.
3Ease of operation
If LCM or cement flows in liquid phase to the loss zone, then they can reach the fracture, but they end up drifting away deep into the fractures long before they solidify
Solution Approach 1:
The patent changes the physical state parameter of the sealing material from liquid/suspension phase to solid pellet phase. The eutectic metal alloy is delivered as solid pellets that are then melted by the heater element and allowed to solidify in controlled fashion. This parameter change enables precise control over the sealing location, as the material solidifies immediately when the heater is deactivated, preventing drift into deep fractures.
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 deployment tool effectively delivers and solidifies eutectic metal alloy at targeted locations within the well, providing a reliable solution for sealing lost circulation zones and maintaining drilling efficiency.
Implementation Method 1
The heater in the deployment tool is activated while the drill string is continuously rotated and drilling fluid is pumped. The eutectic metal alloy pellets melt through the deployment tool toward the crucible that allows deposition on the targeted zone.
Implementation Method 2
a crucible on the end where the heater is located to deposit the melted eutectic alloy
Implementation Method 3
A heat source is necessary to melt the eutectic metal so that it can reach the desired location, and then the heating source is removed or deactivated to allow the eutectic metal alloy to cool and solidify to repair the fractures.
Data Source
AI summary
A method repairing lost circulation conditions during drilling operations, including deploying a deployment tool to a lost circulation zone, charging the deployment tool with eutectic metal alloy pellets, activating a heater to melt the pellets through the deployment tool and out of the crucible onto the targeted zone to form a patch, removing the deployment tool, and milling away excess cooled and cured eutectic metal alloy.