Eutectic Alloy Wellbore Plug Deployment Tool
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Solution Overview
Problem
Existing wellbore plug deployment tools face challenges in achieving a gas-tight seal in highly deviated or horizontal wellbores due to inadequate coverage and slumping of metal sealants, which results in poor anchoring and pressure retention.
Innovation Solution
A wellbore plug deployment tool utilizing a eutectic alloy sheath that expands upon cooling, combined with centralizing mechanisms and temperature control via thermite cores, ensures complete annular coverage and anchoring, even in deviated wells, by strategically igniting thermite cores and using expandable components like slips and vanes to direct the metal flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal sealant is used in highly deviated or horizontal wellbores, then anchoring and pressure retention are improved, but metal slumping and inadequate coverage occur
Solution Approach 1:
The wellbore is divided into multiple zones with separate heating elements positioned at different locations (upper, middle, lower sections). Each heating element independently melts and deposits metal sealant in its designated zone, preventing slumping by confining the molten metal to specific segments rather than allowing it to flow freely under gravity.
Solution Approach 2:
Different regions of the wellbore are treated with localized heating and metal deposition. The heating elements are positioned to create specific thermal zones that melt and deposit metal sealant only where needed, ensuring uniform distribution and proper anchoring in each local area rather than relying on gravity-driven flow.
2Device complexity
If conventional wellbore plug deployment tools are used, then simplicity is maintained, but gas-tight seal achievement fails in deviated wells
Solution Approach 1:
The deployment tool features a nested structure with an inner tube containing heating elements positioned inside an outer tube that holds the metal sealant. The inner tube can be withdrawn to allow controlled deposition of molten metal in the annular space between the inner and outer tubes, creating a gas-tight seal while maintaining a relatively simple overall tool design.
Solution Approach 2:
The patent replaces gravity-dependent mechanical metal flow with thermally-controlled metal melting and deposition. Instead of relying on gravitational force to move and distribute metal sealant, the system uses localized heating elements to melt and deposit metal in controlled zones, ensuring reliable sealing in deviated and horizontal wellbores where gravity is ineffective.
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 tool achieves a robust, gas-tight seal with enhanced pressure retention capabilities across packers, effectively addressing the limitations of existing technologies in deviated and horizontal wellbore applications by ensuring uniform metal distribution and anchoring.
Implementation Method 1
The eutectic material may be melted for example by heating via various mechanisms, including without limitation heat delivery lines (e.g., electric lines), pyrotechnic devices and chemical reactions, for example thermite.
Implementation Method 2
The eutectic material may expand when it is cooled and solidifies.
Implementation Method 3
The eutectic material may expand when it is cooled and solidifies.
Implementation Method 4
The eutectic material may be melted for example by heating via various mechanisms, including without limitation heat delivery lines (e.g., electric lines), pyrotechnic devices and chemical reactions, for example thermite.
Data Source
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AI summary
A tool for deploying a wellbore plug in a well using flowable eutectic material is disclosed. A tool having a mandrel, an obstruction, and a flowable quantity of eutectic material in a solid state is positioned in the wellbore. The obstruction is actuated and the flowable material is heated to melt. The obstruction supports the flowed material as it cools to form a plug in the wellbore.