Exothermic Cast-In-Place Well Plugging for Gas-Tight P&A Seals
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Solution Overview
Problem
Conventional plug and abandonment (P&A) operations face challenges such as contamination from drilling fluid channels and regulatory requirements for permanent barriers across hydrocarbon-bearing formations, which are costly and inefficient, especially when using large blowout preventers and cementing methods.
Innovation Solution
A method involving a downhole tool to remove casing, deploy a blocking device, and use an exothermic fluid to liquefy and solidify a plugging material, forming a cast-in-place plug that expands to create a tight seal without mixing with drilling fluids, allowing for through-tubing operations without the need for large blowout preventers and reducing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cementing procedures are used to create permanent barriers, then regulatory requirements for plugging operations are met, but contamination from drilling fluid channels occurs and large blowout preventers are required
Solution Approach 1:
The invention changes the physical state parameter of the plugging material by using phase transition. The material is introduced in solid form, then heated to melt and flow into the annulus, and finally allowed to solidify again to form the barrier. This parameter change enables the material to adapt to the wellbore geometry and fill channels without requiring large equipment or causing contamination
Solution Approach 2:
The invention replaces the mechanical system of large blowout preventers and cementing procedures with a thermal processing system. Instead of using mechanical force to pump and set cement, the invention uses heating to melt and redistribute the plugging material, eliminating the need for large surface equipment and reducing contamination risks
2Reliability
If large blowout preventers and cementing methods are used, then regulatory requirements are met, but operational efficiency and cost-effectiveness decrease
Solution Approach 1:
The invention extracts the plugging function from the complex cementing procedure and large blowout preventer system. By using a removable heating device that can be deployed and retrieved, the invention separates the heating function from the plugging material, enabling simpler, faster operations that maintain regulatory compliance while improving efficiency
Solution Approach 2:
The plugging material performs multiple functions: it provides the permanent barrier, it responds to thermal energy by melting and flowing to fill channels, and it self-seals by solidifying in place. This self-service capability eliminates the need for complex external equipment and multiple operation steps, improving productivity
3Ease of manufacture
If conventional plugging materials are used, then basic plugging function is achieved, but corrosion resistance and durability are insufficient
Solution Approach 1:
The invention uses composite plugging material comprising a polymer matrix with embedded inorganic fillers or reinforcement. This composite structure provides both the basic plugging function and enhanced corrosion resistance and durability, meeting the harsh downhole environment requirements while maintaining ease of deployment
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 approach enables efficient and cost-effective P&A operations by creating a permanent, gas-tight seal within the wellbore, reducing the need for large offshore drilling units and minimizing contamination, while meeting regulatory requirements with a more durable and corrosion-resistant plug.
Implementation Method 1
deploying an exothermic fluid downhole, wherein activation of the exothermic material liquefies the plugging material
Implementation Method 2
activation of the exothermic material liquefies the plugging material
Implementation Method 3
allowing the plugging material and the exothermic fluid to solidify form a cast-in-place plug
Data Source
AI summary
A method of plugging a hydrocarbon well includes deploying a downhole tool to remove at least a portion of a casing at a section of well to be plugged. Deploying a blocking device downhole to block a bottom of the section of well to be plugged. Deploying a plugging material downhole onto the blocking device to fill an area to be plugged. Deploying an exothermic fluid downhole, wherein activation of the exothermic material liquefies the plugging material. Allowing the plugging material and the exothermic fluid to solidify form a cast-in-place plug that fills the section of well to be plugged.