Expandable Casing Patch for Wellbore Sealing
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Solution Overview
Problem
Conventional casing patches struggle to be installed in wellbore casings with geometrical constraints like nipples, leading to a significant loss in internal diameter and limiting hydrocarbon production or further operations.
Innovation Solution
An expandable casing patch system with a base tubing and under-gaged sealing components that radially expand to develop interference contact with the wellbore casing, utilizing a deployment apparatus with a thruster, main expansion swage, anchor, and front expansion swage to ensure proper sealing and anchoring without damaging the casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional casing patches are installed in wellbore casings with geometrical constraints (nipples), then the damaged area is sealed, but the internal diameter is significantly reduced
Solution Approach 1:
The casing patch transitions from a compressed low-profile state during deployment to an expanded state that conforms to the wellbore casing inner diameter. The patch includes expandable elements that can be actuated hydraulically or mechanically to increase its external diameter, thereby maintaining adequate internal diameter while providing effective sealing against the casing wall.
Solution Approach 2:
The patch material properties change during deployment - transitioning from a flexible, compressible state that allows passage through restrictions to a rigid, expanded state that provides sealing. The patch may undergo phase changes, density changes, or structural transformations that enable it to adapt to the wellbore geometry while maintaining sealing effectiveness.
2Reliability
If conventional casing patches are used to seal damaged areas, then the opening is isolated, but further operations are limited due to reduced internal diameter
Solution Approach 1:
The patch is designed with dynamic expansion capabilities that allow it to be deployed in a compact form through wellbore restrictions, then expanded in-place to provide full sealing while preserving the original wellbore internal diameter for production operations. This dynamic transformation enables both effective isolation and maintained productivity.
Solution Approach 2:
The patch system employs a nested deployment structure where the sealing elements are contained within a deployable carrier that passes through the wellbore. The carrier is collapsed or nested during insertion to fit through restrictions, then the sealing elements are deployed and expanded to their functional size, allowing the well to be sealed without permanently reducing the internal diameter.
3Reliability
If the patch is expanded to seal against the wellbore casing, then sealing is achieved, but the deployment through restrictions becomes difficult
Solution Approach 1:
The patch incorporates dynamic geometry that allows it to be compressed to a small diameter for deployment through wellbore restrictions, then expanded radially to contact the casing wall for sealing. The transition from compressed to expanded state is controlled through hydraulic pressure, mechanical actuators, or material property changes that enable the patch to adapt its size to different operational requirements.
Solution Approach 2:
The patch utilizes flexible, thin-walled structures that can be collapsed or folded to reduce their external diameter during deployment. These flexible membranes or shells can be compressed circumferentially to fit through restrictions, then expanded radially to provide sealing contact, leveraging the material's ability to deform in different directions.
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 expandable casing patch system effectively seals and anchors the wellbore casing, maintaining the internal diameter and enabling efficient hydrocarbon production or further operations without significant loss, even in constrained geometries.
Implementation Method 1
Upon radial expansion of the under-gaged sealing component, the under-gaged sealing component develops an interference contact with the wellbore casing
Implementation Method 2
The thruster provides force for propelling the main expansion swage through and radially expanding the expandable casing patch
Implementation Method 3
The anchor is engageable to the internal wall to provide reaction force to propagate the main expansion swage through the expandable casing patch
Data Source
AI summary
An apparatus, method, and system for repairing wellbore casing. In one embodiment, an expandable casing patch system for a wellbore includes a casing patch deployment apparatus. The casing patch deployment apparatus includes a shaft having a frontward end and a rearward end as well as a thruster and a main expansion swage disposed on the shaft. The casing patch deployment apparatus also includes an anchor disposed on the shaft. The anchor is disposed frontward of the main expansion swage. In addition, the casing patch deployment apparatus includes a front expansion swage disposed frontward of the anchor and attached to the shaft. The front expansion swage has a diameter less than a diameter of the main expansion swage. The expandable casing patch system also includes an expandable casing patch.