Expandable Mesh and Epoxy Repair for Production Tubing Pinholes
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Solution Overview
Problem
Pinholes in production tubing cause fluid escape, leading to loss of product, reduced well productivity, and safety hazards, with current repair methods being expensive and causing extended downtimes.
Innovation Solution
A tubing mesh stent assembly (TMS) with expandable mesh and hydraulically activated packers is deployed to seal leaks, using reactive epoxy compounds to form a permanent barrier, minimizing downhole intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current conventional repair practices are used to address pinholes, then tubing integrity is restored, but repair costs increase and well downtime extends
Solution Approach 1:
The patent changes the physical and chemical parameters of the repair materials by using expandable mesh that transforms from a compressed state to an expanded state, and epoxy that transitions from liquid to solid. This allows the repair system to be deployed in a compact form and then transform at the repair site to create a permanent seal, reducing retrieval needs and downtime
Solution Approach 2:
The patent employs composite materials combining expandable mesh structure with reactive epoxy compounds. The mesh provides structural support and containment while the epoxy provides chemical bonding and sealing. This composite approach creates a durable repair that eliminates the need for retrieval and reduces operational downtime
2Reliability
If current conventional repair practices are used to address pinholes, then tubing integrity is restored, but repair costs increase
Solution Approach 1:
The repair system is self-contained and self-activating. The expandable mesh expands automatically when deployed, and the epoxy cures in situ without requiring external intervention or retrieval operations. This self-service capability eliminates expensive retrieval operations and reduces overall repair costs
Solution Approach 2:
The patent utilizes parameter changes in the epoxy material from liquid to solid state through chemical reaction, and the mesh from compressed to expanded state. These parameter changes enable the repair system to create a permanent seal in situ, eliminating the need for expensive retrieval operations and reducing overall repair costs
3Reliability
If expandable mesh stent assembly is deployed with epoxy compounds, then leak sealing effectiveness improves, but device complexity increases
Solution Approach 1:
The repair system is segmented into distinct functional components: the expandable mesh stent assembly, the reactive epoxy compounds, and the delivery mechanism. This segmentation allows each component to perform its specific function efficiently while simplifying the overall deployment process and reducing operational complexity
Solution Approach 2:
The patent employs dynamic transformation of the mesh from a compressed deployable state to an expanded functional state. This dynamic capability allows the system to adapt to the tubing geometry and create an effective seal without requiring complex custom-fitted components for each repair scenario
4Loss of time
If minimal downhole intervention is used, then well downtime is reduced, but repair reliability may be compromised
Solution Approach 1:
The repair system is self-contained and self-activating. The expandable mesh expands automatically when deployed, and the epoxy cures in situ without requiring external intervention or retrieval operations. This self-service capability eliminates the need for expensive retrieval operations and reduces overall repair costs
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 method provides a cost-effective solution with minimal downtime, ensuring well integrity and preventing future leaks by creating a reinforced seal that remains in place for the life of the well.
Implementation Method 1
pumping a first reactive epoxy-containing compound through the tubing mesh stent assembly to fill the leak, allowing all epoxy-containing compounds to react for up to 24 hours or more to cure
Implementation Method 2
expanding the tubing mesh stent assembly to firmly contact a wall of the well completion component being repaired
Implementation Method 3
setting the tubing mesh stent assembly in place using a plurality of packers positioned at each end of the tubing mesh stent assembly
Data Source
AI summary
A method to repair well completion components includes evaluating tubing-casing annulus (TCA) communication to locate a leak, determining a placement depth, preparing a tubing mesh stent assembly and one or more epoxy compounds at a well surface, performing workover operations, installing a retrievable plug, running the tubing mesh stent assembly into the well to the leak depth, expanding the tubing mesh stent assembly, setting the tubing mesh stent assembly in place, pumping a first reactive epoxy-containing compound through the tubing mesh stent assembly to fill the leak, allowing all epoxy-containing compounds to react for up to 24 hours or more to cure, reversing workover operations to resume normal production, and testing the well under pressure to ensure integrity at normal operating conditions. A system for repairing leaks in well completion components includes a tubing mesh stent assembly including an upper section, a middle section, and a lower section.