Expandable Wellbore Patch for Drilling Fluid Loss Control
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Solution Overview
Problem
Drilling fluid loss from wellbores during oil and gas drilling can lead to uncontrolled hydrocarbon inflow, pressure changes, and potential blowouts, necessitating costly and time-consuming mud addition and posing safety hazards.
Innovation Solution
Deployment of a radially expandable wellbore patch formed from a helically wound tube that expands elastically to seal formation openings, using a deployment tool to prevent expansion until positioned in the wellbore, then releasing to restrict fluid outflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drilling fluid is continuously pumped to maintain hydrostatic pressure, then pressure control is improved, but fluid loss to formation openings increases
Solution Approach 1:
The patch is divided into multiple overlapping segments that can be deployed sequentially along the wellbore. Each segment addresses a specific zone of formation openings, allowing localized sealing without requiring continuous high-volume fluid pumping throughout the entire wellbore.
Solution Approach 2:
The expandable patch acts as an intermediary barrier between the drilling fluid and the formation openings. It intercepts and seals formation voids and openings before the drilling fluid can escape, reducing fluid loss while maintaining pressure control.
2Reliability
If drilling fluid volume is increased to compensate for losses, then pressure control is maintained, but drilling efficiency decreases
Solution Approach 1:
The patch is deployed in advance to seal formation openings before significant fluid loss occurs. This preliminary sealing action prevents the need for continuous mud addition and maintains drilling efficiency by avoiding repeated trips to replenish fluid volume.
Solution Approach 2:
The patch is a consumable, disposable component that provides temporary sealing until the drilling operation is complete or the patch degrades. This approach is more efficient than continuously managing large volumes of drilling fluid to compensate for ongoing losses.
3Reliability
If the patch is made highly elastic for maximum expansion, then sealing effectiveness is improved, but control during deployment deteriorates
Solution Approach 1:
The patch transitions from a constrained, low-profile state during deployment to an expanded, high-seal state once positioned. The dynamic expansion is controlled by the deployment mechanism that releases constraints at the target location, allowing the patch to adapt its properties based on operational needs.
Solution Approach 2:
The deployment tool acts as an intermediary that controls the patch during transport and only releases it when properly positioned. This intermediary mechanism prevents premature expansion while ensuring accurate placement before the patch expands to its sealing configuration.
4Reliability
If multiple overlapping patches are deployed to ensure complete sealing, then sealing effectiveness is improved, but device complexity increases
Solution Approach 1:
The sealing system is segmented into multiple patches that can be deployed independently or in sequence. This segmentation allows for modular deployment where patches are placed at specific intervals along the wellbore, managing complexity through standardization of individual units.
Solution Approach 2:
Each patch is designed as a universal component that can be deployed using the same deployment mechanism and serves the same sealing function. This universality reduces system complexity compared to having different specialized devices for different sealing zones.
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
Reduces fluid loss, enhances drilling efficiency, improves wellbore safety by preventing pressure loss, and minimizes the risk of blowouts, while allowing continued drilling with minimal equipment adjustments.
Implementation Method 1
the patch is released and expands elastically in the wellbore, increasing in diameter
Implementation Method 2
radial expansion of the tube member is a result of elastic unfurling of the sheet
Data Source
AI summary
A wellbore patching system includes a radially expandable tube member including a sheet wrapped in a spiral. The sheet includes a first circumferential edge and a second circumferential edge opposite the first circumferential edge and coupled to the first circumferential edge. The radially expandable tube member includes a hollow interior. The wellbore patching system includes a deployment tool including: a tool body; and a restraining device coupled to the tool body and configured to prevent radial expansion of the tube member when the tool body is positioned within the hollow interior of the tube member and the restraining device is applied to the tube member. The first circumferential edge is bent to form a first hook, the second circumferential edge is bent to form a second hook, and the first circumferential edge is coupled to the second circumferential edge by the first hook engaging the second hook.