In-Situ Pipe Cladding With Dual Lasers for Downhole Repair
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Solution Overview
Problem
Downhole pipes, such as casings and tubings, often corrode, rust, or erode, requiring costly replacement due to the need for retrieval from the downhole environment for repair, which is inefficient and time-consuming.
Innovation Solution
An in-situ cladding method using a dual head laser and wire feeding system that allows for cladding within the pipe, where a primary laser beam melts the cladding wire onto the target surface in one direction and a secondary laser beam, with an internal purging system, forms layers that are then welded together without the need for pipe retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional laser cladding is used on downhole pipes, then the pipe can be repaired, but the pipe must be retrieved from the downhole environment which causes downtime and increased costs
Solution Approach 1:
The patent replaces traditional mechanical retrieval and off-site repair processes with an in-situ laser cladding system that can repair pipes directly in the downhole environment. The laser cladding apparatus is deployed through the pipe using a conveyance system, eliminating the need to retrieve the pipe for repair.
Solution Approach 2:
The patent introduces an intermediary in-situ cladding system that operates within the downhole environment. This system includes a laser source, wire feeding system, and conveyance mechanism that can deliver repair capabilities to the pipe without requiring pipe removal.
2Reliability
If traditional laser cladding is used on downhole pipes, then the pipe can be repaired, but the process is costly in terms of expense and downtime
Solution Approach 1:
The patent replaces expensive mechanical retrieval and off-site repair operations with an in-situ laser cladding system. This substitution eliminates costly logistics associated with pipe retrieval, transportation, and shutdown time.
3Loss of time
If in-situ cladding is performed within the pipe, then downtime is reduced, but the system must operate in a restricted geometric environment
Solution Approach 1:
The patent segments the cladding system into modular components: a laser source, wire feeding system, conveyance mechanism, and control systems. This segmentation allows the system to navigate restricted geometries while maintaining repair capabilities.
Solution Approach 2:
The patent introduces an intermediary conveyance system that delivers the laser cladding apparatus through the pipe. This mediator enables operation in restricted geometries by providing a delivery and positioning mechanism that navigates the confined space.
4Loss of time
If in-situ cladding is performed within the pipe, then downtime is reduced, but the system requires integration of multiple components in a compact configuration
Solution Approach 1:
The patent merges multiple functional components (laser source, wire feeding system, conveyance mechanism, and control systems) into an integrated in-situ cladding apparatus. This consolidation enables the system to operate within the confined pipe environment while maintaining all necessary repair functions.
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
Enables efficient repair of downhole pipes by eliminating the need for removal and replacement, improving the efficiency of the cladding process through the use of a dual head laser system that can weld layers without repositioning, thus reducing downtime and costs.
Implementation Method 1
A laser beam 108 may be used to melt the cladding wire 104 onto the target surface 106
Implementation Method 2
melting the cladding wire onto the target surface with the primary beam
Implementation Method 3
blowing gas onto the cladding wire using an internal purging system integrally formed with the secondary beam, forcing melting of the cladding wire in a first desired direction
Implementation Method 4
switching off the primary beam and switching on the secondary beam and welding the first layer and the second layer together using the secondary beam
Data Source
AI summary
An in-situ cladding method including providing a pipe with a target surface with a defected area. The method also includes lowering an in-situ cladding system into the pipe. The in-situ cladding system includes a dual head laser, with primary and secondary beams, and a wire feeding system. The method also includes lowering the wire feeding system into the pipe, feeding a cladding wire onto the target surface, melting the cladding wire onto the target surface with the primary beam, and blowing gas onto the cladding wire using an internal purging system. The method further includes forcing melting of the cladding wire in a first desired direction to form a first layer, forcing melting of the cladding wire in a second desired direction to form a second layer, switching off the primary beam and switching on the secondary beam, and welding the first and second layers together using the secondary beam.