Integrated Well Plugging Tool for P&A Operations
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Solution Overview
Problem
Current methods for plugging wells require multiple tool changes and operations, including perforating, cleaning, and flushing, which are inefficient and time-consuming, especially in ensuring direct contact between the hardenable concrete plug and the rock formation.
Innovation Solution
A combined three-part tool comprising a perforating lance, a cleaning unit, and a flushing unit integrated into a single apparatus, where the perforating lance creates holes, the cleaning unit mechanically cleans the pipe interior, and the flushing unit uses acid to dissolve and flush away concrete, all performed sequentially without needing to retrieve the pipe to the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate tools are used for perforation, cleaning, and flushing operations, then each operation can be performed with specialized equipment, but the operational time increases and efficiency decreases
Solution Approach 1:
The patent combines three separate tools (perforating tool, cleaning tool, and flushing tool) into a single integrated tool assembly. The perforating section with explosive charges, the cleaning section with mechanical cleaners, and the flushing section with fluid injection capabilities are all integrated into one device that can be deployed simultaneously, eliminating the need for multiple tool changes and reducing operational time while maintaining the quality of each function.
Solution Approach 2:
The integrated tool assembly performs multiple functions simultaneously - it can perforate the casing, clean the borehole wall, and flush debris all in one deployment. This multi-functional design allows a single tool to replace three separate specialized tools, improving efficiency without compromising the effectiveness of each individual operation.
2Reliability
If the pipe is retrieved to the surface to change tools, then each operation can be performed with optimal specialized equipment, but the operational efficiency and productivity decrease
Solution Approach 1:
The patent integrates multiple operational functions into a single deployable tool assembly that remains in the wellbore throughout the entire process. The perforating, cleaning, and flushing sections are all part of one tool that is lowered on a wire line, performs all functions sequentially in situ, and is then retrieved - eliminating the need for surface retrieval and tool changes, thereby maintaining operational quality while significantly improving productivity.
3Ease of manufacture
If conventional cleaning methods are used, then the pipe can be cleaned, but the concrete remains in the annular space may prevent direct contact between the new concrete plug and the rock formation
Solution Approach 1:
The patent employs a flushing section that uses high-pressure fluid injection to remove concrete remnants from the annular space between the casing and the borehole wall. The fluid is injected through nozzles directed at the concrete, effectively clearing the path and ensuring that when the new concrete plug is pumped in, it achieves direct contact with the rock formation, thereby improving the reliability of the plugging operation.
Solution Approach 2:
The flushing fluid used in the flushing section contains acid that chemically dissolves the concrete in the annular space. This chemical action accelerates the removal of concrete remnants more effectively than mechanical cleaning alone, ensuring complete clearance and guaranteeing direct contact between the new concrete plug and the rock formation.
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 integrated tool enables a single apparatus to perform perforation, cleaning, and flushing operations in a well, enhancing efficiency by ensuring direct contact between the concrete plug and the rock formation, reducing operational time and minimizing leakage risks.
Implementation Method 1
a perforating lance comprising a number of explosive charges which, by detonation, form a row of holes in the pipe and out into the surrounding layer of concrete
Implementation Method 2
a flushing unit to loosen, dissolve and flush away the hardened cement material between the outer wall of the pipe and the wall of the bore hole
Data Source
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AI summary
A tool (10) is described for the handling of wells through a formation, and which shall be taken out of operation with a device for a closing plug of a material that can be hardened, such as concrete, where there is a casing pipe in the well that is cemented against the wall in the bore hole with concrete, and it is characterised in that the tool comprises an assembled unit (10) from the following three sections; a perforating lance (32) comprising a number of explosive charges to form by detonation a row of holes in the pipe and out into the surrounding layer of concrete, a cleaning unit (34) for mechanical cleaning of the inner wall of the pipe in the perforated area and a flushing unit (36) to loosen, dissolve and flush away the hardened cement material between the outer wall of the pipe and the wall of the bore hole. Also described is a method to plug a well that shall be taken out of operation.