Activatable Liquid Solder Coating for Controlled Wellbore Sealing
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Solution Overview
Problem
Current wellbore completion processes lack a reliable method for controllably releasing metal materials in liquid form to form barriers or seals within the wellbore, which is essential for efficient hydrocarbon production and wellbore operations.
Innovation Solution
A metal material coated with a controllably activatable layer that remains in an undercooled liquid state is positioned downhole, allowing it to be activated using heat, ultrasonic energy, magnetic fields, electric fields, compressive stress, or chemical dissolution to release and solidify, forming metal barriers or seals at desired locations within the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal material is positioned downhole in liquid form to form barriers or seals, then the ability to create reliable seals and anchor casings is improved, but the control over release timing and location deteriorates
Solution Approach 1:
The metal material is introduced into the wellbore in an undercooled liquid state before the actual sealing operation is needed. This preliminary positioning allows the material to be in place and ready, but kept dormant until the precise moment of activation, thus solving both the reliability of sealing and the control of release timing
Solution Approach 2:
The invention changes the physical state parameter of the metal material by maintaining it in an undercooled liquid state below its freezing point. This parameter change allows the material to remain fluid for positioning and then transition to solid upon activation, providing both ease of deployment and controlled release
2Reliability
If traditional high-temperature processes are used to form metal barriers, then the metal material can be reliably solidified, but the risk of thermal damage to wellbore components and formation increases
Solution Approach 1:
The invention utilizes the phase transition of metal material from liquid to solid state through controlled freezing rather than through high-temperature melting. The metal is introduced in an undercooled liquid state and solidifies upon activation, achieving reliable barrier formation without exposing wellbore components to high temperatures
Solution Approach 2:
The invention converts the normally harmful effect of rapid cooling (which could cause thermal shock) into a beneficial controlled freezing process. By introducing the metal in an undercooled state and controlling the freezing activation, the rapid phase change becomes a reliable sealing mechanism rather than a source of thermal damage
3Stability of the object's composition
If metal material is introduced in solid form, then the material stability is improved, but the ability to flow and form seals in complex wellbore geometries deteriorates
Solution Approach 1:
The invention changes the temperature parameter of the metal material to below its freezing point while maintaining it in a liquid state through undercooling. This allows the material to have the compositional stability of solid metal while maintaining the fluidity needed to flow into complex wellbore geometries and form complete seals
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 the formation of reliable metal barriers and seals that anchor casings, create plugs, and isolate zones efficiently, facilitating wellbore operations such as cementing, perforation, and production, while avoiding the need for high-temperature processes.
Implementation Method 1
activating the layer comprises subjecting, at a downhole location, the layer to heat
Implementation Method 2
the metal material may be in a liquid state prior to activation of the layer and activating the layer releases the metal material in the liquid state
Implementation Method 3
activating the layer comprises subjecting, at a downhole location, the layer to heat, ultrasonic energy
Implementation Method 4
activating the layer comprises subjecting, at a downhole location, the layer to heat, ultrasonic energy, magnetic fields
Implementation Method 5
activating the layer comprises subjecting, at a downhole location, the layer to heat, ultrasonic energy, magnetic fields, electric fields
Implementation Method 6
activating the layer comprises subjecting, at a downhole location, the layer to heat, ultrasonic energy, magnetic fields, electric fields, compressive stress
Implementation Method 7
activating the layer comprises subjecting, at a downhole location, the layer to heat, ultrasonic energy, magnetic fields, electric fields, compressive stress, or chemical dissolution
Data Source
AI summary
Metal material coated with a layer that is controllably activated can be positioned downhole in a wellbore prior to performing a wellbore operation. After the wellbore operation is performed, the layer can be activated to release the metal material.