Expandable Polymer Grout for Irregular Wellbore Bonding
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Solution Overview
Problem
Existing bonding materials for wellbore equipment fail to securely attach and conform to extreme environmental conditions and irregular geometries, necessitating a need for materials that can bond dissimilar surfaces and adapt to uncertain or irregular wellbore geometries.
Innovation Solution
The use of expandable polymer grout systems comprising an isocyanate component and an organic polyol component, which react to form a polymer bond that can expand and conform to irregular geometries, securing wellbore equipment and materials under extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding materials are used, then the bonding process is simple, but the materials fail to securely attach and conform to extreme environmental conditions and irregular geometries
Solution Approach 1:
The bonding material utilizes phase change from liquid to solid through polymerization, transforming from a flowable state that can conform to irregular geometries into a solid state that provides secure bonding. This parameter change enables the material to adapt to complex wellbore shapes while maintaining reliable attachment under extreme conditions
Solution Approach 2:
The invention employs composite polymer formulations combining multiple components (isocyanate, polyol, catalysts, additives) that work synergistically to achieve both conformability to irregular geometries and secure bonding reliability. The composite nature allows simultaneous optimization of flow properties for adaptation and mechanical properties for reliable attachment
2Adaptability or versatility
If bonding material must conform to uncertain or irregular geometries, then adaptability improves, but material complexity increases
Solution Approach 1:
The bonding material is delivered as a fluid slurry through hydraulic pumping systems, allowing it to flow into and conform to uncertain or irregular geometries without requiring complex molding or shaping equipment. The hydraulic delivery system simplifies the overall complexity by using fluid dynamics rather than mechanical form-fitting
Solution Approach 2:
The material undergoes controlled parameter changes during delivery and curing, transitioning from a pumpable slurry state to a solidified bonded state. This parameter transformation allows the material to adapt to complex geometries during flow, then lock into place upon curing, managing complexity through temporal separation of conformability and structural integrity
3Reliability
If bonding material must withstand extreme temperatures and pressures, then reliability improves, but material selection becomes more limited
Solution Approach 1:
The invention uses composite polymer formulations specifically designed to withstand extreme wellbore temperatures and pressures while maintaining bonding effectiveness. The composite structure incorporates heat-resistant and pressure-resistant components that enable reliable performance across diverse extreme conditions without limiting material compatibility
Solution Approach 2:
The bonding material's physical and chemical parameters are optimized to remain stable under extreme temperatures and pressures. The polymerization reaction and resulting polymer structure are designed to maintain integrity and bonding strength across a wide range of extreme conditions, enabling versatile application in different wellbore environments
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 expandable polymer grout systems effectively bond to both metallic and non-metallic materials, adapting to uncertain geometries and maintaining a secure seal under extreme conditions, with properties such as resilience and lubricity, ensuring durability and functionality.
Implementation Method 1
combining components of an expandable polymer grout system to form a grout... combining, with the deployment system, components of an expandable polymer grout system within the wellbore to form a grout... combining, with a deployment system, components of an expandable polymer grout system to form a grout
Implementation Method 2
expandable polymer grout systems... which react to form a polymer bond that can expand and conform to irregular geometries
Implementation Method 3
allowing the grout to cure thereby securing the sensor to the downhole equipment within the wellbore... allowing the grout to cure thereby forming a casing centralizer on the outer surface of the casing
Data Source
AI summary
An expandable polymer grout system comprises an isocyanate component and an organic polyol component that when combined form a grout for bonding to equipment used in a wellbore. In a first instance, the grout is used with a retrieval system to bond to an obstruction in a wellbore for retrieving the obstruction from the wellbore. In a second instance, the grout is used with a deployment system to secure a sensor to downhole equipment within a wellbore. In a third instance, the grout is used to secure a casing centralizer to an outer surface of a casing before the casing is placed in a wellbore. In a fourth instance, the grout is molded to form a casing centralizer on an outer surface of a casing before the casing is placed in a wellbore.