Rapidly Solidifying Sealant Injection for Fractured Wellbores
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Solution Overview
Problem
Conventional methods for addressing loss circulation events in highly fractured formations are time-consuming and expensive, and existing loss circulation materials are often ineffective, leading to significant mud loss and potential well integrity issues.
Innovation Solution
The use of a rapidly solidifying sealant, delivered via an injector tool integrated into the drilling BHA, which is activated to precisely inject and solidify within formation fractures, preventing mud loss and maintaining well integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional loss circulation materials are used to block fractures, then drilling operations can continue, but the materials are ineffective against significant fractures and require time-consuming procedures
Solution Approach 1:
The patent changes the physical and chemical parameters of the sealant material to enable rapid solidification under downhole conditions. The sealant is formulated to transition from a pumpable fluid state to a solidified plug state quickly after injection, creating an effective barrier against significant fractures in record time
Solution Approach 2:
The injector tool is pre-positioned in the drilling assembly and the sealant is pre-prepared in containers ready for deployment. When loss circulation is detected, the system can immediately inject the sealant without requiring retrieval or assembly operations, achieving rapid response time
2Reliability
If drilling mud is pumped continuously to maintain hydrostatic pressure, then well integrity is maintained, but mud is lost into fractured formations
Solution Approach 1:
The rapidly solidifying sealant acts as an intermediary material injected between the drilling mud and the fractured formation. It creates a physical barrier that prevents direct communication between the mud column and the fractures, allowing hydrostatic pressure to be maintained while eliminating mud loss
Solution Approach 2:
The invention extracts the problematic fluid pathway by injecting a solidifying material that plugs the fracture entries. This removes the direct connection that causes mud loss, effectively taking out the loss mechanism from the system
3Reliability
If casing is removed and re-cemented to address loss circulation, then the fractured zone can be sealed, but the procedure is time-consuming and expensive
Solution Approach 1:
The injector tool is integrated into the existing drilling assembly and can be deployed without removing the drill string from the wellbore. The tool self-activates upon detection of loss circulation conditions and automatically injects the sealant, eliminating the need for costly and time-consuming casing operations
Solution Approach 2:
The injector tool is designed as a multi-functional device that can be integrated into standard drilling operations and activated only when needed. It serves both as a normal drilling component and as a rapid response sealant injection system, providing versatility without requiring separate equipment
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 approach minimizes mud loss, reduces non-productive time, and eliminates the need for casing cementation, thereby enhancing drilling efficiency and reducing operational costs.
Implementation Method 1
a rapidly solidifying sealant, delivered via an injector tool integrated into the drilling BHA, which is activated to precisely inject and solidify within formation fractures
Data Source
Figure 1
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AI summary
A tool (1) is used to inject a rapidly solidifying sealant (921) into and across highly fractured oil and gas wellbore formations when a significant loss circulation zone or event is encountered. A system including the tool (1) allows for application of the sealant (921) to the formation without requiring removal of the drill string (100) from the borehole. The tool (1) may have operatively associate with containers (3) storing sealant (921) and or sealant components that are provided downhole from the surface via wireline or the like.