Removable Expandable Metal Seal for Well Casing Integrity
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Solution Overview
Problem
Current methods for sealing orphaned and abandoned wells, such as using cement, are costly and prevent future access to oil or gas reserves, while also failing to effectively prevent gas emissions like methane from entering the atmosphere.
Innovation Solution
A method involving a camera to locate perforations and microfractures in well casings, followed by the deployment of an expandable metal sealing device with a hydraulic cylinder and shear pin to create a gas-tight seal that can be easily removed for future well reactivation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cement is used to plug the wellbore, then gas emissions are prevented, but future access to oil or gas is lost and costs increase
Solution Approach 1:
The sealing device transitions from a static cement plug to a dynamic, expandable metal seal that can be activated only when needed. The seal remains removable and can be deployed or removed based on future well usage requirements, providing adaptability while preventing gas emissions during the sealing phase.
Solution Approach 2:
The seal changes its physical state from a rigid cement structure to an expandable metal configuration. The metal seal can be expanded to engage the casing wall for sealing, then contracted or removed to restore access, allowing parameter changes in both physical state and functional capability.
2Object-affected harmful factors
If cement is used to seal the well, then gas leakage is stopped, but the cost increases significantly
Solution Approach 1:
The patent replaces expensive cement sealing with a more economical expandable metal seal that can be deployed and removed relatively easily. The metal seal uses a hydraulic cylinder and shear pin mechanism that is less costly than cement plugging operations and can be reset or removed if needed.
Solution Approach 2:
The sealing device is designed to be self-activating through hydraulic expansion. The hydraulic cylinder automatically expands the metal seal against the casing wall when activated, eliminating the need for complex cement pumping operations and reducing overall sealing costs.
3Adaptability or versatility
If an expandable metal seal is used, then future access is maintained, but the sealing reliability must be ensured
Solution Approach 1:
The expandable metal seal utilizes a curved or spherical expansion geometry that allows uniform engagement with the casing wall. The hydraulic cylinder expands the metal seal in a controlled manner, ensuring consistent contact and reliable sealing across the entire seal surface.
Solution Approach 2:
The seal is pre-positioned within the wellbore cavity, ready for immediate activation. The hydraulic cylinder and shear pin mechanism are pre-assembled to ensure that when activation occurs, the seal engages reliably with the casing wall before any gas leakage can occur.
4Adaptability or versatility
If the seal is made removable, then future reactivation is enabled, but the sealing force must be sufficient to prevent gas leakage
Solution Approach 1:
The seal design incorporates asymmetric features where the expansion force is applied in one direction to engage the casing wall, while the removal mechanism acts in the opposite direction. The shear pin is designed to fail at a specific force threshold, allowing easy removal after sealing, but requiring sufficient sealing force during operation.
Solution Approach 2:
The sealing force is made dynamic rather than static. The hydraulic cylinder can apply high expansion force when needed for sealing, then the system can be deactivated and removed with minimal force. This dynamic capability allows the seal to provide sufficient sealing force during operation while enabling easy removal for future reactivation.
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 provides a cost-effective and reversible seal that prevents gas leakage, allowing for potential future reactivation of wells while ensuring environmental integrity by thoroughly checking for cross-contamination and maintaining well integrity.
Implementation Method 1
a hydraulic cylinder attached to the sealing device by a shear pin into the well. Expanding the sealing device to engage the casing wall such that a gas seal is made between the sealing device and the casing wall, the sealing device being expanded through engagement by the hydraulic cylinder.
Implementation Method 2
An expandable sealing device is attached to the shear pin with the expandable sealing device being sufficiently expandable to engage the casing wall with sufficient force to shear the shear pin.
Data Source
AI summary
A method of sealing a well having a casing wall comprises transporting a camera into the casing wall making a visual recording by visually recording perforations, microfractures or other breach type damages of the wall and vertical location thereof on the wall. Selecting a vertical location for sealing the well, the vertical location being determined from the visual recording. Transporting an expandable sealing device being made of an expandable metal and a hydraulic cylinder attached to the sealing device by a shear pin into the well. Expanding the sealing device to engage the casing wall such that a gas seal is made between the sealing device and the casing wall, the sealing device being expanded through engagement by the hydraulic cylinder.