Two-Stage Resin Plug for Wellbore Abandonment
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Solution Overview
Problem
Resin plugs used for wellbore abandonment face issues due to shrinkage during hardening, which creates gaps between the plug and the wellbore wall, compromising their effectiveness as a permanent barrier.
Innovation Solution
A 2-stage resin plug comprising a heavier resin with a faster setting rate and a lighter resin with a slower setting rate, where the heavier resin sets first, and the lighter resin fills any void created by shrinkage before it sets, ensuring a tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin plug is used to seal an abandoned wellbore, then it provides a barrier function, but shrinkage during hardening creates gaps that compromise sealing effectiveness
Solution Approach 1:
The resin plug is segmented into multiple layers with different densities and setting rates. The heavier resin with faster setting rate forms the base layer, while the lighter resin with slower setting rate forms the upper layer that fills shrinkage gaps.
Solution Approach 2:
The invention changes the physical parameters of the resin by using two different resins with different densities and setting rates. This parameter variation allows the upper resin to remain fluid longer and fill the gaps created by shrinkage of the lower resin.
2Reliability
If a single resin is used for the plug, then the structure is simple, but shrinkage creates voids that reduce barrier performance
Solution Approach 1:
The invention uses a composite resin system consisting of two different resins with complementary properties. The heavier, faster-setting resin provides structural stability, while the lighter, slower-setting resin ensures complete gap filling and void elimination.
Solution Approach 2:
The heavier resin with faster setting rate performs the preliminary action of setting first to provide a stable base structure. This preliminary setting creates the framework that the lighter resin then fills completely, ensuring no voids remain.
3Productivity
If the resin sets quickly, then placement time is reduced, but shrinkage gaps form before the light resin can fill them
Solution Approach 1:
The setting process occurs in periodic stages: first the heavier resin sets quickly to establish the base structure, then the lighter resin sets more slowly to fill any remaining gaps. This staged, periodic setting ensures both speed and completeness.
Solution Approach 2:
The heavier resin performs the preliminary setting action first, creating a stable foundation. This preliminary action allows the lighter resin to subsequently fill gaps without the risk of the entire plug moving or destabilizing.
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 2-stage resin plug effectively eliminates shrinkage-induced gaps, forming an impermeable seal that can withstand high hydrostatic pressures, enhancing the plug's durability and reliability in wellbore abandonment.
Implementation Method 1
an amount of a heavier resin and an amount of a light weight resin, the heavier resin configured to have a faster setting rate than the light weight resin, the heavier resin residing in the wellbore below the light weight resin
Implementation Method 2
the seal being formed by the heavier resin setting first followed by setting of the light weight resin thereafter
Implementation Method 3
a void formed during setting of the heavier resin is filled by the light weight resin before the light weight resin sets
Data Source
AI summary
A resin plug for wellbore abandonment includes: an amount of a heavier resin and an amount of a light weight resin, the heavier resin configured to have a faster setting rate than the light weight resin. The resin plug creates a seal for wellbore abandonment by the heavier resin setting first followed by setting of the light weight resin thereafter. Any void formed during setting of the heavier resin is filled by the light weight resin before the light weight resin sets.