Sleeved Valve Cement Injection for Well Casing Integrity

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Solution Overview

Problem

In the petroleum industry, wells face issues with corrosion, erosion, and improper cement bonding, leading to pressure buildup and reduced integrity due to loss of metal and cement in casing strings, which current remediation methods like perf and squeeze cement jobs often exacerbate by creating microchannels.

Innovation Solution

A system and method involving a sleeved valve with a cement port and a tool with a cement injection needle are used to hydraulically connect and inject cement into the annulus, ensuring proper cement placement and sealing within the casing string, thereby addressing metal loss and cement deficiencies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If holes are made within the casing/liner to access the annulus for cement injection, then cement can be injected into the annulus, but microchannels may develop that further jeopardize the integrity of the well

Engineering Contradiction:

Improveannulus integrityVSAvoidmicrochannel formation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

A sleeved valve is installed within the casing string to serve as an intermediary access point to the annulus. The valve includes a body with a first opening facing the annulus and a second opening facing the interior of the well, with a closure member that can seal against the first opening. This intermediary structure allows cement injection without creating harmful microchannels in the casing/liner itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The valve body is segmented into distinct openings and chambers: a first opening to access the annulus, a second opening to receive the injection tool, a first chamber between the openings, and a second chamber within the closure member. This segmentation allows controlled cement flow paths that prevent microchannel formation while maintaining annulus integrity.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If cement is squeezed through holes in the casing/liner, then cement can be placed in the annulus, but the integrity of the well is reduced

Engineering Contradiction:

Improvecement injection capabilityVSAvoidwell integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The sleeved valve acts as a mediator that provides a controlled interface between the well interior and the annulus. The valve body with its first and second openings, along with the closure member, creates a safe pathway for cement injection that preserves well integrity while enabling effective cement placement in the annulus.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The closure member is preliminarily positioned within the valve body with its sealing surface ready to seal against the first opening. This preliminary preparation ensures that when cement injection occurs, the flow is controlled through predetermined paths rather than creating uncontrolled microchannels, thereby maintaining well integrity while achieving cement placement.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If cement may not be placed where it should be due to loss of cement to the formation or error, then cementing operation is simplified, but annulus integrity is compromised

Engineering Contradiction:

Improvecementing operation simplicityVSAvoidannulus integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The sleeved valve provides a controlled intermediary pathway that directs cement flow precisely into the annulus. The valve body with its specifically oriented first opening facing the annulus and second opening facing the well interior, combined with the closure member, ensures cement is placed only where intended, preventing loss to the formation while maintaining operational simplicity and annulus integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances the integrity of the well by ensuring effective cementation and preventing fluid leakage, improving the structural stability and safety of the well by maintaining the annulus integrity without creating additional holes or microchannels.

Implementation Method 1

applying hydraulic pressure, through the cement injection needle and onto the first cement port, to open the first cement port to the annulus

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Data Source

PatentUS11674364B2Restoring well casing—casing annulus integrity using a cement port in a sleeved valve and a cement injection and pressure testing tool

Publication Date: 2023.06.13 SAUDI ARABIAN OIL CO

AI summary

A system includes a sleeved valve disposed within a casing string. The sleeved valve has a first cement port configured to open and close to an annulus and a first opening. The first opening and the first cement port are hydraulically connected within the sleeved valve. The system further includes a tool made of a tubular body having an outer diameter smaller than an inner diameter of the casing string. The tool includes a tool orifice and a cement injection needle in hydraulic communication with the tool orifice. The cement injection needle fits inside the first opening and, upon entering the first opening, a first hydraulic connection is created between the tool orifice and the first cement port.