In-situ Sol-Gel Solid Formation for Wellbore Zonal Isolation

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Solution Overview

Problem

Wellbore equipment is subjected to abrasive wear and reduced longevity due to the use of highly abrasive slurries during well completion and fracturing operations, leading to inefficient pumping and increased energy expenditure.

Innovation Solution

The sol-gel process is employed to place solids in a wellbore by pumping colloids of monomers that polymerize in-situ, forming solids without the need for harsh slurries, thereby reducing abrasive effects on equipment and improving pumping efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If abrasive slurries are pumped into the wellbore to place solid material, then the solid material can be delivered to the desired location, but the wellbore equipment is subjected to severe abrasive wear and reduced longevity

Engineering Contradiction:

Improvesolid material placementVSAvoidequipment longevity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention changes the physical and chemical parameters of the solid material from hard, irregular particles to soft, spherical gel beads formed through sol-gel transformation. This parameter change reduces the abrasive nature of the material while maintaining its ability to be pumped and placed in the wellbore, thereby protecting equipment longevity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a slurry as an intermediary carrier that contains precursors which transform into solid material in-situ. The slurry itself is less abrasive than traditional slurries because it carries dissolved or finely dispersed precursors rather than hard particles, reducing wear on pumping equipment while still delivering the desired solid material to the target location

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If hard, irregularly shaped solid material is used in slurries, then the material can provide structural function (plugging, propping, gravel packing), but the slurry becomes highly abrasive to pumping machinery

Engineering Contradiction:

Improvestructural function of solid materialVSAvoidabrasive wear on machinery

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention transforms the parameters of solid material from hard and irregular to soft and spherical through the sol-gel process. The gel beads maintain sufficient structural integrity for plugging and isolation functions while their soft, rounded morphology dramatically reduces abrasive effects on pumping machinery

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the harmful abrasive properties of solid material into a benefit by using the sol-gel transformation. The material starts as a non-abrasive precursor in slurry form, then transforms into the desired solid structure at the target location, effectively converting what would be a harmful characteristic into a beneficial process feature

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Speed

If high velocity slurry flow is used to deliver solid material, then the material can be pumped efficiently through the wellbore, but the kinetic energy of particles causes severe abrasive wear and material loss

Engineering Contradiction:

Improveslurry flow velocityVSAvoidmaterial loss from abrasive wear

Core Design Contradiction:

SpeedVSLoss of substance

Solution Approach 1:

The invention changes the material parameters from hard particles to soft gel beads that can withstand high velocity flow without causing abrasive wear. The soft, deformable nature of the gel beads allows them to be pumped at high speeds while minimizing kinetic energy transfer to equipment surfaces, thereby reducing material loss from abrasive wear

Inventive Principle:

Principle #35Parameter changes

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 extends the life of wellbore equipment and enhances operational efficiency by minimizing abrasive wear and friction, allowing for more effective fracturing and completion operations.

Implementation Method 1

pumping a sol of hydrolyzed metallic alkoxides into the wellbore or in a fracture that gels and hardens in-situ

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

pumping a sol of hydrolyzed metallic alkoxides into the wellbore or in a fracture that gels and hardens in-situ

Methodology Applied

Scientific EffectGelation: Gel

Data Source

PatentUS7810562B2In-situ formation of solids for well completions and zonal isolation

Publication Date: 2010.10.12 SCHLUMBERGER TECH CORP

AI summary

A sol of metallic alkoxide is pumped into a desired location in a wellbore and allowed to gel, creating solids in-situ. The sol is either unstabilized, requiring rapid placement before gelling, or the sol is stabilized, permitting off-site mixing. Sols can be stabilized with either surfactant or with interfacial polymers. Large concentrations of surfactant can be placed in the sol to create templates around which gelation occurs, creating porous solids.