Downhole UV System for Lost Circulation Sealing
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Solution Overview
Problem
Conventional lost circulation materials struggle to effectively seal un-uniform and larger voids in subterranean wells due to unpredictable activation conditions such as temperature and pH, leading to potential plugging of the downhole assembly or failure to harden, which can result in fluid loss and wellbore instability.
Innovation Solution
A system utilizing a loss circulation material with oligomers, monomers, and photo-initiators, activated by an ultraviolet source integrated with the drill string, which generates free radicals to trigger cross-linking or polymerization reactions, ensuring the material hardens and sets within the lost circulation zone, even in unpredictable conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lost circulation materials are used with temperature or pH activators, then the material can harden in the lost circulation zone, but the activation conditions are unpredictable which may cause the material to harden prematurely in the downhole assembly or fail to harden in the loss zone
Solution Approach 1:
The patent changes the activation parameter from temperature/pH-dependent chemical activators to ultraviolet light-dependent photo-initiators. This allows precise control of the hardening process by activating the material only when exposed to UV light at the desired location, eliminating unpredictable premature or failed activation.
Solution Approach 2:
The patent replaces the chemical activation mechanism (temperature or pH triggers) with a photonic activation mechanism (ultraviolet light). This substitution provides deterministic control over when and where the material hardens, solving the reliability issue caused by unpredictable environmental conditions.
2Reliability
If the loss circulation material hardens before reaching the loss zone, then the material seals prematurely, but this plugging of the downhole assembly requires replacement of the entire assembly
Solution Approach 1:
By replacing chemical activation with UV light activation, the patent enables precise spatial control of hardening. The material remains fluid during transport and only hardens when irradiated by UV light at the target location, preventing premature plugging of the downhole assembly.
Solution Approach 2:
The patent prepares the loss circulation material in an unactivated state with photo-initiators embedded, allowing it to be pumped to the lost circulation zone without hardening. The actual hardening action is performed only after the material reaches the desired location and is exposed to UV light, preventing premature setting.
3Reliability
If conventional LCM is used for uniformly shaped voids, then sealing can be achieved, but un-uniform and larger voids cannot be effectively sealed
Solution Approach 1:
The patent uses a composite material system combining oligomers, monomers, and photo-initiators that can be adjusted to match various void sizes and shapes. This composite formulation, activated by UV light, provides adaptability to seal un-uniform and larger voids that conventional LCM cannot effectively address.
Solution Approach 2:
The patent enables adjustment of material parameters such as viscosity, curing speed, and final hardness through the selection of specific oligomers, monomers, and photo-initiators. This allows the material to be optimized for different void geometries and sizes, significantly improving adaptability compared to conventional LCM.
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 system ensures reliable sealing of lost circulation zones by hardening the material in place, providing sufficient compressive strength to withstand overburden pressure and allowing for continued drilling operations once the polymer has set.
Implementation Method 1
The loss circulation material is exposed to the ultraviolet light to activate the loss circulation material. The loss circulation material is delivered to the lost circulation zone.
Implementation Method 2
A loss circulation material is delivered into the fluid flow path of the drill string, the loss circulation material having an oligomer, a monomer, and a photo-initiator. The loss circulation material is exposed to the ultraviolet light to activate the loss circulation material.
Data Source
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AI summary
Method and systems for sealing a lost circulation zone of a subterranean well include extending a drill string into the subterranean well, the drill string having an ultraviolet system, an actuator, and a fluid flow path. The actuator is instructed to transmit an on signal to the ultraviolet system to switch the ultraviolet system to an on condition. In the on condition the ultraviolet system generates ultraviolet light directed towards the fluid flow path of the drill string. A loss circulation material is delivered into the fluid flow path of the drill string, the loss circulation material having an oligomer, a monomer, and a photo -initiator. The loss circulation material is exposed to the ultraviolet light to activate the loss circulation material. The loss circulation material is delivered to the lost circulation zone.