Abandoned Well Capping System with Segmented Plates and Valves
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Solution Overview
Problem
Current well capping systems fail to effectively manage gas leaks and pressure build-up during abandonment and re-entry, leading to safety risks and inefficiencies, with no provision for controlled gas release or prevention of groundwater contamination, and complex re-entry protocols.
Innovation Solution
A system comprising production and surface casing plates with nipples connected to independent valves allows for controlled gas release and sealing, preventing groundwater ingress, while enabling efficient re-entry and hydrostatic killing of the well.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous fillet weld is used to seal the well, then the sealing effectiveness is improved, but gas pressure build-up risk increases and safety is worsened
Solution Approach 1:
The cap plate is segmented into multiple sections with gaps between them, allowing the well to be sealed while providing controlled pathways for gas pressure relief. This segmentation resolves the contradiction by maintaining sealing effectiveness through the overall cap structure while preventing dangerous pressure build-up through the intentional gaps.
2Device complexity
If tack welds are used to attach cap plates, then installation complexity is reduced, but groundwater contamination risk increases
Solution Approach 1:
Different regions of the cap plate assembly have different welding requirements: some areas use tack welds for simplicity while critical sealing areas use continuous welds to prevent groundwater contamination. This local differentiation resolves the contradiction by applying the appropriate welding method to each specific location based on its functional requirements.
3Ease of manufacture
If simple steel plate covers are used, then manufacturing cost is reduced, but safety during re-entry is worsened due to undetected gas leaks
Solution Approach 1:
Pressure sensors and detection devices are introduced as intermediary elements between the sealed well and the external environment. These intermediaries allow simple steel plate covers to be used for cost-effective sealing while the detection devices monitor for gas leaks and pressure build-up, providing safety warnings without requiring complex cap structures.
4Reliability
If the well is fully sealed during abandonment, then sealing effectiveness is improved, but re-entry protocol complexity increases
Solution Approach 1:
Pressure relief gaps and monitoring devices are installed during the abandonment sealing process as preliminary safety measures. This allows the well to be fully sealed for effectiveness while the pre-installed features automatically manage pressure and alert to potential issues, simplifying future re-entry protocols by eliminating the need for complex pressure management procedures.
Data Source
AI summary
The invention describes a system for capping an abandoned well having production casing and surface casing. The system enables the effective sealing of the production casing volume from the surface casing volume such that any gases leaking from either volume can be independently released from independent valves. The system is particularly effective in improving the safety of re-entering an abandoned well.


