Downhole Well Plug Heater Assembly for Slim Deviated Wells

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing well plugging and sealing technologies face challenges in deviated wells and those with obstacles, as current tools are either too large to maneuver effectively or have reduced heat output when minimized, leading to incomplete seals due to insufficient alloy quantity or inadequate heating.

Innovation Solution

A self-contained cartridge system for down-hole chemical heaters with a thermite-based heat source, wrapped in a temporary plastic coating for flexibility and visibility, combined with a tubular heater body and insulating sleeve to reduce tool diameter while maintaining heat efficiency and structural integrity, and a refractory lining to prevent heat concentration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the tool diameter is reduced to improve maneuverability in deviated wells, then the tool can navigate obstacles and corners more effectively, but the heat output is reduced leading to insufficient heating of the alloy

Engineering Contradiction:

ImprovemaneuverabilityVSAvoidheat output

Core Design Contradiction:

Ease of operationVSPower

Solution Approach 1:

The alloy is placed inside the heater body rather than on the exterior, nesting the sealing material within the heating device. This allows the tool to maintain a smaller outer diameter for better maneuverability while still containing sufficient alloy quantity inside the heater cavity for complete sealing operations.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The alloy is distributed in a radial arrangement around the heater body in multiple layers, utilizing the radial dimension to maximize heat contact area. This dimensional arrangement ensures efficient heat distribution throughout the alloy mass while maintaining a compact tool profile.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If the amount of alloy is reduced to decrease tool diameter, then the tool becomes more maneuverable, but incomplete plugs are formed due to insufficient alloy quantity

Engineering Contradiction:

Improvetool diameterVSAvoidalloy quantity

Core Design Contradiction:

Volume of moving objectVSQuantity of substance

Solution Approach 1:

The alloy is nested within the heater body cavity, allowing sufficient alloy quantity to be contained within the compact heater structure. This internal placement ensures that the tool maintains a reduced diameter while still carrying adequate alloy for complete well sealing.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Multiple layers of alloy with different properties are used in combination - a first alloy layer with higher melting point for structural integrity and a second alloy layer with lower melting point for sealing. This composite arrangement maximizes the sealing effectiveness while minimizing the total alloy quantity required.

Inventive Principle:

Principle #40Composite materials

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

Enables flexible on-site adjustments, improved maneuverability in deviated wells, and efficient heat distribution for complete sealing in challenging well environments, reducing the need for frequent tool replacements and enhancing seal quality by focusing alloy deployment.

Implementation Method 1

a self-contained cartridge system for down-hole chemical heaters with a thermite-based heat source

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 2

tubular heater body and insulating sleeve to reduce tool diameter while maintaining heat efficiency

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

refractory lining to prevent heat concentration

Methodology Applied

Scientific EffectThermal protection: Refractory Material

Implementation Method 4

utilises the fact that such alloys contract upon melting and expand again when they re-solidify

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 5

the alloy expands to form a tight seal with the walls of the well

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS11634966B2Combined well plug/chemical heater assemblies for use in down-hole operations and associated heater cartridges

Publication Date: 2023.04.25 BISN TEC

AI summary

The present invention provides a cartridge (1) for a chemical heater used in down-hole operations. The cartridge (1) comprises a quantity of a chemical reaction heat source (2) wrapped in a temporary coating (3) that is capable of maintaining the shape of the cartridge (1) prior to use but which is consumed during the burn of the heater. The present invention also provides a eutectic/bismuth based alloy well plugging/sealing tool (5). The tool (5) having a tubular heater body (6) with an internal cavity (8) capable of receiving a chemical heat source and a quantity of eutectic/bismuth based alloy (7) provided in thermal communication with the heater body (6) around an outer surface of the heater body (6). The tool has a sleeve (10) provided around an outer surface of the alloy (7), which insulates and/or mechanically protects the alloy (7) down-hole. In this way the sleeve (10) enables the diameter of tool (5) to be reduced whilst maintaining its functionality. In further aspect, the present invention also discloses the provision of a refractory lining (20) on the inner walls of the tubular heater body of chemical heaters, such as the heater (6) used in the eutectic/bismuth based alloy well plugging/sealing tool (5).