Well Tool Forced Flow Molten Mass Heat Distribution
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Solution Overview
Problem
Existing well plugging and abandonment methods using pyrotechnic mixtures suffer from uneven heat distribution within the molten mass, leading to inefficient melting of surrounding materials and potential incomplete formation of a permanent well barrier due to temperature gradients.
Innovation Solution
A well tool device with a flow generating mechanism, such as a foldable impeller, is used to create a forced flow of the molten mass, ensuring heat is distributed evenly across the molten mass and efficiently transferred to the periphery, thereby melting surrounding components like tubing, cement, and cap rock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If pyrotechnic mixture is ignited to generate heat for melting surrounding materials, then the permanent well barrier is formed, but the heat distribution within the molten mass becomes uneven with highest temperatures in the center and lowest in the periphery
Solution Approach 1:
The patent applies the dynamics principle by introducing a flow generating device that creates forced circulation of the molten mass. The device includes an impeller or propeller that rotates to generate flow patterns, transforming the static molten mass into a dynamic flowing system. This continuous movement redistributes heat from the hot center to the cooler periphery, preventing temperature stratification and improving overall heat utilization efficiency.
Solution Approach 2:
The patent utilizes hydraulic principles by employing a flow generating device that operates within the liquid/molten mass environment. The device leverages fluid dynamics to create circulation patterns, using the properties of the molten mass itself as the working fluid. The impeller design and rotation mechanism exploit hydraulic forces to generate effective flow and heat distribution throughout the molten mass.
2Reliability
If the periphery of the molten mass hardens due to heat loss, then the pyrotechnic mixture burns inside the hardened periphery, but the surrounding material melting is limited
Solution Approach 1:
The flow generating device continuously circulates the molten mass, preventing the periphery from hardening by constantly bringing fresh hot molten material to the boundaries. This dynamic renewal of the molten mass at the periphery ensures sustained heat transfer to surrounding materials, maintaining melting efficiency throughout the process and ensuring complete plugging reliability.
Solution Approach 2:
The patent implements continuous useful action through the ongoing operation of the flow generating device throughout the pyrotechnic process. The device operates continuously to maintain molten mass circulation, ensuring that heat transfer to surrounding materials remains effective and uninterrupted. This continuous action prevents premature hardening and ensures complete melting and plugging.
3Loss of energy
If a flow generating device is added to distribute heat evenly, then heat utilization is improved, but the device complexity increases
Solution Approach 1:
The flow generating device is designed with multi-functionality to justify its inclusion. It serves multiple purposes: distributing heat evenly, preventing periphery hardening, maintaining molten mass circulation, and ensuring complete melting of surrounding materials. This universal application addresses multiple problems simultaneously, making the added complexity worthwhile by significantly improving overall process efficiency and reliability.
Solution Approach 2:
The patent applies parameter changes by modifying the physical state and flow characteristics of the molten mass. The flow generating device changes the velocity, circulation pattern, and temperature distribution parameters of the molten mass. By controlling these parameters, the system achieves improved heat utilization without requiring fundamentally different equipment, only adjustments to operational parameters and the addition of a relatively simple flow generation mechanism.
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 solution enhances heat distribution and utilization, leading to a more homogeneous melt and accelerated formation of a permanent well barrier, reducing the risk of incomplete plugging and improving the efficiency of the plugging process.
Implementation Method 1
a pyrotechnic mixture provided in the housing; after ignition, the pyrotechnic mixture turns into a molten mass
Implementation Method 2
The heat generating process melts surrounding materials to form the permanent well barrier
Implementation Method 3
the flow generating device is configured to generate a forced flow of the molten mass... distributes heat from the parts of the molten mass which has the highest temperature to the part of the molten mass which has the lowest temperature
Data Source
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AI summary
It is disclosed a well tool device and a method for forming a permanent well barrier. The well tool device (10) comprises: - a housing (20) having a circular cross-section and a longitudinal extension; - a pyrotechnic mixture (40) provided in the housing (20); - a flow generating device (60) provided in the housing (20); - a motor (70) for driving the flow generating device (60); wherein, after ignition, the pyrotechnic mixture (40) turns into a molten mass; and wherein the flow generating device (60) is configured to generate a forced flow of the molten mass. The method comprises the steps of: - installing the well tool device (10) in a well; - igniting the pyrotechnic mixture (40), the pyrotechnic mixture turns into a molten mass upon ignition; - starting the motor (70); and generating a forced flow of the molten mass by means of the flow generating device (60).