Internal Well Tool Coating Using Portable ALD and CVD Deposition
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Solution Overview
Problem
Well tools used for downhole operations are susceptible to internal corrosion and abrasion due to exposure to fluids like hydrogen sulfide and mercury, leading to reduced lifespan and performance issues.
Innovation Solution
A portable coating system that translates and rotates within the well tool to deposit protective coatings using reactant gases, forming multiple layers inside the tool without the need for a commercial vacuum chamber, utilizing techniques like ALD and CVD to create a durable barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional commercial vacuum chamber coating systems are used, then coating quality and durability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the essential coating deposition function from the complex commercial vacuum chamber system and implements it using a portable coating system that can be positioned inside the well tool itself. This eliminates the need for large vacuum chambers while maintaining coating effectiveness through localized reactant gas delivery.
Solution Approach 2:
The patent introduces a portable coating system as an intermediary device that bridges the gap between traditional vacuum chamber coating and field applications. This portable system uses reactant gases as intermediaries to deliver coating material to the well tool interior surfaces without requiring a full vacuum chamber environment.
2Reliability
If coatings are deposited using traditional vacuum chamber methods, then protective coating quality is improved, but manufacturing time and cost increase
Solution Approach 1:
The portable coating system is designed to be pre-positioned inside the well tool at the jobsite, allowing coating application to begin immediately without the need to transport tools to external vacuum chambers. This preliminary positioning eliminates transportation time and setup delays.
Solution Approach 2:
The well tool is equipped with integrated reactant gas delivery systems that allow it to receive and process coating materials autonomously at the jobsite. This self-service capability eliminates the need for external vacuum chamber facilities and reduces dependency on centralized coating operations.
3Productivity
If well tools are coated at the jobsite using portable systems, then productivity and cost efficiency are improved, but coating uniformity and precision may worsen
Solution Approach 1:
The portable coating system incorporates movable components including the elongated member that can translate and rotate within the well tool interior. This dynamic positioning capability allows the system to adapt to different geometries and achieve uniform coating distribution across complex internal surfaces despite the portable nature of the equipment.
Solution Approach 2:
The system uses controlled reactant gas delivery with barriers that can be adjusted to regulate gas flow and coating deposition. This feedback mechanism allows operators to control coating thickness and uniformity by adjusting barrier positions and gas flow rates, maintaining precision despite the simplified portable setup.
4Reliability
If multiple coating layers are deposited using portable systems, then protective barrier effectiveness is improved, but device complexity and process time increase
Solution Approach 1:
The coating application process is segmented into multiple sequential layers using the same portable system. Each layer is deposited through controlled reactant gas delivery, and the barriers are reused for each layer application. This segmentation approach builds effective multi-layer protection without requiring additional complex equipment for each layer.
Solution Approach 2:
The portable coating system is designed as a universal device that can deposit multiple coating layers using the same reactant gas delivery mechanism and barrier structure. This multi-functionality allows the system to apply different coating materials or repeat the same coating process for multiple layers without requiring separate specialized equipment for each layer type.
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 effectively protects well tools from corrosion and abrasion, extending their lifespan and maintaining performance by applying coatings at the jobsite, reducing costs and time compared to traditional methods.
Implementation Method 1
utilizing techniques like ALD and CVD to create a durable barrier
Implementation Method 2
utilizing techniques like ALD and CVD to create a durable barrier
Data Source
AI summary
A method of coating an interior surface of a housing defining a volume includes partitioning the volume into a first zone and a second zone, the first zone isolated from fluid communication with the second zone; introducing one or more reactant gases, plasma, ions, or a combination thereof to the first zone and the second zone; and forming one or more coating layers on all or a portion of the interior surface within the first and second zones via reaction of the reactant gases, the plasma, or the combination thereof. A device for coating an interior surface of a housing is also provided.