Adaptive Seat Wellbore Isolation Eliminates Milling

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Solution Overview

Problem

Conventional frac plugs are costly and difficult to remove after hydraulic fracturing, especially in horizontal wells, and dissolvable plugs are not reliable due to incomplete dissolution causing wellbore restrictions, necessitating additional milling trips.

Innovation Solution

The adaptive seat is a simple, low-cost, unitary sealing and plug assembly that can be deployed in a liner system to isolate well zones, featuring a collet mechanism for secure placement and a dissolvable dart or ball for hydraulic fracturing, allowing for quick deployment and no need for milling removal, with a large internal diameter for easy passage of subsequent tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional frac plugs are used for wellbore isolation, then reliable zone isolation is achieved, but removal requires costly milling operations and restricts treatment depth

Engineering Contradiction:

Improvewellbore isolation reliabilityVSAvoidremoval cost and complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent employs a disposable dissolvable plug made from water-soluble or biodegradable materials that reliably isolate wellbore zones during treatment then automatically dissolve after treatment completion, eliminating the need for costly milling operations and enabling treatment at greater depths where retrieval is impractical

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The plug's material properties are specifically engineered to change parameters over time - maintaining structural integrity and sealing capability during the treatment period, then transitioning to a dissolvable state after treatment, allowing reliable isolation when needed and easy removal afterward

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If dissolvable plugs are used to avoid milling, then removal cost is reduced, but incomplete dissolution causes wellbore restrictions

Engineering Contradiction:

Improveremoval costVSAvoidcomplete dissolution reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The dissolvable plug is constructed from composite materials with controlled dissolution rates - incorporating water-soluble polymers, biodegradable waxes, and erodible binders that ensure complete and uniform dissolution after treatment, preventing wellbore restrictions while maintaining cost-effectiveness

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The plug is designed as a temporary isolation device that completely dissolves after serving its purpose, with material composition specifically selected to ensure 100% dissolution without leaving restrictive debris, combining low cost with high reliability

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If conventional composite frac plugs are used, then adequate sealing is achieved, but deployment time and operational cost increase

Engineering Contradiction:

Improvesealing performanceVSAvoiddeployment speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The plug is segmented into functional zones with different materials optimized for specific purposes - sealing elements, structural support, and dissolution components - allowing simplified construction that deploys faster while maintaining adequate sealing performance through targeted material placement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plug uses parameter changes in material properties over time, starting with adequate sealing capability upon deployment, then transitioning to complete dissolution, enabling faster initial deployment compared to complex conventional plugs while ensuring reliable isolation during the treatment window

Inventive Principle:

Principle #35Parameter changes

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 adaptive seat enables faster and more cost-effective wellbore isolation, reducing the need for costly composite frac plugs and eliminating the requirement for milling, allowing for efficient hydraulic fracturing and subsequent production without the need for removal, thus minimizing operational costs and well intervention.

Implementation Method 1

a dissolvable dart or ball for hydraulic fracturing, allowing for quick deployment and no need for milling removal

Methodology Applied

Scientific EffectDissolution: Solvation

Data Source

PatentEP3452689B1Wellbore isolation method with running tool for recess mounted adaptive seat support for an object for sequential treatment of zone sections with and without milling

Publication Date: 2022.03.09 CROW STEPHEN L

Figure 1~3
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Figure 8~10

AI summary

A coiled adaptive seat (10) is held to a smaller diameter for delivery with a tool (40) that can feature a locating lug (42) for desired alignment of the seat with an intended groove (16) in the inner wall of a tubular. The release tool retracts a cover (48) from the seat allowing its diameter to increase as it enters a groove. Alternatively, the adaptive seat is released near the groove and pushed axially in the string to the groove for fixation. Once in the groove the inside diameter of the string is a support for a blocking object so that sequential treatment of parts of a zone can be accomplished. The blocking object is removed with pressure, dissolving, milling or disintegration leaving a narrow ledge in the tubular bore from the seat that can simply be left in place or milled as well. An E4#10 from Baker Hughes is modified for adaptive seat delivery.