Beaded Matrix Plugs for Wellbore Flow Control
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Solution Overview
Problem
Current wellbore completion and control technologies face challenges in efficiently managing fluid flow and pressure differentials, leading to increased costs and reduced hydrocarbon recovery, particularly in deviated or horizontal boreholes, where existing solutions often fail to provide effective plugging and permeability control.
Innovation Solution
The use of beaded matrix plugs with a permeable housing and a hardenable substance that can be temporarily rendered impermeable, allowing for in-situ plugging and un-plugging to control fluid flow and withstand significant pressure differentials, reducing the need for additional completion strings and enhancing the durability of screens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional completion strings and screens are used to control fluid flow, then flow control is achieved, but device complexity and operational costs increase
Solution Approach 1:
The completion system is divided into modular components: the tubular element with integrated beaded matrix plugs, bridge plugs, and packers. Each component can be independently installed and configured, allowing simplified completion strings while maintaining effective flow control across multiple zones
Solution Approach 2:
The beaded matrix plugs integrate multiple functions into a single component: flow control through permeable material, plugging capability through bridge plugs, and sealing through packers. This consolidation eliminates the need for separate completion strings and reduces operational complexity
2Productivity
If permeable materials are used for flow control, then fluid flow is managed, but pressure differential resistance decreases
Solution Approach 1:
The beaded matrix plugs combine permeable materials (such as sintered metal or porous ceramic) with supporting structures and sealing elements. This composite construction allows the permeable material to provide flow control while the supporting structure maintains structural integrity and pressure resistance under high differential pressure conditions
3Reliability
If additional completion tools are used to ensure reliable plugging, then plugging reliability improves, but operational costs increase
Solution Approach 1:
The bridge plugs and packers are designed as multi-functional components that can serve multiple purposes: sealing annular spaces, providing mechanical support for beaded matrix plugs, enabling flow control, and facilitating future intervention. This universality reduces the total number of tools needed while maintaining reliable plugging
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
This solution enables precise control of fluid flow, reduces the need for additional completion tools, and maintains structural integrity under high pressure, allowing for efficient hydrocarbon recovery and reduced operational costs by using beaded matrix plugs that can be selectively permeable or impermeable, thus addressing the limitations of existing technologies.
Implementation Method 1
a beaded matrix plug flow control device includes a plug housing and a permeable material disposed therein. The housing includes a bore disposed longitudinally through the device of more than one diameter. This creates a shoulder within the inside surface of the device. While it is not necessarily required to provide the shoulder, it can be useful in applications where the device is rendered temporarily impermeable and might experience differential pressure thereacross.
Data Source
AI summary
A tubing component for use in a downhole environment including a tubular having a plurality of openings therein and a plurality of beaded matrixes disposed in the plurality of openings the beaded matrixes being configured to be pluggable in situ in the downhole environment. A method for controlling flow in a wellbore.