Bridge Plug Isolation for Sand-Laden Wellbore Treatment
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Solution Overview
Problem
Existing well completion tools face challenges in selectively treating multiple wellbore perforations without malfunctioning due to sand or debris, leading to potential tool failure and costly corrections, especially when using cup seals that are not well-suited for repeated use in sand-laden environments.
Innovation Solution
A completion tool with upper and lower sealing members, a valve housing, a bypass plug, and a resettable anchor device for secure anchoring and fluid management, allowing for selective treatment and perforation of wellbore intervals without removing the tool string, using mechanical force applied to the tubing string to actuate the anchor and bypass valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cup seals are used for isolation in sand-laden environments, then the tool can isolate wellbore intervals, but the seals are prone to wear and failure due to sand and debris presence
Solution Approach 1:
The patent removes the cup seals from the tool assembly entirely, replacing them with a bridge plug isolation system. This extraction eliminates the harmful interaction between cup seals and sand/debris, as the bridge plug operates as a solid-body isolation mechanism that does not rely on sealing surfaces contacting the wellbore in the presence of solids.
Solution Approach 2:
The patent employs a disposable bridge plug isolation system that is designed for single-use. The bridge plug is set to isolate the interval, used for the treatment operation, and then discarded or retrieved. This approach accepts the cost of the isolation device as a trade-off for eliminating the reliability issues associated with reusable cup seals in sand-laden environments.
2Adaptability or versatility
If multiple moving components are used for tool actuation, then the tool can perform multiple functions, but the presence of sand increases the risk of jamming and malfunction
Solution Approach 1:
The patent removes complex mechanical actuation mechanisms with multiple moving parts. Instead, it employs a simplified system where the bridge plug is set by expanding it radially (typically using hydraulic pressure or mechanical expansion), and isolation is achieved without complex valve trains or actuating components that could jam in sand.
Solution Approach 2:
The patent replaces complex mechanical actuation systems with alternative mechanisms. For example, hydraulic actuation is used to expand the bridge plug, and isolation is achieved through pressure differential and mechanical expansion rather than through complex mechanical linkages that could fail in sandy conditions.
3Productivity
If the tool is designed for repeated use in a single run, then operational efficiency is improved, but the risk of seal failure and tool malfunction increases with each use
Solution Approach 1:
The patent segments the completion operation into discrete, isolated intervals. Each interval is isolated using a bridge plug, treated, and then the plug is discarded or moved. This segmentation allows the tool to systematically work through multiple intervals in a single run without the cumulative wear and failure risk associated with reusable seals, as each isolation event uses a fresh, unused bridge plug.
Solution Approach 2:
The patent employs a discard-and-move approach where bridge plugs are set, used for isolation during treatment, and then discarded or retrieved. This eliminates the need to reuse seals that would accumulate wear, allowing the tool to maintain high reliability across multiple interval treatments in a single run by constantly using fresh isolation devices.
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 reliable and efficient treatment and perforation of multiple wellbore intervals with reduced risk of tool malfunction and debris-related issues, allowing for repeated use without the need for frequent tool retrieval, thus minimizing operational delays and costs.
Implementation Method 1
a bypass plug slidable within the valve housing between an open position in which fluid passage through the housing is permitted, and a sealed position in which fluid passage through the housing is prevented
Implementation Method 2
a resettable anchor device operatively mounted beneath the lower sealing member for setting against the casing of a wellbore
Implementation Method 3
the anchor device operable by application of mechanical force to the tubing string
Implementation Method 4
upper and lower sealing members defining a straddle zone between the upper and lower sealing members
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A tool assembly and method for completing a well are provided. The tool is deployed on tubing string and includes a fluid treatment assembly with cup seals above and below the treatment ports. An equalization valve beneath the fracturing assembly can be opened or closed to control fluid passage between the coiled tubing and treatment zone to the wellbore below.