Bypass Crossover Sub Selector for Multi-Zone Fracturing
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Solution Overview
Problem
In multi-zone fracturing processes, existing fracturing tools with crossover sub-assemblies face reduced lifespan due to repeated use, requiring frequent repairs or replacements, which hampers efficient fracturing operations in oil and gas wells.
Innovation Solution
The fracturing tool employs multiple crossover sub-assemblies connected by couplers with phased window alignment, allowing bypass flow communication and utilizing an isolation sleeve with a J-hook mechanism for axial and rotational movement to selectively align windows for different radial directions, enabling efficient fracturing without rotating the sub-assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single crossover sub-assembly is used in multi-zone fracturing processes, then the device complexity is reduced, but the reliability deteriorates due to reduced lifespan requiring frequent repairs or replacements
Solution Approach 1:
The system divides the single crossover sub-assembly into multiple segmented units (first, second, and third crossover sub-assemblies) connected in series. Each segment can be independently activated or deactivated by rotating the isolation sleeve to align its window with the corresponding crossover sub window, allowing phased operation that extends overall system lifespan while maintaining manageable complexity through modular architecture.
2Adaptability or versatility
If the isolation sleeve is rotated to align windows for different radial directions, then the adaptability is improved for fracturing in different directions, but the ease of operation deteriorates due to the complexity of rotation and alignment mechanisms
Solution Approach 1:
The isolation sleeve serves multiple functions: it acts as a rotational selector for different radial directions, a flow distributor to different zones, and a timing mechanism for phased activation. By integrating these functions into a single component that rotates to align windows, the system achieves universal adaptability for multi-zone fracturing in different radial directions while consolidating control operations.
3Duration of action of stationary object
If multiple crossover sub-assemblies are used in series with bypass flow communication, then the reliability is improved through extended lifespan, but the device complexity increases due to additional components and coupling mechanisms
Solution Approach 1:
The isolation sleeve is nested within the bore of the crossover sub-assemblies, with seals positioned within the bore to create phased communication pathways. This nested configuration allows the isolation sleeve to control flow distribution to multiple crossover sub-assemblies without requiring external complex mechanisms, extending operational duration through phased activation while containing complexity within the nested structure.
Data Source
AI summary
Fracturing tools for fracturing multiple zones of a wellbore are disclosed. In certain embodiments, the fracturing tools comprise two or more crossover subs coupled together and having a crossover sub window alignment assembly operatively associated with either an isolation sleeve disposed within the bores of the crossover sub-assemblies or with the crossover sub assemblies themselves. Actuation of the crossover sub window alignment assembly opens and closes the windows of each of the crossover sub-assemblies so that different crossover sub-assemblies can be activated to fracture various wellbore locations.