Ceramic Rupture Dome for Controlled Wellbore Isolation
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Solution Overview
Problem
Existing solutions for pressure isolation in deviated or non-vertical wells, such as tubing end-plugs and rupture domes, face challenges like difficulty in removal, interference with further operations, and irregular rupture passages, which can restrict fluid flow and damage equipment.
Innovation Solution
A frangible ceramic rupture dome with a specific arcuate shape and surface features to control fragmentation, designed to withstand high pressure from one side and rupture when pressure exceeds a threshold on the other side, allowing controlled removal and minimizing damage to wellbore equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a metallic or aluminum disc is used as a tubing end-plug for pressure isolation, then the plug can be easily installed and removed, but the metal disc becomes difficult or expensive to remove from the bottom workface and interferes with further drilling operations
Solution Approach 1:
The invention extracts the harmful metallic component from the system by replacing it with a frangible ceramic disc that breaks into small, non-interfering fragments. The ceramic material is specifically chosen to be non-metallic so that when it ruptures, the fragments do not interfere with further drilling or wellbore operations, thereby removing the harmful effect while maintaining the pressure isolation function.
Solution Approach 2:
The frangible ceramic disc is designed to be discarded after use by intentionally breaking it into small fragments through controlled rupture. Unlike metallic plugs that must be carefully retrieved, the ceramic disc is meant to be broken and left in place, with its fragments being harmless to subsequent operations. This transforms the removal process from a complex retrieval operation to a simple controlled breakage.
2Strength
If a frangible ceramic disc with precise arcuate shape is used to provide maximum pressure resistance, then the barrier to fluid pressure is strong, but the resulting passage after rupture is irregular and restricts fluid flow
Solution Approach 1:
The ceramic disc is segmented into two functional zones: an arcuate sealing portion that provides pressure resistance and a central rupture zone with radial score lines that control fragmentation. When the disc ruptures, the score lines guide the breakage into small, uniform fragments that do not obstruct the bore, maintaining fluid flow productivity while the arcuate portion had provided the necessary strength during the isolation period.
Solution Approach 2:
Different regions of the ceramic disc have different properties: the outer arcuate portion is designed for strength and pressure resistance, while the central region contains radial score lines that create controlled weak points for rupture. This local differentiation allows the disc to provide maximum pressure resistance where needed while ensuring clean, non-obstructing fragmentation in the rupture zone, thereby maintaining fluid flow after breakage.
3Ease of operation
If a breaking implement is dropped down the tubing to rupture the dome, then the dome can be broken downhole, but in deviated or horizontal wellbores the implement cannot be propelled by gravity alone and may become a projectile or fail to reach the dome
Solution Approach 1:
The invention replaces the gravitational mechanical dropping system with a pressurized fluid activation system. Instead of relying on gravity to propel a breaking implement, a small pilot hole is drilled through the ceramic disc and a breaking tool is activated by injecting pressurized fluid through this hole. This substitution eliminates the reliability issues associated with gravity-dependent operations in deviated wellbores and prevents projectile formation, as the breaking tool is activated in place by fluid pressure rather than being dropped from above.
4Adaptability or versatility
If multiple wireline plugs are used for operations in deviated wells, then more plug options are available, but wireline plugs may be difficult to retrieve from deep deviated wellbores and may be impossible to inject in non-vertical orientations
Solution Approach 1:
The frangible ceramic disc is designed to be self-activating through pressure differential rather than requiring external wireline delivery mechanisms. The disc remains intact during injection and operations, automatically rupturing when the pressure differential across it exceeds a threshold. This self-service mechanism eliminates the need for complex wireline plug delivery and retrieval systems, making the system adaptable to deviated and horizontal wellbores without the operational difficulties associated with wireline plug manipulation.
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 rupture dome effectively isolates high-pressure zones in wells, allowing selective pressure control and safe removal without plugging or damaging equipment, ensuring a clean passage and reducing operational complexities.
Implementation Method 1
configured to hold high fluid pressure applied to the convex side
Implementation Method 2
a portion of the body defined between the convex side and concave side forming a breakaway section, being frangible, and configured to hold high fluid pressure applied to the convex side, and to break when fluid pressure applied to the concave side exceeds a threshold
Data Source
Figure 1
Figure 2
Figure 3~3A
AI summary
A one-time-use pressure-actuated conduit closure is provided, to selectively withstand fluid pressure from one side of the device until the closure is removed remotely, the closure device being a frangible dome designed to withstand fluid pressures from one side but to rupture upon application of higher pressure on its other side, which provides a mechanism to isolate downhole fluid under (high) pressures in part of a well during operations for a period of time selected by an operator, and then to remove the isolation by breaking the rupture dome remotely by application of extra fluid pressure or other forces from surface. The frangible dome has features in at least one surface to guide and control its breakage to provide controlled shard sizes and shapes and a predictable opening for minimal obstruction of the conduit when broken away.