High Pressure Circulating Shoe Track with Redundant Isolation

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Solution Overview

Problem

Current shoe track equipment is limited by a pressure rating of about 5,000 PSIG, which is insufficient for deep well completions exceeding 15,000 PSIG, and existing float shoes with check valves fail to provide effective dual isolation due to differential pressure issues, necessitating costly and unreliable cementing procedures.

Innovation Solution

A dual barrier system comprising a high pressure rated packer and dual flappers is implemented, where the wash pipe extends through a packer and lower flapper to hold a sleeve open for circulation, and an isolation packer swells to prevent fluid migration, with flappers oriented to block flow in both directions, eliminating the need for high-pressure rated float shoes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If float shoes with check valves are used to aid circulation, then circulation is enabled during running in, but the check valves fail under differential pressure from high pressure formations

Engineering Contradiction:

Improvecirculation capabilityVSAvoidcheck valve reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The isolation function is segmented into multiple components: upper flapper valve, lower flapper valve, and swell packer, each handling specific pressure isolation tasks. This segmentation allows the system to withstand high differential pressures that would cause failure in a single check valve system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The swell packer is deployed beforehand to isolate the high pressure zone before the float shoe encounters full differential pressure. This pre-isolation cushions the check valves from excessive pressure differentials that would cause their failure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If cementing is used to isolate the shoe track, then pressure isolation is achieved, but the procedure is expensive and seal reliability is compromised

Engineering Contradiction:

Improvepressure isolation reliabilityVSAvoidisolation procedure cost and complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses disposable flapper valves and swell packers instead of permanent cement seals. These components are designed to be replaced rather than reused, providing reliable isolation without the high cost and complexity of cementing operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The mechanical flapper valve system replaces the chemical cementing process. The flappers provide mechanical isolation that is as reliable as cement seals but can be installed and removed without the expensive and time-consuming cementing procedure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If high pressure rated equipment is used, then pressure resistance is improved, but equipment complexity and cost increase

Engineering Contradiction:

Improvepressure resistanceVSAvoidequipment complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Only the specific components exposed to high pressure (flapper valves and packer) are designed for high pressure resistance, while other parts of the completion assembly can use standard pressure ratings. This localized approach to pressure resistance reduces overall equipment complexity and cost.

Inventive Principle:

Principle #3Local quality

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 safe and economical advancement of the bottom hole assembly into high-pressure zones by providing effective dual isolation, allowing circulation during deployment and well control with the dual flapper and packer system, overcoming the limitations of existing float shoes.

Implementation Method 1

an isolation packer such as a swell packer begins to swell to close off the annulus against the open hole to prevent fluids from further downhole from migrating up to the screens adjacent the producing zone

Methodology Applied

Scientific EffectSwelling:

Implementation Method 2

Retracting the wash pipe allows closure of both flappers. Flow is blocked in opposed directions by the flappers and packer in the shoe track

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS9915126B2High pressure circulating shoe track with redundant pressure isolation feature

Publication Date: 2018.03.13 BAKER HUGHES CO

AI summary

A dual barrier system withstands pressure differentials well above those of the check valves in a float shoe used to allow circulation of a bottom hole assembly on the way to a desired depth. The bottom hole assembly can have screens and an internal wash pipe that pushes a sleeve to hold open a lower flapper for running in. The wash pipe also holds open an upper flapper that has opposed orientation to facilitate circulation when running in. Once on location an annulus packer closes off the producing zones where the screens are located from a lower zone that can have higher pressures. A high pressure packer is set against the shoe track and the wash pipe is retracted through this packer. Retracting the wash pipe allows closure of both flappers. Flow is blocked in opposed directions by the flappers and packer in the shoe track.