Coiled Tubing Friction Reducer Control for Lock-Up Prevention
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Solution Overview
Problem
The challenge of efficiently transporting coiled tubing (CT) in horizontal wellbores due to friction forces, which can lead to lock-ups and require the use of larger-diameter CT or rotation, both of which present logistical and economic challenges. Additionally, determining the optimal start time and pump rate for friction reducer fluids to prevent lock-ups is complex and requires accurate modeling of downhole conditions.
Innovation Solution
A system and method that utilize a controller with a processor to monitor wellbore conditions and predict future lock-ups of coiled tubing by modeling the state of the unspooled CT and attached toolstring. The system automatically controls a pump to inject friction reducer fluid into the wellbore, optimizing the amount used to prevent lock-ups and minimize operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If larger-diameter CT is used to overcome friction forces, then CT transportation capability is improved, but logistical challenges with road transport and crane-lifting/loading increase
Solution Approach 1:
The system dynamically changes operational parameters (pump rate, friction reducer injection timing and amount) to optimize CT transportation without changing physical CT dimensions. This resolves the contradiction by achieving better friction overcoming capability through parameter optimization rather than increasing CT diameter.
2Force
If CT rotation is used to overcome friction forces, then CT transportation is improved, but economic practicality deteriorates due to current CT technology limitations
Solution Approach 1:
The system replaces the mechanical rotation approach with a fluid-dynamic approach using friction reducer fluids pumped through the CT. This substitution achieves friction overcoming capability without requiring complex CT rotation mechanisms, thereby maintaining economic practicality.
3Length of moving object
If friction reducer fluid is pumped to extend CT reach, then CT transportation in horizontal wellbores is improved, but determination of optimal pump start time and pump rate becomes complex
Solution Approach 1:
The system uses real-time feedback from a torque sensor to monitor downhole conditions and dynamically adjusts pump start time and pump rate. This feedback mechanism simplifies control by automatically determining optimal parameters based on actual torque measurements, resolving the complexity of manual optimization.
Solution Approach 2:
The system performs preliminary modeling of downhole conditions and friction forces before the CT injection operation. This preliminary analysis provides predicted optimal pump parameters, simplifying the control process by pre-determining settings based on modeled conditions.
4Productivity
If modeling downhole conditions is performed to determine optimal FR pumping parameters, then CT transportation optimization is improved, but process complexity increases due to varying model parameters
Solution Approach 1:
The system uses the torque sensor data generated during the CT injection operation itself to update and refine the downhole condition model in real-time. This self-service approach simplifies modeling complexity by using naturally occurring measurement data from the operation rather than requiring separate complex measurement systems.
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 system effectively predicts and prevents coiled tubing lock-ups, ensuring continuous injection and reducing operator burden by automating the process. It optimizes the use of friction reducer fluid, minimizing waste and operational costs.
Implementation Method 1
technologies such as friction reducer fluids are traditionally used to extend the CT reach
Data Source
AI summary
Systems and methods for performing a wellbore cleanout operation in a production tubing in a wellbore extending through a reservoir. The systems and methods include a sensor usable to detect a wellbore production volume of a production fluid from the production tubing per unit time, a conveyance, and a controller including a processor. The controller is operable to automatically determine a differential flowrate for locations along the production tubing based on a difference between a recorded flowrate and a modeled flowrate at the locations, determine any of the locations where the differential flowrate is equal to or greater than a predetermined threshold, and control deployment of the conveyance into the wellbore to perform the cleanout operation at any of the determined locations where a change in a wellbore cleanout utility function using the modeled flowrate compared to using the recorded flowrate is equal to or greater than an improvement factor.