Collapsible Baffle Sub for Wellbore Zone Isolation

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Solution Overview

Problem

Current well stimulation treatments face challenges in efficiently isolating and treating multiple production zones within a wellbore, leading to inefficiencies and increased costs due to fluid leakage and protection issues during fracturing and acidizing processes.

Innovation Solution

A collapsible baffle sub is introduced into the wellbore casing string, which can be actuated to collapse and seal with an untethered object, effectively isolating production zones by blocking fluid flow between them, allowing for targeted stimulation treatments without fluid loss or unwanted interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If sequential treatment of multiple production zones is performed without isolation, then treatment operations can proceed continuously, but fluid leaks to previously treated zones causing loss of treatment fluid and reduced pressure build-up efficiency

Engineering Contradiction:

Improvetreatment efficiencyVSAvoidfluid loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The wellbore is segmented into multiple isolated zones using collapsible baffle subs positioned between production zones. Each zone can be treated independently while maintaining isolation from other zones, preventing fluid migration and enabling efficient sequential treatment without cross-contamination or fluid loss to previously treated intervals.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Collapsible baffle subs serve as intermediary isolation devices between production zones. These baffles are deployed to create physical barriers that prevent direct fluid communication between zones, allowing treatment fluid to be contained within the target zone and maintain effective pressure for stimulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If isolation devices are deployed between production zones, then fluid flow is blocked and pressure build-up improves, but device complexity and operational steps increase

Engineering Contradiction:

Improveisolation effectivenessVSAvoidisolation device structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The isolation system uses dynamically deployable collapsible baffle subs rather than permanently installed complex structures. The baffles are collapsed during deployment to pass through the wellbore, then expanded to provide isolation. This dynamic approach simplifies the initial installation while maintaining effective isolation when deployed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The collapsible baffle subs are designed to be self-deploying and self-sealing. Once deployed, the baffles automatically expand and seal against the wellbore wall, creating effective isolation without requiring additional complex actuation mechanisms or external support systems during the treatment process.

Inventive Principle:

Principle #25Self-service

3Loss of energy

If collapsible baffles are used for isolation, then fluid leakage is prevented and zone isolation is improved, but the risk of baffle collapse or sealing failure increases

Engineering Contradiction:

Improvefluid containmentVSAvoidbaffle structural integrity

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The collapsible baffle subs utilize flexible yet structurally sound constructions that can collapse for deployment and expand for isolation. The flexible shell design allows the baffle to adapt to wellbore conditions while maintaining sufficient structural integrity to prevent collapse under treatment pressures and maintain reliable sealing between production zones.

Inventive Principle:

Principle #30Flexible shells and thin films

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 collapsible baffle sub enables efficient isolation and treatment of production zones, improving pressure build-up and reducing operational costs by preventing fluid leakage and protecting previously treated zones from additional fracturing, thus enhancing the overall efficiency of well stimulation operations.

Implementation Method 1

Methodology Applied

Scientific EffectPhysical barrier blocking: Physical Containment

Data Source

PatentUS10364637B2Downhole sub with collapsible baffle and methods for use

Publication Date: 2019.07.30 HALLIBURTON ENERGY SERVICES INC

AI summary

A collapsible baffle sub installable within a casing string of a hydrocarbon well. The collapsible baffle sub includes a movable sleeve and a collapsible baffle. By moving the sleeve from a first to a second position using a setting tool, the collapsible baffle is permitted to collapse within the collapsible baffle sub. Once collapsed, the collapsible baffle may receive an untethered object, such as a ball, forming a seal between the untethered object and the collapsible baffle and isolating sections of the wellbore for treatment.