Completion System Diverter Removal via Reverse Fluid Flow
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Solution Overview
Problem
Existing completion systems face challenges in accurately predicting the dissolution rate of dissolvable balls in downhole environments, which complicates the operation of sleeves and port management during wellbore completion operations.
Innovation Solution
A completion system that includes a tubular with a communication path and diverter seats, where diverters can be selectively activated and removed using fluid pressure and covers that shift to open or close ports, eliminating the need for dissolvable diverters and allowing for efficient fluid communication and removal of unwanted fluids and solids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If dissolvable balls are used to actuate sleeves and control ports, then the system can achieve automatic operation and port management, but the dissolution rate becomes difficult to predict and control in downhole environments
Solution Approach 1:
The patent extracts the dissolvable ball mechanism and replaces it with a mechanical diverter system that can be retrieved. Instead of relying on unpredictable chemical dissolution, the system uses a physical diverter that can be activated and removed through controlled fluid pressure operations, eliminating the reliability issue while maintaining automated port control capabilities.
Solution Approach 2:
The patent introduces a diverter seat and cover mechanism as an intermediary system between the fluid flow and the port control. This mechanical intermediary allows for reliable, predictable operation through fluid pressure activation without requiring dissolvable materials, thus resolving the contradiction between automation and predictability.
2Ease of operation
If dissolvable diverters are used, then the system can simplify the diverter management process, but it becomes difficult to control the timing and completion of diverter removal
Solution Approach 1:
The patent employs a self-service mechanism where fluid pressure automatically activates the cover to shift positions and control port opening/closing, and subsequently enables diverter removal. The system uses the existing fluid circulation infrastructure to perform the removal operation without requiring additional intervention or complex timing control mechanisms.
Solution Approach 2:
Instead of allowing passive dissolution of diverters over time, the system inverts the approach by using active fluid pressure to rapidly activate and remove diverters on demand. This reverses the time-dependent dissolution process into a controllable, on-demand mechanical operation.
3Reliability
If multiple operations are performed separately, then each operation can be optimized individually, but the overall completion time and operational complexity increase
Solution Approach 1:
The patent merges multiple completion operations into a single integrated sequence. The diverter activation, port control, and diverter removal operations are combined into one continuous fluid circulation process, allowing all operations to be performed in a single run without requiring separate interventions, thus improving productivity while maintaining operational reliability.
Solution Approach 2:
The completion system is designed with multi-functionality to handle diverter activation, port control, and diverter removal using the same fluid circulation mechanism. This universal approach eliminates the need for separate specialized operations, reducing overall completion time while maintaining the reliability of each individual function.
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
This system enables precise control over fluid communication and diverter management, enhancing the accuracy and efficiency of wellbore completion operations by allowing for the reverse removal of diverters and unwanted materials in a single operation, thereby improving the reliability of wellbore completion processes.
Implementation Method 1
a cover disposed over the second port and configured to prevent fluid communication until a threshold pressure is applied to shift the cover
Implementation Method 2
reverse fluids flow out of the second port, into the flowbore, and uphole to displace the diverter from the diverter seat and transport the diverter uphole
Data Source
AI summary
Completion Systems and Methods to Perform Completion Operations are disclosed. A completion system includes a tubular having a wall that defines a flowbore within the tubular and extending into a zone of an annular region external to the tubular. The completion system also includes a first port disposed in the wall and configured to provide fluid communication between the flowbore and the annular region, and a communication path disposed at least partially within the wall and configured to provide fluid communication with an annulus of a well outside of the zone. The completion system further includes a second port disposed in the wall and configured to provide fluid communication between the flowbore and the communication path, a cover disposed over the second port and configured to prevent fluid communication during a fracturing operation, and a diverter seat disposed in the flowbore of the tubular uphole of the second port.