Well Completion Port Cover and Valve for Proppant Flowback Control
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Solution Overview
Problem
Current completion systems face challenges in achieving differential flow rates through ports during various well operations and in reducing proppant flowback, which affects the efficiency of hydrocarbon resource extraction and formation fracturing.
Innovation Solution
A completion system comprising a tubular with shiftable covers and valves that differentially control fluid flow through ports, using a cover to uncover ports upon diverter activation and a valve to restrict proppant flowback, along with a screen to filter particles greater than a threshold size, ensuring controlled fluid flow and minimizing proppant return.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single port is used for both fracturing and production operations, then device complexity is reduced, but it becomes impossible to achieve differential flow rates and control proppant flowback during different operations
Solution Approach 1:
The single port is segmented into multiple ports (first port and second port) that can be independently controlled. The cover selectively covers or uncovers different ports based on operational requirements, enabling differential flow rates during fracturing and production operations while maintaining relatively simple device structure.
2Productivity
If the port remains open during production operations, then hydrocarbon resources can flow freely into the tubular, but proppant flows back into the tubular causing contamination
Solution Approach 1:
The screen acts as an intermediary component placed at the second port. It allows hydrocarbon resources to flow freely into the tubular while blocking proppant particles from entering. This mediator component resolves the contradiction by permitting desired flow while preventing harmful contamination.
3Object-generated harmful factors
If the port is covered during fracturing operations, then proppant flowback is prevented, but fluid flow into the formation is restricted
Solution Approach 1:
The cover is segmented to selectively cover or uncover different ports based on operational phase. During fracturing, the cover uncovers the first port to allow high fluid flow rates into the formation while covering the second port to prevent proppant flowback. During production, the configuration is reversed. This selective segmentation resolves the contradiction.
Solution Approach 2:
The cover and valve components are made dynamic, allowing the system to transition between different operational states. The cover can move between covering and uncovering positions, and the valve can open or close, enabling the system to adapt to different operational requirements (fracturing vs. production) and resolve the contradiction between preventing proppant flowback and maintaining fluid flow rate.
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 manages differential flow rates and reduces proppant flowback, enhancing hydrocarbon extraction efficiency by allowing controlled fracturing and production operations while preventing solid particle return into the tubular.
Implementation Method 1
a screen that covers the second port and that filters particles greater than a threshold size from flowing through the second port into the tubular
Data Source
AI summary
Completion systems, methods to produce differential flow rate through a port during different well operations, and methods to reduce proppant flow back are disclosed. A completion system includes a tubular extending through a wellbore and having a first port and a second port. The completion system also includes a cover disposed along an interior of the tubular and configured to cover the first port and the second port while the cover is in a first position and is configured to uncover the first port and the second port while the cover is in a second position. The completion system further includes a valve disposed along the tubular and configured to differentially restrict fluid flow through the first port during different well operations.