Composite Packer Spacer for Single-Trip Perforation Isolation

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Solution Overview

Problem

Current methods for isolating or plugging perforations in a well often require multiple trips and result in a permanent reduction of the inner casing diameter, whereas there is a need for a solution that can effectively plug perforations in a single trip without reducing the casing diameter.

Innovation Solution

A downhole tool comprising a packer assembly with moveable sealing assemblies and a spacer that allows for a single trip to isolate perforations, using a settable material like cement or epoxy to fill the annular space and perforations, which can be drilled out after curing, maintaining the casing diameter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If temporary or retrievable tools are used to isolate zones, then the perforations can be isolated, but multiple trips in the well are required

Engineering Contradiction:

Improveperforation isolationVSAvoidmultiple trips

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The tool is divided into distinct segments including a packer assembly with upper and lower sealing elements, a spacer section with multiple slots, and a drillable bridge plug section. This segmentation allows each component to perform its specific function independently while being deployable as a single integrated tool string, enabling complete perforation isolation and plugging in one trip

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The drillable bridge plug and spacer are nested within the packer assembly during deployment. The spacer with slots is positioned within the annular space created by the packer, and the bridge plug is contained within the spacer structure. This nested configuration allows all components to be deployed together in a single trip while maintaining their functional independence

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If permanent packers are used to isolate zones, then the perforations can be isolated, but the inner casing diameter is permanently reduced

Engineering Contradiction:

Improveperforation isolationVSAvoidinner casing diameter

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The bridge plug is designed with drillable material properties that allow it to be easily removed after serving its isolation function. The material composition and structural parameters are specifically selected to enable drilling removal, restoring the casing inner diameter to its original size while maintaining effective perforation isolation during the treatment process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The drillable bridge plug is designed as a temporary, disposable component that serves its isolation function during the plugging operation and then is easily removed by drilling. This disposable approach eliminates the need for permanent casing modification while providing reliable perforation isolation during the treatment process

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Loss of time

If a single trip tool is used to plug perforations, then the number of trips is reduced, but the tool complexity increases

Engineering Contradiction:

Improvenumber of tripsVSAvoidtool structure

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The packer assembly is designed to perform multiple functions: creating an isolated annular space, providing a deployment mechanism for the spacer and bridge plug, and enabling subsequent drilling removal. The spacer section with slots serves both as a structural element and as a conduit for settable material. This multi-functionality reduces the need for multiple specialized tools while maintaining operational effectiveness

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The spacer section acts as an intermediary component between the packer assembly and the drillable bridge plug. It provides the structural framework that holds the bridge plug in place during deployment, creates the annular space for settable material flow, and facilitates the transition from deployment to drilling removal phases

Inventive Principle:

Principle #24Intermediary (Mediator)

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 the effective plugging of perforations in a single trip without reducing the well's inner diameter, allowing for efficient repair of inadvertently placed perforations in both heel and lateral portions of the well.

Implementation Method 1

The spacer has a plurality of ports or slots therethrough. The settable material is injected into the annulus and through the slots into the perforations

Methodology Applied

Scientific EffectFluid flow through porous material: Porosity

Implementation Method 2

using a settable material like cement or epoxy to fill the annular space and perforations, which can be drilled out after curing

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS10920513B2Composite permanent packer spacer system

Publication Date: 2021.02.16 HALLIBURTON ENERGY SERVICES INC

AI summary

A downhole tool for shutting off perforations has upper and lower sealing assemblies. A spacer separates the upper and lower sealing assemblies. The upper and lower sealing assemblies may engage a well above and below perforations to be shut off. A settable material may be injected into a space between the upper an lower assemblies, and into the perforations.