Delayed Port Assembly With Burst Disk for Controlled Wellbore Opening
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Solution Overview
Problem
Existing port subs in wellbore operations face issues with premature opening of flow ports during pressure tests, leading to unintended actuation of hydraulically actuated tools and increased operational costs due to the use of dissolvable balls and ball seats, which can also leave debris and slow down operations.
Innovation Solution
A port assembly with a burst disk and a dissolvable barrier that delays the opening of flow ports by configuring the assembly to be tangentially positioned in the port sub, allowing the burst disk to rupture first, followed by the dissolvable barrier breaking after a predetermined time, thus preventing immediate fluid flow and ensuring controlled port opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dissolvable ball and ball seat configuration is used to prevent premature opening of flow ports during pressure testing, then the flow ports can be protected from accidental opening, but the operational cost increases and wellbore operations slow down due to the time required to pump the ball down to the seat
Solution Approach 1:
The patent removes the dissolvable ball and ball seat components from the system entirely. Instead, it uses a flow port assembly with a burst disk and dissolvable barrier that passively prevents premature opening without requiring active components to be pumped into position, thereby eliminating the time delay and operational complexity associated with ball seat operations
Solution Approach 2:
The patent employs a disposable dissolvable barrier that is inexpensive and single-use. This barrier is positioned in the flow port and dissolves automatically after serving its protective function, eliminating the need for reusable components like ball seats and reducing operational complexity and cost
2Reliability
If a dissolvable ball and ball seat configuration is used to prevent premature opening of flow ports during pressure testing, then the flow ports can be protected from accidental opening, but wellbore operations become more complex and costly
Solution Approach 1:
The patent removes the dissolvable ball and ball seat components from the system entirely. Instead, it uses a flow port assembly with a burst disk and dissolvable barrier that passively prevents premature opening without requiring active components to be pumped into position, thereby eliminating the time delay and operational complexity associated with ball seat operations
Solution Approach 2:
The dissolvable barrier automatically dissolves after a predetermined time without requiring external intervention or complex operational sequences. The system self-regulates the timing of flow port opening through the inherent dissolution characteristics of the barrier material, eliminating the need for manual ball seat operations
3Ease of operation
If an outer cap is displaced into the wellbore when the flow port is opened, then the flow port can be opened, but debris is left in the wellbore which could block flow paths and impede production
Solution Approach 1:
The patent employs a disposable dissolvable barrier that is inexpensive and single-use. This barrier is positioned in the flow port and dissolves automatically after serving its protective function, eliminating the need for reusable components like ball seats and reducing operational complexity and cost
Solution Approach 2:
The dissolvable barrier is designed to be discarded after its protective function is complete. It dissolves automatically, leaving no debris in the wellbore, and the flow port opens cleanly without requiring displacement of caps or other components that would generate debris
4Ease of operation
If flow ports are opened to hydraulically actuate tools, then the tools can be actuated, but the mechanism may be actuated prematurely if there is a pressure spike in the wellbore during a casing pressure test
Solution Approach 1:
The dissolvable barrier is positioned in the flow port before the pressure test to prevent premature opening. It creates a predetermined barrier that must be dissolved before the flow port can open, ensuring that even if pressure spikes during the test, the tool actuation mechanism cannot be triggered until the barrier dissolves at the appropriate time
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 safe pressure testing without prematurely opening flow ports, reduces operational costs, and maintains wellbore cleanliness by avoiding debris, while providing controlled fluid flow through a delayed opening sequence.
Implementation Method 1
The burst disk is configured to rupture at a pressure corresponding to at least a predetermined time prior to the dissolvable barrier dissolving
Implementation Method 2
a dissolvable barrier adjacent to but spaced apart from the burst disk outer surface to define a cavity therebetween
Data Source
AI summary
A port assembly for controlling fluid flow through a flow port of a port sub. The port assembly comprises a dissolvable barrier, a burst disk for protecting the dissolvable barrier from fluids inside the port sub, and optionally a protective layer for protecting the dissolvable barrier from external fluids. When the burst disk is ruptured by increased fluid pressure inside the port sub, the dissolvable barrier starts disintegrating from exposure to the fluid. When the dissolvable barrier and protective layer are broken through, a flow passage is opened in the port assembly to permit fluid flow therethrough. The flow passage may be positioned tangentially in the port sub. The breakthrough time of the dissolvable barrier may be preconfigured by providing one or more thinner areas therein and/or placing a corrosive material in the port assembly.