Dissolvable Plug Assembly for Zonal Flow Control
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Solution Overview
Problem
Existing well completion technologies lack efficient mechanisms to control the flow of well fluids from multiple fluid producing zones into a wellbore, leading to uncontrolled production and potential issues like water or gas intrusion.
Innovation Solution
A well completion assembly featuring multiple Inflow Control Devices (ICDs) and dissolvable plugs and balls, where the plugs are connected in series and can be released to close specific ICDs by fitting into compartments of decreasing diameters, using extendable members and springs for secure seating, and employing dissolvable balls to activate plug detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple ICDs are installed to control flow from multiple zones, then flow control capability is improved, but device complexity increases
Solution Approach 1:
The wellbore is divided into multiple compartments, each containing an ICD device for independent zone control. This segmentation allows each zone to be controlled separately while maintaining overall system manageability through modular design
Solution Approach 2:
A universal plug design is implemented that can be used across multiple compartment types. The plugs share common features such as ball seats, extendable members, and sealing mechanisms, allowing a single plug design to control different ICD configurations throughout the wellbore
2Manufacturing precision
If plugs are used to close specific ICDs, then flow control precision is improved, but ease of operation deteriorates
Solution Approach 1:
The plug system is designed to be self-actuating through the use of dissolvable balls. When a dissolvable ball is introduced, it automatically triggers the plug to detach and seal the appropriate compartment without requiring manual intervention or complex control mechanisms
Solution Approach 2:
The mechanical system for plug actuation is replaced with a chemical dissolution mechanism. Instead of using mechanical keys, motors, or hydraulic systems to trigger plug closure, the invention uses dissolvable balls that chemically break down to release the plug, simplifying the operation
3Ease of operation
If dissolvable balls are used to activate plug detachment, then ease of operation is improved, but reliability deteriorates
Solution Approach 1:
The dissolution rate of the balls is carefully controlled by adjusting their physical and chemical parameters such as material composition, size, and surface area. This ensures reliable and predictable plug activation under specific downhole conditions while maintaining ease of operation
4Ease of manufacture
If compartments are arranged with successively smaller diameters, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The compartments are designed with asymmetric diameter progression, where each successive compartment has a slightly smaller diameter. This asymmetric design simplifies the manufacturing process by using a tapering approach rather than requiring precise identical dimensions for each compartment, while the modular nature maintains operational simplicity
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 solution enables precise control of fluid flow from each producing zone, preventing unwanted fluids like water from entering the wellbore, while allowing continued production from other zones, thus optimizing hydrocarbon extraction.
Implementation Method 1
Each plug includes a spring connected to the extendable member. With the spring in a biased state, the extendable member is retracted within the plug. In response to the extendable member being radially aligned with the profile, the spring returns to an unbiased state to radially push the extendable member into the slot.
Implementation Method 2
Each plug defines a ball seat configured to receive a ball. Each plug, upon receiving the ball in the ball seat and in response to pressure, is configured to detach from remaining plugs and to travel in a downhole direction towards the multiple compartments.
Data Source
AI summary
An assembly for closing inflow control devices (ICDs) using dissolvable balls and plugs includes ICDs, each of which can be installed at a respective fluid producing zone of a subterranean zone to control flow of well fluids from the respective fluid producing zone into a wellbore. The assembly includes compartments corresponding to the ICDs, each to be installed within a respective compartment. The compartments are serially connected to each other and arranged sequentially from an uphole location to a downhole location. The compartments define successively smaller diameters from the uphole location to the downhole location. The assembly includes plugs corresponding to compartments. Each plug can be received in a respective compartment to close flow of well fluids from the subterranean zone into the wellbore through a respective ICD installed in the respective compartment. The plugs are serially connected to each other and installed uphole of the compartments.