Dissolvable Seal Members for Controlled Downhole Flow Paths
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Solution Overview
Problem
Current methods for creating flow paths in hydrocarbon-producing wells, such as perforating and pressure-activated tools, suffer from skin damage and inefficiency, and lack wellbore control after pressure testing.
Innovation Solution
A downhole communication tool with a cylindrical housing and radially extending ridges, each with dissolvable seal members that prevent fluid communication until a pressure test is completed, allowing for controlled flow paths to be formed after the test.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a perforating gun is used to create flow paths, then flow paths are created between the casing string and subterranean formation, but skin damage occurs due to debris from perforations
Solution Approach 1:
The patent replaces the mechanical perforating system (shaped charges) with a chemical dissolution system. Dissolvable seal members made of erosion-resistant materials dissolve chemically to create flow paths, eliminating the mechanical debris that causes skin damage while maintaining the ability to create flow paths between the casing string and subterranean formation.
Solution Approach 2:
The patent changes the state of the seal members from solid mechanical barriers to dissolving chemical barriers. The seal members are made of materials that erode and dissolve over time or when exposed to certain fluids, transforming the flow path creation mechanism from mechanical penetration to chemical dissolution, thereby reducing skin damage.
2Productivity
If a pressure activated tool is used to open flow paths, then flow paths are created once threshold pressure is reached, but the valve opens inaccurately and cannot close once opened
Solution Approach 1:
The patent replaces the mechanical pressure-activated valve system with a controlled dissolution system. Instead of relying on mechanical valve opening at a threshold pressure, the dissolvable seal members gradually dissolve to create flow paths, providing more accurate and controllable flow path activation without the inaccuracy and irreversibility of mechanical valves.
3Reliability
If the casing string is configured with no fluid passages for pressure testing, then pressure testing can be performed, but no flow paths exist for subsequent production or stimulation
Solution Approach 1:
The patent incorporates dissolvable seal members in advance within the casing string that initially block flow paths to maintain pressure test integrity. After successful pressure testing, these seal members dissolve to automatically create flow paths for production or stimulation, eliminating the need for separate trips to create flow paths.
Solution Approach 2:
The patent transforms the static casing string configuration into a dynamic system where the seal members change state from blocking to dissolving. This dynamic transformation allows the system to adapt from a pressure-test-ready configuration to a flow-path-ready configuration without requiring additional intervention.
4Adaptability or versatility
If multiple trips are made to run perforating gun separately, then flow paths can be created, but operational efficiency decreases and cost increases
Solution Approach 1:
The patent combines the pressure testing function and flow path creation function into a single integrated system. The dissolvable seal members are installed during the initial casing string deployment, allowing pressure testing to be performed first, followed by automatic flow path creation as the seal members dissolve, eliminating the need for separate trips to run perforating guns.
Solution Approach 2:
The dissolvable seal members are pre-installed in the casing string during initial deployment, preparing the system for both pressure testing and subsequent flow path creation in a single operational sequence, thereby eliminating multiple trips and improving operational efficiency.
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 efficient and controlled fluid communication between the wellbore and subterranean formation post-pressure test, reducing skin damage and operational inefficiencies while maintaining wellbore control.
Implementation Method 1
Each dissolvable seal member may be configured to prevent fluid communication between the flowbore and a subterranean formation
Data Source
AI summary
A downhole communication tool is provided. The downhole communication tool may include a cylindrical housing, a plurality of ridges, and a plurality of flow control assemblies. The cylindrical housing may have an inner surface, a first end portion, and a second end portion. The inner surface may define a flowbore extending axially between the first and second end portions. The plurality of ridges may extend radially outward from the cylindrical housing between the first and second end portions. Each ridge may have a ridge outer surface and define one or more ports that extend radially between the flowbore and the ridge outer surface. Each flow control assembly may be mounted about a respective port of the one or more ports and include a dissolvable seal member extending across the respective port. Each dissolvable seal member may be configured to prevent fluid communication between the flowbore and a subterranean formation.