Downhole Completion Tool Pressure-Activated Aperture Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current downhole completion tools face challenges in performing pressure tests without causing skin damage and inefficiencies due to the need for separate trips to create flowpaths for hydrocarbon production or stimulation, and existing pressure-activated tools are inaccurate and lack control post-pressure test.
Innovation Solution
A downhole tool with a housing, inner annular casing, and pistons that allow for controlled fluid communication between the wellbore and subterranean formation through a series of pressure thresholds, enabling pressure testing and subsequent fluid flow without additional trips, using a combination of pistons and retention members to manage fluid paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a perforating gun is used to create flowpaths, then flowpaths are created between the casing string and subterranean formation, but skin damage occurs due to debris from perforations
Solution Approach 1:
The tool divides the flowpath creation function into multiple stages: pressure testing phase (with sealed apertures) and production phase (with opened apertures). The segmented design allows the same tool to serve multiple purposes without causing skin damage, as the apertures are opened only after successful pressure testing.
Solution Approach 2:
The tool performs pressure testing before creating permanent flowpaths. The pressure-activated mechanism ensures that flowpaths are only created after the pressure test is completed successfully, preventing skin damage by avoiding premature perforation or aperture opening.
2Adaptability or versatility
If a separate trip is made to run the perforating gun downhole, then flowpaths can be created, but operational efficiency decreases and cost increases
Solution Approach 1:
The tool merges the pressure testing function and flowpath creation function into a single integrated device. The pressure-activated aperture opening mechanism allows both functions to be performed in one deployment, eliminating the need for a separate trip to run a perforating gun and thereby improving operational efficiency.
Solution Approach 2:
The downhole tool is designed as a multi-functional device that can perform both pressure testing and flowpath creation. The universal design allows the same tool to serve multiple purposes: sealing apertures during pressure testing and opening them for production, eliminating the need for multiple specialized tools and trips.
3Productivity
If a differential valve is used to open flowpaths at threshold pressure, then the number of trips is reduced, but accuracy of pressure activation decreases and wellbore control is lost
Solution Approach 1:
The tool incorporates a feedback mechanism where the pressure-activated aperture opening is reversible. If the pressure exceeds a predetermined threshold after opening, the apertures automatically close, providing feedback control that maintains wellbore safety while allowing efficient single-trip operation.
Solution Approach 2:
The aperture opening mechanism is designed to be dynamic and reversible rather than static and permanent. The apertures can open and close based on pressure conditions, allowing the tool to adapt to changing wellbore conditions and maintain control while reducing the number of trips required.
4Measurement precision
If apertures are sealed during pressure testing, then accurate pressure testing can be performed, but flowpath creation requires additional complexity
Solution Approach 1:
The tool uses the pressure differential from the pressure test itself to activate the aperture opening mechanism. The pressure-activated design eliminates the need for external actuators or complex control systems, allowing the tool to service itself by using the test pressure to open the apertures after successful testing.
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 tool allows for accurate pressure testing and controlled fluid communication, reducing skin damage and operational inefficiencies, maintaining wellbore control and enabling efficient hydrocarbon production or stimulation without additional trips, thereby enhancing well completion processes.
Implementation Method 1
a first piston (104) configured to be displaced by a force provided by a first pressure (P1) applied to the flowbore (34)
Implementation Method 2
the annular cover (74) shearing a retention member (62) configured to retain the annular cover (74)
Implementation Method 3
a biasing member (68) configured to exert a force on the annular cover (74) at a second pressure (P2) applied to the flowbore (34)
Implementation Method 4
a second piston (108) configured to be displaced by a force provided by a third pressure (P3) applied to the annular space (64)
Data Source
AI summary
A downhole tool and method of operation thereof is provided. The downhole tool may be configured to permit fluid communication between a combined flowbore of the casing string and the downhole tool and the subterranean formation or wellbore, or both, after a pressure test has been completed, a second threshold pressure is reached or applied, and a third threshold pressure has been applied to the downhole tool.