Downhole Completion System with Zone Isolation Verification
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Solution Overview
Problem
Existing downhole completion systems face challenges in verifying the isolation and sealing properties of annular barriers, leading to uncertainty in well performance after completion.
Innovation Solution
Incorporating a sensor device that measures pressures in both zones separated by the annular barrier system, ensuring proper isolation by maintaining constant pressure in the second zone during expansion and pressurization of the production zone, and utilizing a shuttle valve and pressure sensors to equalize and compare pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If annular barriers are expanded using pressurised fluid or heated compound, then the annular barrier provides zone isolation between first and second zones, but it becomes difficult to control and verify if the expansion has been performed correctly
Solution Approach 1:
The patent implements a feedback mechanism by installing pressure sensors in both the first zone (production zone) and the second zone (isolated zone). The sensor device continuously monitors pressure in both zones and provides feedback to verify that the annular barrier is properly isolating the zones. When the barrier is correctly expanded, pressure changes in the first zone do not affect the second zone, confirming proper isolation.
Solution Approach 2:
The patent introduces an intermediary verification system consisting of pressure sensors and a control unit that mediates between the annular barrier expansion process and the verification of its effectiveness. The sensors act as intermediaries to detect pressure conditions, and the control unit processes this information to determine whether proper isolation has been achieved, eliminating the need for direct visual or manual verification of the expanded barrier.
2Reliability
If two annular barriers are used to isolate a production zone, then zone isolation can be provided, but testing of isolation and sealing properties cannot be performed by conventional testing tools
Solution Approach 1:
The verification system is integrated directly into the annular barrier assembly, allowing the system to verify its own isolation performance without requiring external testing equipment. The pressure sensors are positioned to monitor pressures on both sides of the barrier, enabling the system to self-verify that proper isolation has been achieved through automated pressure comparison and analysis.
Solution Approach 2:
The sensor device serves multiple functions: it monitors pressure in both zones during expansion, verifies proper isolation after expansion, and can detect potential failures or leaks. This multi-functional verification system replaces the need for separate conventional testing tools and procedures.
3Productivity
If pressure changes are made in the production zone during expansion and fracturing, then the annular barrier can be deployed and formation can be fractured, but uncertainty arises regarding whether proper isolation and sealing has been achieved
Solution Approach 1:
The control unit receives continuous pressure feedback from sensors in both zones and analyzes this information to determine whether proper isolation has been achieved. The system can distinguish between pressure changes caused by normal operations (expansion, fracturing) and pressure changes indicating improper isolation or leaks, providing reliable information about isolation status throughout the well operation process.
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 reliable verification of zone isolation and sealing properties, ensuring effective well operation by confirming the annular barrier's ability to maintain pressure integrity between zones.
Implementation Method 1
the sensor device being adapted to measure the first pressure of the first zone and the second pressure of the second zone for verifying the zone isolation
Implementation Method 2
an annular barrier system to be expanded in an annulus between a production casing and a wall of a borehole... an annular space between the inner sleeve face of the expandable metal sleeve and the tubular metal part, the annular space having a space pressure
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The present invention relates to a downhole completion system comprising a production casing installed in a borehole and an annular barrier system to be expanded in an annulus between a production casing and a wall of a borehole or another well tubular structure downhole for providing zone isolation between a first zone having a first pressure and a second zone having a second pressure of the borehole, the downhole completion system comprising an annular barrier comprising a tubular metal part adapted to be mounted as part of the production casing, the tubular metal part having an outer face, an expandable metal sleeve surrounding the tubular metal part and having an inner sleeve face facing the tubular metal part and an outer sleeve face facing the wall of the borehole, each end of the expandable metal sleeve being connected with the tubular metal part, and an annular space between the inner sleeve face of the expandable metal sleeve and the tubular metal part, the annular space having a space pressure, wherein the downhole completion system further comprises a sensor device which is in communication with the first zone and/or second zone, respectively, the sensor device being adapted to measure the first pressure of the first zone and the second pressure of the second zone for verifying the zone isolation. The present invention also relates to a verification method for verifying zone isolation and to a monitoring method for monitoring a condition of a well.