Downhole Flow Control System with Recoverable Dart Retrieval
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Solution Overview
Problem
Current systems for actuating downhole tools in multi-zone oil and gas wells are complex, expensive, and prone to failure, with plugging devices like darts remaining in situ, limiting well access and requiring extensive time for production to commence, and are not adaptable for multiple sliding sleeve configurations.
Innovation Solution
A downhole flow control apparatus featuring a tubular body with transverse ports and a port covering device movable by a piston using downhole fluid pressure, with unique locating means and retrieval mechanisms, allowing for sequential actuation and retrieval of darts that can open or close sliding sleeves in multiple zones with a single trip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plugging device like a dart is dropped down a tubular to actuate downhole tools, then tool actuation is achieved, but wellbore access is limited and intervention tools cannot reach standard locations
Solution Approach 1:
The plugging device is designed to be retrieved from the wellbore after actuation, rather than remaining in situ. The retrieval system includes a fish head with engagement features that allow the dart to be pulled out through the tubular, restoring full wellbore access for standard intervention tools
Solution Approach 2:
The system transitions from a permanent plug approach to a recoverable plug approach. The dart is discarded in the sense that its primary function (sealing and actuation) is completed, but it is recovered through the retrieval mechanism to eliminate long-term wellbore obstruction
2Productivity
If a disappearing plug section is used to allow production, then fluid flow is enabled, but significant time is required for dissolution before production can commence
Solution Approach 1:
The chemical dissolution mechanism is replaced with a mechanical retrieval system. Instead of relying on time-consuming chemical dissolution, the plug is mechanically pulled out through the tubular using the retrieval system, enabling immediate production startup
Solution Approach 2:
The plug section is extracted from the wellbore through the retrieval mechanism rather than dissolving in place, eliminating the waiting period required for chemical dissolution and enabling immediate production
3Reliability
If unique interaction grooves are used for sliding sleeve actuation, then specific zone control is achieved, but a single intervention tool cannot manipulate multiple sleeves with different configurations
Solution Approach 1:
The retrieval tool is designed with universal engagement features that can interact with multiple different sliding sleeve configurations. The fish head includes various engagement mechanisms that can accommodate unique grooves from different zones, allowing a single tool to manipulate multiple sleeves with different configurations
Solution Approach 2:
The retrieval tool incorporates adjustable and adaptable engagement features that can dynamically adjust to different groove configurations. The tool can be reconfigured between zones to match the specific interaction requirements of each sliding sleeve, enabling versatility across multiple zones
4Reliability
If darts remain in situ after actuation, then tool actuation is completed, but extensive time is required for dart removal and production startup
Solution Approach 1:
The plugging device is extracted from the wellbore through the retrieval system immediately after actuation, rather than remaining in situ. The fish head engagement features allow the dart to be pulled out through the tubular, eliminating the time required for dart removal and enabling immediate production startup
Solution Approach 2:
The system transitions from a permanent plug approach to a recoverable plug approach, where the dart is recovered through the retrieval mechanism rather than remaining in the wellbore, eliminating delays associated with dart removal and production startup
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 adaptable actuation of downhole tools, allowing for simultaneous communication with multiple zones, facilitating faster production startup and simplified dart retrieval, while enabling standard intervention tool access and adaptable operation across various sliding sleeves.
Implementation Method 1
The piston may be operable using downhole fluid pressure
Data Source
AI summary
A downhole flow control apparatus comprising: at least one tubular body locatable at a zone of a well, the tubular body having a longitudinal through bore and one or more transverse ports and a port covering device which, in use, is movable from a lower position in which the or each port is covered to an upper position in which the or each port is open; and at least one plugging device which is operable to travel downhole from the surface to locate within and seal the through bore of the tubular body, the plugging device including moving means to cause the port covering device to move from the lower position to the upper position thus allowing fluid communication between the through bore and the or each port.