Downhole Mixing Fracturing Tool for High-Rate Stimulation
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Solution Overview
Problem
Conventional formation stimulation methods face challenges such as high capital costs, equipment wear, and limitations in pumping rates due to the abrasive and viscous nature of fracturing fluids, which restrict the creation of multiple fractures in deep, large bore wells, and result in premature screenouts and high fluid volumes.
Innovation Solution
A method and apparatus that involve inserting a manipulatable fracturing tool with configurable ports into a wellbore to mix and pump two components of a composite fluid independently, allowing for real-time control of fluid composition and flow, enabling efficient fracture creation and extension without the need for extensive surface mixing and high-rate blending equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional surface-mixed fracturing fluid is pumped down the wellbore, then fracture initiation can be achieved, but the pumping rate is limited due to the abrasive and viscous characteristics of the fluid causing equipment wear and failure
Solution Approach 1:
The fracturing fluid is divided into two separate components that are pumped independently through separate flowpaths. Component 1 is pumped through the tubing while Component 2 is pumped through the annular space, allowing each component to be delivered at optimal rates without the wear and viscosity limitations of pre-mixed fluid.
Solution Approach 2:
The wellbore itself serves as the mixing chamber, acting as an intermediary where the two components combine after being separately transported. This eliminates the need for surface mixing equipment and allows high-rate delivery without the harmful effects of pumping abrasive pre-mixed fluid.
2Productivity
If high-rate pumping of abrasive fracturing fluid is used to increase productivity, then more fractures can be created, but downhole wellbore equipment suffers wear, damage, or degradation
Solution Approach 1:
The fluid delivery system is segmented into two independent flowpaths that converge downhole. By pumping components separately, the system achieves high aggregate pumping rates while each individual pump handles less abrasive material, reducing wear and maintaining equipment reliability.
Solution Approach 2:
The two fluid components are prepared and pumped separately in advance of their mixing point. This preliminary separate transport allows optimization of each pump's operating conditions to minimize wear while maintaining high overall delivery rates needed for rapid fracture creation.
3Manufacturing precision
If conventional surface mixing of fracturing fluid is used, then fluid composition can be controlled, but capital costs increase due to the need for high-rate blending equipment and specialized pumping equipment
Solution Approach 1:
The wellbore acts as the mixing intermediary, eliminating the need for complex surface blending equipment. The two components are pumped separately through simple flowpaths and combine naturally in the wellbore, reducing capital costs while maintaining composition control through independent pumping rates.
Solution Approach 2:
The mixing function is extracted from the surface equipment and relocated to the downhole environment. This removes the need for expensive high-rate blending equipment at the surface, simplifying the overall system while preserving the ability to control fluid composition through separate component delivery.
4Productivity
If the rate of stimulation fluid leak-off into the formation exceeds the pumping rate, then premature screenout occurs and proppant compacts within the fracture, but increasing pumping rate is limited by equipment wear
Solution Approach 1:
The fluid delivery system is segmented into two independent high-rate flowpaths that can be optimized separately. This allows the aggregate delivery rate to exceed formation leak-off rates and prevent screenout, while each individual pump operates at manageable rates that preserve equipment durability.
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 approach reduces capital costs, minimizes equipment wear, and allows for higher pumping rates and real-time control of fracturing fluid composition, effectively creating and extending fractures in deep wells while avoiding premature screenouts.
Implementation Method 1
mixing the first component of the composite fluid with the second component of the composite fluid within the wellbore
Implementation Method 2
a fracturing fluid may be introduced into a portion of a subterranean formation penetrated by a wellbore at a hydraulic pressure sufficient to create or enhance at least one fracture therein
Data Source
AI summary
A method of servicing a wellbore comprising inserting a first tubing member into the wellbore, wherein a manipulatable fracturing tool is coupled to the first tubing member and comprises one or more ports configured to alter a flow of fluid through the manipulatable fracturing tool, positioning the manipulatable fracturing tool proximate to a formation zone, manipulating the manipulatable fracturing tool to establish fluid communication between the flowbore of the first tubing member and the wellbore, introducing a first component of a composite fluid into the wellbore via the flowbore of the first tubing member, introducing a second component of the composite fluid into the wellbore via an annular space formed by the first tubing member and the wellbore, mixing the first component with the second component within the wellbore, and causing a fracture to form or be extended within the formation zone.