Downhole Sleeve Actuation With Dual-Sensor Impact Confirmation
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Solution Overview
Problem
Existing mechanisms for actuating downhole sleeve assemblies in wellbores face issues such as premature activation due to false positives from non-target impacts, time-consuming operations for removing obstructions, and costly drilling out procedures, which affect the efficiency and accuracy of staged wellbore completion operations.
Innovation Solution
An actuation device with an impact sensor and confirmation sensor system that generates signals to accurately count sleeve assemblies and confirm target engagement, using a controller to activate the device only when the correct sleeve is reached, and a removable plug to manage fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ball-drop actuation is used with varying ball seat diameters to selectively open sleeve assemblies at different zones, then the capability to selectively open sleeve assemblies is achieved, but the cross-sectional flow area of the bores decreases toward the downhole end of the wellbore
Solution Approach 1:
The invention segments the actuation mechanism into distinct functional components: a ball for flow obstruction, a dart for selective engagement, and a seat for positioning. This segmentation allows each component to perform its specific function independently, enabling selective actuation without requiring varying bore diameters throughout the wellbore.
Solution Approach 2:
The dart serves as an intermediary component between the ball and the sleeve assembly seat. It transfers the actuation force and provides precise positioning, allowing the ball to maintain a consistent diameter while still achieving selective actuation at different zones through the dart's engagement with the seat.
2Ease of operation
If active darts with impact sensors are used to count sleeve assemblies and determine dart position, then selective actuation without varying seat sizes is enabled, but false positives from impacts with non-sleeve structures cause premature activation
Solution Approach 1:
The system uses impact sensors to detect impacts during dart descent and provides feedback to a controller. The controller analyzes the impact characteristics and compares them against predetermined criteria to distinguish between valid sleeve assembly impacts and false positives from other wellbore structures, thereby improving activation accuracy.
Solution Approach 2:
The system changes the parameters used for impact detection by analyzing multiple characteristics of impact signals (such as force magnitude, duration, and pattern) rather than relying on a single threshold. This parameter-based differentiation allows the system to reliably distinguish between impacts from sleeve assemblies and other wellbore structures.
3Productivity
If balls are introduced into the wellbore to obstruct flow through the dart or seat on the dart at later time, then flow obstruction for formation stimulation is achieved, but the ball must be removed by well flowback or coiled tubing drilling which is time consuming and costly
Solution Approach 1:
The ball is pre-positioned on the dart during assembly before the dart is deployed into the wellbore. This preliminary placement ensures the ball is already in position to obstruct flow when the dart is activated, eliminating the need for subsequent ball removal operations and reducing overall time loss.
Solution Approach 2:
The dart and ball assembly is designed as a self-contained unit where the ball automatically engages with the sleeve assembly seat when the dart is actuated. This self-service mechanism eliminates the need for external ball removal operations, as the system handles its own deployment and activation functions.
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
Enhances the accuracy and efficiency of sleeve assembly actuation by reducing false activations and minimizing time-consuming operations, thereby improving the precision and speed of wellbore treatment processes.
Implementation Method 1
an impact sensor that generates an impact signal in response to a physical impact experienced by the actuation device as the actuation device travels through the plurality of sleeve assemblies
Implementation Method 2
a confirmation sensor that generates a confirmation signal in response to detection of a detectable feature associated with at least one of the plurality of sleeve assemblies
Implementation Method 3
a controller in communication with the impact sensor and confirmation sensor to receive the impact signal and the confirmation signal, wherein the controller increases an impact count if the confirmation signal is within a predetermined time window of the impact signal
Implementation Method 4
a surface structure on an external surface of the housing, the surface structure having an inactive state and an activated state, and wherein the surface structure allows the device to (i) travel through the plurality of sleeve assemblies when the surface structure is in the inactive state; and (ii) seat in the target sleeve assembly when the surface structure is in the activated state
Data Source
AI summary
Actuation devices are provided for actuating a target sleeve assembly in a plurality of sleeve assemblies installed in a wellbore tubing string. In some embodiments, the actuation device comprise an impact sensor that detects a physical impact to the actuation device as it travels through the sleeve assemblies, and a confirmation sensor that confirms that a given impact is due to contact with a sleeve assembly and not some other structure in the wellbore tubing. In some embodiments, the actuation device comprises a removable plug that is configured to prevent reseating of the plug in the actuation device after removal. Related systems and methods are also provided.