Downhole Tool Real-Time Control for Plug Setting
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Solution Overview
Problem
In wellbore operations, the existing methods for conveying downhole tools lack real-time feedback on wellbore conditions, leading to potential premature setting of plugs and damage due to excessive travel rates, vibrations, and obstructions, which can result in inefficient hydrocarbon production and tool damage.
Innovation Solution
A downhole tool system equipped with sensors and a controller that provides real-time data on wellbore conditions, allowing for dynamic adjustment of fluid flow rate and wireline tension to optimize the travel rate and prevent premature plug setting, ensuring safe deployment and efficient hydrocarbon extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the downhole assembly is conveyed at high travel rates, then the productivity of wellbore operations is improved, but the reliability deteriorates due to premature plug setting and tool damage from obstructions and vibrations
Solution Approach 1:
The system incorporates sensors that provide real-time feedback on wellbore conditions (obstructions, vibrations, travel rate) to a controller, which dynamically adjusts pump rate and wireline tension to maintain optimal travel rates while preventing premature plug setting and tool damage
Solution Approach 2:
The system dynamically adjusts operating parameters (pump rate, wireline tension) in real-time based on sensor feedback, transitioning from static pre-defined parameters to dynamic control that adapts to changing wellbore conditions during the conveying operation
2Productivity
If the downhole assembly is conveyed at high travel rates, then the productivity of wellbore operations is improved, but the reliability deteriorates due to tool damage from excessive vibrations and acceleration
Solution Approach 1:
Vibration and acceleration sensors provide real-time feedback to the controller, which adjusts pump rate and wireline tension to maintain travel rates within safe limits, preventing excessive vibrations and acceleration that could damage the tool
Solution Approach 2:
The system detects early signs of excessive vibration or acceleration and preemptively adjusts operating parameters to counteract harmful effects before they can cause tool damage
3Reliability
If real-time sensor feedback and dynamic control are implemented, then the reliability of plug setting is improved, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The controller serves multiple functions: it processes data from various sensors (position, vibration, acceleration, flow rate), determines wellbore conditions, and dynamically adjusts multiple operating parameters (pump rate, wireline tension), reducing the need for separate dedicated control devices
Solution Approach 2:
The system combines multiple sensing functions and control functions into an integrated downhole tool assembly, where sensors monitor multiple parameters simultaneously and the controller coordinates all adjustments in a unified manner
Data Source
AI summary
An apparatus for use in a wellbore is disclosed. The apparatus includes a downhole tool coupled to a wireline for conveying the downhole tool into the wellbore and for providing a data communication between the downhole tool and a surface device. The downhole tool further includes a settable device, a setting tool for setting the settable device in the wellbore, a sensor that provide measurements relating to downhole parameter, and a controller for determining the downhole parameter from the measurements and in response thereto altering an operation parameter.