Downhole Valve Assembly With Cement-Isolated Production Flowpath
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Solution Overview
Problem
Existing well completion systems require time-consuming and costly operations to deploy valve assemblies downhole after cementing and fracturing, which can damage devices and increase operational costs.
Innovation Solution
A valve assembly with a valve housing, top and bottom sleeves, and a flow control device that allows for fluid communication and control, preventing cement intrusion and enabling efficient fluid injection and production without requiring subsequent deployment of work strings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If valve assemblies are deployed downhole on a work string after cementing and fracturing, then device functionality is ensured, but operational time and costs increase
Solution Approach 1:
The valve assembly is integrated into the wellbore string during the initial cementing operation, with frac ports initially closed. The valve assembly remains in place throughout the fracturing process, eliminating the need for subsequent work string deployments to install valve assemblies.
Solution Approach 2:
The valve assembly is combined with the wellbore string and cementing apparatus, allowing it to be deployed simultaneously with the cementing operation rather than as a separate subsequent operation.
2Reliability
If valve assemblies are deployed after cementing, then proper placement is achieved, but operational costs increase
Solution Approach 1:
The valve assembly is pre-positioned on the wellbore string before cementing, ensuring proper placement is achieved during the initial operation rather than requiring costly subsequent deployment operations.
Solution Approach 2:
The valve assembly serves multiple functions: it acts as part of the cementing apparatus, enables controlled fracturing through initially closed ports, and provides ongoing flow control, eliminating the need for separate operational interventions.
3Ease of operation
If work strings are run downhole to reach valve assemblies, then valve access is achieved, but device damage risk increases
Solution Approach 1:
The valve assembly is accessed and operated during the initial cementing and fracturing operations rather than requiring subsequent work string deployments, eliminating the risk of device damage from repeated tool runs.
Solution Approach 2:
The valve assembly is designed to be operated remotely through the wellbore string infrastructure already in place, allowing it to service itself without requiring additional intervention equipment that could cause damage.
4Ease of manufacture
If cementing is performed with open frac ports, then cement placement is simplified, but cement intrusion into flow paths occurs
Solution Approach 1:
The frac ports are initially closed during the cementing operation, allowing cement to be placed without risk of intrusion into the flow path. The closed ports are then opened after cementing is complete to enable fracturing operations.
Solution Approach 2:
The valve assembly divides the flow path into separate regions: the central passage for production flow and the annular region for cement isolation. The top sleeve with sleeve port controls communication between these regions, preventing cement intrusion while maintaining flow paths.
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
The assembly facilitates efficient fluid injection and production by preventing cement intrusion, reducing operational time and costs, and maintaining device integrity during cementing and fracturing processes.
Implementation Method 1
the top sleeve is in sealing engagement with the valve housing for defining a dead-end chamber within the annular region
Implementation Method 2
to enable fluid pressurization of the dead-end chamber and prevent cementitious material from flowing into the annular region
Implementation Method 3
the top sleeve being provided with a sleeve port and being slidable within the valve housing between (i) a first position where the sleeve port is occluded by the outer wall of the valve housing and (ii) a second position where the sleeve port communicates with the housing port
Implementation Method 4
a flow control device coupled to the top sleeve and operable to control a flow of fluids along the fluid pathway when the top sleeve is in the production position
Implementation Method 5
a bottom sleeve operatively mounted within the valve housing and slidable within the central passage between a closed position where the bottom sleeve occludes the housing port, and an open position where the bottom sleeve is spaced from the housing port
Data Source
AI summary
A valve assembly for integration within a wellbore string has a valve housing with a housing port, a bottom sleeve mounted and slidable within the valve housing between closed and open positions, and a top sleeve mounted within the valve housing and defining an annular region therebetween. The top sleeve has a sleeve port and is slidable within the valve housing between a first position where the top sleeve engages the valve housing and defines an annular chamber within the annular region, and a production position where the sleeve port is in fluid communication with the housing port to define a fluid pathway along which fluids flow from the reservoir through the annular chamber. While in the first position, the annular chamber has an inlet allowing fluid to flow into and pressurize the annular chamber to prevent particulates from flowing into the annular region.