Electrically-Actuated BHA for Reliable Wellbore Completion

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Solution Overview

Problem

Current wellbore completion methods for horizontal and deviated wellbores face challenges with mechanically-actuated tools, particularly in long horizontal wells, due to difficulties in providing reliable electrical signals and power, leading to inefficient fracturing operations and limited ability to monitor fracture growth accurately.

Innovation Solution

The use of electrically-enabled coiled tubing for bidirectional communication and power supply to a bottomhole assembly (BHA) with electrically-actuated components, including variable diameter packers and microseismic sensors, allowing for more efficient and accurate completion of multiple zones in a single trip and improved monitoring of fracture growth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanically-actuated tools are used in long horizontal wellbores, then the apparatus can be deployed, but reliable electrical signals and power cannot be provided for actuation and monitoring

Engineering Contradiction:

Improvereliability of electrical signals and powerVSAvoiddifficulty in providing electrical signals and power

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces mechanically-actuated tools with electrically-actuated tools. The BHA includes an electrically-actuated bridge plug and electrically-actuated perforating charges that can be controlled from surface via electrical signals transmitted through the coiled tubing, eliminating the need for mechanical actuation mechanisms and enabling reliable remote control and monitoring.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The coiled tubing system is designed to serve multiple functions: it acts as both the mechanical deployment medium for the BHA and as the electrical conduit for transmitting power and control signals to the electrically-actuated components. This multi-functionality resolves the contradiction by integrating both mechanical and electrical capabilities into a single system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If conventional BHA with single sealing element is used, then the wellbore can be sealed below perforations, but the apparatus length increases making it difficult to run to toe of very long horizontal wellbores

Engineering Contradiction:

Improveability to run to toe of very long horizontal wellboresVSAvoidlength of BHA

Core Design Contradiction:

Ease of operationVSLength of moving object

Solution Approach 1:

The patent extracts the perforating function from the BHA by using separately deployable perforating charges that can be set after the BHA is in place. This allows the BHA itself to be more compact and easier to deploy to the toe of long horizontal wellbores, while the perforating operation is performed as a separate step using the existing wellbore infrastructure.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If wireline deployed bridge plugs are used, then zones can be isolated, but wireline cannot reliably pull bridge plugs to surface requiring multiple plugs to be left in wellbore

Engineering Contradiction:

Improveability to retrieve bridge plugsVSAvoidnumber of bridge plugs required

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces wireline mechanical retrieval with electrical actuation. The bridge plug incorporates an electrically-actuated release mechanism that can be controlled from surface through the coiled tubing electrical system, enabling reliable retrieval of the bridge plug without requiring excessive wireline pulling capacity. This eliminates the need to leave multiple bridge plugs in the wellbore.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Measurement precision

If microseismic sensors are integrated into BHA, then fracture growth can be monitored, but the apparatus requires reliable power and communication which is difficult to provide

Engineering Contradiction:

Improveability to monitor fracture growthVSAvoidpower and communication reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The coiled tubing electrical system provides multiple functions simultaneously: it powers the microseismic sensors, transmits control signals to the electrically-actuated components, and communicates data back to surface. This integrated electrical infrastructure resolves the reliability issue by providing a unified system for power and communication to all downhole components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10662750B2Methods and electrically-actuated apparatus for wellbore operations

Publication Date: 2020.05.26 KOBOLD CORP

AI summary

Embodiments of a bottomhole assembly (BHA) for completion of a wellbore are deployed on electrically-enabled coiled tubing (CT) and permit components of the BHA to be independently electrically actuated from surface for completion of multiple zones in a single trip using a single BHA having at least two electrically-actuated variable diameter packers. One or both of the packers may be actuated to expand or retract for opening and closing off a variety of flowpaths between the BHA and the wellbore, in new wellbores, old wellbores, cased wellbores, wellbores with sleeves and in openhole wellbores. Additional components in the BHA, which may also be electrically—actuated or powered, permit perforating, locating of the BHA in the wellbore such as using casing collar locators and microseismic monitoring in real time or in memory mode.