Expandable Ball Seat and Temporary Screen Shield for Cementing
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Solution Overview
Problem
Current downhole tools require sequentially sized balls to activate each stage, leading to inefficiencies and sand production issues after fracturing, as they cannot effectively prevent sand from flowing back into the wellbore, causing fractures to close.
Innovation Solution
A downhole tool with an expandable ball seat and temporary member that allows a single ball to treat multiple zones, featuring an inner sleeve with a screen and outer sidewall, where the temporary member shields the screen during cementing and can be removed to allow wellbore utilization, and the expandable ball seat aligns with frac ports to control fluid flow and sand filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sequentially sized balls are used to activate each downhole tool stage, then each stage can be opened in sequence, but the process becomes complex and requires multiple different sized balls
Solution Approach 1:
The expandable ball seat is designed to accommodate balls of different sizes through its expandable structure. A single ball size can be used to activate multiple downhole tool stages because the ball seat can expand to match the ball diameter, and the inner sleeve can slide to different positions to open different frac ports sequentially.
2Ease of manufacture
If the screen is exposed during cementing, then cement can flow through the tool, but sand can contaminate the screen and reduce filtration efficiency
Solution Approach 1:
The temporary member is installed beforehand to protect the screen during the cementing operation. It extends into the inner diameter of the tool to shield the screen from cement and sand contamination. After cementing is complete, the temporary member is removed, restoring full screen functionality for sand filtration during production.
3Reliability
If the temporary member completely blocks the inner diameter, then the screen is fully protected from cement, but pressure cannot be communicated to the screen cavity
Solution Approach 1:
The temporary member is designed with selective coverage - it extends into the inner diameter of the tool to shield the screen from cement and sand contamination, but does not extend completely through. This allows pressure to be communicated to the screen cavity while still providing protection from solid contamination.
4Adaptability or versatility
If multiple downhole tools are used for multiple zones, then each zone can be treated independently, but sand production cannot be prevented after fracturing
Solution Approach 1:
The tool assembly is segmented into multiple downhole tools with individual frac ports and screens, allowing independent treatment of multiple zones. Each tool maintains its own screen for sand filtration, and the expandable ball seat mechanism allows sequential activation using a single ball size.
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
Enables efficient fracturing and production by allowing a single ball to activate multiple zones, preventing sand from flowing back and maintaining fracture integrity, while allowing the wellbore to be used post-cementing.
Implementation Method 1
the temporary member may be positioned closer to a proximal surface of the sleeve than the screen, create an overhang away from the inner sleeve, and extend downward to create a shield over portions of an inner sidewall of the screen
Implementation Method 2
Once the expandable ball seat expands, a diameter of the expandable ball seat may have a diameter that is greater than the ball
Implementation Method 3
When the ball is positioned on the expandable ball seat, pressure may be applied within the downhole tool to compress the adjustable member. Responsive to compressing the adjustable member, the inner sleeve may slide vertically within the outer sidewall
Implementation Method 4
the screen, which may be a screen, check valve, slotted grooves or flapper... configured to filter materials flowing from the geological formation into the downhole tool including sand that has been pumped
Data Source
AI summary
A tool comprising a movable sleeve with an inner diameter, an outer diameter, and a screen. The screen being configured to filter materials flowing into a first port within the moveable sleeve, wherein the outer diameter of the movable sleeve is positioned adjacent to an inner diameter of the tool, wherein the screen is configured to move with the moveable sleeve. The tool further comprising a temporary member positioned on the inner diameter of the moveable sleeve, the temporary member being configured to temporarily cover an inner sidewall of the screen.