Downhole Flow Control Membrane Perforator Assembly
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Solution Overview
Problem
Existing flow control assemblies in subterranean formations face challenges in maintaining a pressure seal during packer setting operations while allowing for fluid flow control at high pressures, as components like polylactic acid plugs may not withstand pressure thresholds.
Innovation Solution
A flow control assembly comprising a membrane and a perforator that provides a pressure seal and allows fluid flow by perforating the membrane in response to a setting pressure exceeding a threshold, utilizing a piston to move the membrane towards the perforator, creating a fluid flow path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polylactic acid plugs are used to seal during packer setting, then the assembly can maintain a pressure seal during setting operations, but the plugs cannot withstand pressure above a certain threshold and fail to provide reliable sealing at high pressures
Solution Approach 1:
The patent changes the material parameter from biodegradable polymers (PLA) to elastomeric materials that can withstand high pressures. The elastomeric material is specifically selected to maintain its mechanical properties and sealing capability under the high pressure conditions required for packer setting operations, thereby resolving the contradiction between material strength and sealing reliability.
Solution Approach 2:
The invention uses a composite structure combining an elastomeric material with a membrane structure. The elastomeric material provides the necessary pressure resistance while the membrane configuration enables the pressure-activated flow control function, creating a material system that simultaneously achieves both high pressure withstanding and reliable sealing.
2Reliability
If the membrane remains intact to provide pressure seal, then fluid flow is prevented, but fluid flow control cannot be achieved subsequent to packer setting
Solution Approach 1:
The membrane is pre-configured in a sealed state that maintains the pressure seal during packer setting operations. The pressure-activated mechanism is pre-positioned so that when the threshold pressure is reached during setting, the membrane automatically transitions from sealed to open state, enabling fluid flow control without requiring additional intervention.
Solution Approach 2:
The membrane transitions from a static sealed state to a dynamic open state in response to pressure changes. This dynamic behavior allows the system to maintain sealing during low-pressure setting operations and automatically enable fluid flow when pressure exceeds the threshold, providing both reliable sealing and flow control adaptability.
3Ease of manufacture
If aluminum plugs are used that dissolve on acid exposure, then ports can be created for fluid production, but the plugs cannot withstand high pressure during packer setting
Solution Approach 1:
The patent replaces the chemical dissolution mechanism (acid-reacting aluminum plugs) with a pressure-activated mechanical mechanism. The elastomeric membrane with pressure-activated openings uses mechanical force to create flow paths when pressure exceeds the threshold, eliminating the need for chemical reactions while maintaining ease of port creation and achieving high pressure resistance.
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 reliable pressure seal during packer setting and subsequent fluid flow control at high pressures, ensuring effective fluid management in subterranean formations.
Implementation Method 1
The piston can allow the membrane to move toward the perforator in response to the pressure being above a threshold
Implementation Method 2
The perforator can perforate the membrane in response to the membrane moving toward the perforator
Data Source
AI summary
A flow control assembly can be disposed in a wellbore and can include a membrane that can be perforated in response to a pressure, such as a setting pressure, from an inner area of a tubing. Subsequent to the membrane being perforated, fluid can be allowed to flow from an area external to the tubing to an area internal to the tubing. The membrane may remain closed during a packer setting operation and be perforated subsequent to the packer setting operation.