Flow Restriction Device for Packer Setting in Wellbores

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Solution Overview

Problem

During the placement of an isolation assembly in wellbores for hydrocarbon production, fluid flow through the annulus between the completion assembly and the wellbore can hinder the setting of the packer and result in fluid loss, as the pressure inside the wellbore is greater than the formation pressure, causing undesirable fluid flow and potential debris issues.

Innovation Solution

A flow restriction device is placed above the packer in the annulus to restrict fluid flow, allowing the packer to be set effectively by controlling the fluid pressure and flow, which is achieved through a running tool with a restriction device that sets at a lower pressure than the packer, thereby facilitating the packer's sealing function.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the production valves are opened before setting the packer, then the formation fluid can flow into the wellbore for production, but the wellbore fluid flows through the annulus into the formation causing fluid loss and debris contamination

Engineering Contradiction:

Improveformation fluid productionVSAvoidwellbore fluid loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The system segments the wellbore into isolated zones using the packer to seal the annulus, and the flow restriction device to control flow through the completion assembly. This segmentation allows production to occur while preventing unwanted fluid loss through the annulus.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flow restriction device acts as an intermediary component between the wellbore fluid and the formation, controlling and regulating fluid flow. It mediates the pressure differential to prevent excessive fluid loss while allowing necessary production flow.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the production valves are opened before setting the packer, then the formation fluid can flow into the wellbore, but debris flows into the formation along with the fluid

Engineering Contradiction:

Improveformation fluid productionVSAvoiddebris contamination

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The flow restriction device converts the potentially harmful high-velocity fluid flow that carries debris into a controlled, restricted flow. By restricting the flow path, the device reduces flow velocity and prevents debris from being forced into the formation, while still allowing production to occur.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the packer is set without restricting annulus flow, then the isolation assembly can be placed, but the fluid flow hinders the setting of the packer

Engineering Contradiction:

Improvepacker sealingVSAvoidpacker setting

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The flow restriction device is deployed in advance of setting the packer to pre-restrict the annulus flow. This preliminary action creates favorable conditions for packer setting by reducing fluid flow and pressure differential before the packer is set, ensuring proper sealing.

Inventive Principle:

Principle #10Preliminary action

4Stress or pressure

If the pressure inside the wellbore is greater than formation pressure, then the wellbore can be filled with fluid for pressure maintenance, but fluid flows from the wellbore into the formation

Engineering Contradiction:

Improvewellbore pressureVSAvoidfluid loss into formation

Core Design Contradiction:

Stress or pressureVSLoss of substance

Solution Approach 1:

The flow restriction device serves as an intermediary that manages the pressure differential between the wellbore and formation. It allows the wellbore to maintain higher pressure for fluid filling while restricting the flow path that would otherwise cause excessive fluid loss into the formation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 restriction of fluid flow through the annulus enables proper setting of the packer, preventing fluid loss and ensuring effective sealing, thus enhancing the completion process by maintaining wellbore integrity and reducing operational challenges.

Implementation Method 1

placing a flow restriction device above the packer; setting the flow restriction device in the annulus to restrict flow of fluid through the annulus

Methodology Applied

Scientific EffectFlow restriction: Pressure Drop

Implementation Method 2

an isolation assembly with a packer above the lower completion assembly for isolating an annulus between the lower completion assembly and the wellbore

Methodology Applied

Scientific EffectMechanical sealing: Mechanical Force

Data Source

PatentUS9732583B2Completion systems with flow restrictors

Publication Date: 2017.08.15 BAKER HUGHES CO

AI summary

A method of completing a wellbore is disclosed that in one non-limiting embodiment includes: placing a lower completion assembly that includes a flow device to provide fluid communication between the lower completion assembly and a production zone associated with the lower completion assembly; placing an isolation assembly with a packer above the lower completion assembly for isolating an annulus between the lower completion assembly and the wellbore; placing a flow restriction device above the packer; setting the flow restriction device in the annulus to restrict flow of fluid through the annulus; and setting the packer after setting the flow restriction device.