Selective Frac Plug Check Valve for Pump-Down and Hydraulic Isolation
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Solution Overview
Problem
Drilling operations face significant nonproductive downtime due to the need for secondary deployment methods when fluid communication with the formation is unavailable, particularly in unconventional hydraulic fracturing, leading to increased asset downtime and risks.
Innovation Solution
A frac plug with a ported sleeve and seat mechanism that allows fluid flow during deployment, featuring a freely moving valve (frac ball or dart) to selectively seal off the flow path upon increased pressure, ensuring hydraulic isolation and reducing the need for secondary equipment deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bridge plug or packer is installed to create hydraulic isolation, then hydraulic isolation is achieved, but fluid communication with the formation is eliminated requiring secondary deployment methods
Solution Approach 1:
The check valve is pre-installed within the bridge plug or packer assembly before deployment. The valve remains in a preliminary state that allows fluid communication during the initial deployment phase, enabling the bottom hole assembly to be pumped downhole. After the barrier is set and hydraulic isolation is achieved, the check valve is then activated to seal the flow path, maintaining isolation while preserving the ability to restore fluid communication if needed.
Solution Approach 2:
The check valve transitions from a static component to a dynamic, selectively activatable seal. The valve can change its state based on operational requirements: open during deployment to allow fluid flow, and closed when hydraulic isolation is needed. This dynamic capability resolves the contradiction by allowing the system to adapt between the two opposing states rather than being fixed in one configuration.
2Ease of operation
If perforating guns are used to create new flow paths, then fluid communication is restored, but if they fail to activate, extensive nonproductive downtime occurs requiring reinstallation
Solution Approach 1:
The check valve serves as a pre-prepared contingency measure installed within the bridge plug or packer. If perforating guns fail to create new flow paths, the check valve can be activated to restore fluid communication through the barrier, providing a backup solution that eliminates the need for time-consuming reinstallation of entire perforating gun assemblies or alternative deployment methods.
Solution Approach 2:
The check valve acts as an intermediary mechanism between the isolated hydraulic zones. Rather than requiring direct penetration through the barrier with perforating guns, the check valve provides an alternative pathway for fluid communication, mediating between the need for hydraulic isolation and the need for fluid flow when perforation fails.
3Adaptability or versatility
If tractor or coil tubing deployment methods are used when pump operation is unavailable, then deployment can proceed, but excessive time and additional surface equipment are required
Solution Approach 1:
The check valve enables the pump down system to serve itself as a deployment mechanism even after the barrier is set. By allowing selective activation of the valve to restore fluid communication, the system can use its own pumping capability to deploy subsequent bottom hole assemblies without requiring external tractor or coil tubing equipment, making the system self-sufficient across multiple operational phases.
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 fluid communication maintenance during wellbore operations, minimizing downtime and reducing the risk of equipment reinstallation by allowing selective valve activation based on pressure, thus optimizing wellbore operations.
Implementation Method 1
the valve member is freed to move in response to a change in differential pressure across the wellbore barrier, wherein the valve member seals against the valve seat when the differential pressure is below a threshold differential pressure
Data Source
AI summary
A contingency measure for wireline conveyed installation methods, generally for oil and gas completions, and more specifically in plug and perforation completions. A fracturing (frac) plug has a ported sleeve and a seat that allows a valve mechanism to seat against the apparatus with the application of fluid flow. The plug allows for fluid flow to bypass the valve and flow through the frac plug, to allow pump down operations as long as needed. Once downhole operations are complete, increased fluid pressure on the plug pushes the valve past the bypass ports and plugs the flow through the inner diameter of the frac plug, closing off the fluid flow path through the frac plug. Thus, selective setting of the valve allows for downhole fluid flow as long as needed, and then can hydraulically isolate the region above the frac plug from the region below the frac plug.