Straddle Frac Tool Pump Through Port Debris Removal
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Solution Overview
Problem
Existing straddle assemblies on coiled tubing for fracturing operations face limitations, including lack of access to the borehole below set packers and difficulty in dislodging debris from a lower packer that resists release, due to limited outlets and space constraints.
Innovation Solution
A fracturing tool with spaced releasable packers and a frac port mechanism that opens with compression on the lower packer, allowing circulation above the packer to clean debris and provides a through passage either above or below the packer for further downhole treatment or tool operation, utilizing weight and tension to control port alignment and flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lower packer is set and remains fixed, then the zone isolation is maintained, but debris accumulates around the packer making release difficult
Solution Approach 1:
A jet nozzle is introduced as an intermediary tool between the fracturing operation and the lower packer. The nozzle directs high-velocity fluid jets at the packer surface to erode and remove accumulated debris, facilitating packer release without compromising the reliability of zone isolation during the fracturing process.
Solution Approach 2:
The system performs preliminary debris removal actions before the lower packer release is attempted. By circulating jetting fluid through the nozzle during or after fracturing, debris is pre-cleaned from the packer surface and surrounding area, making the subsequent release operation easier and more reliable.
2Ease of operation
If the frac port is positioned above the lower packer, then debris can be circulated away, but access to the borehole below the packer is blocked
Solution Approach 1:
The system employs dynamic positioning of the jet nozzle relative to the packer. The nozzle can be moved between positions above and below the packer depending on the operational phase. During fracturing, the nozzle is positioned above to circulate debris; during cleanout or extended operations, the nozzle is positioned below to access the borehole area underneath the packer.
Solution Approach 2:
The jet nozzle assembly is designed with multi-functionality to serve different purposes at different times. It can perform debris circulation above the packer, cleanout operations at the packer interface, and provide access to treatments or operations below the packer, making the system adaptable to multiple operational requirements.
3Power
If high velocity fracturing fluid is used, then fracturing effectiveness is improved, but erosion of the frac port increases
Solution Approach 1:
The frac port is pre-hardened through a thermal spray coating process before the fracturing operation begins. This preliminary protective action creates a erosion-resistant surface that can withstand the high-velocity fracturing fluid while maintaining the power and effectiveness of the fracturing process.
Solution Approach 2:
The frac port structure uses composite construction with a base material providing structural integrity and a thermal spray coating layer providing erosion resistance. This composite approach allows the system to handle high-velocity fracturing fluid effectively while minimizing wear and erosion of the port components.
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 effective debris removal and enhanced operational flexibility by allowing circulation above the lower packer to clean away debris and providing access for further downhole treatments or tool operations, while minimizing erosion effects of fracturing fluids.
Implementation Method 1
The housing has relatively moving components for opening the frac port between the packers with weight set on the lower packer
Implementation Method 2
An exit above the lower packer allows a circulation jetting action right above the lower packer to clean away debris that has built up from the fracturing
Implementation Method 3
In another embodiment the housing outlet can be below bottom packer to perform a treatment further downhole or to operate another tool... operation of a sand jet perforator to clean debris or perforate casing
Implementation Method 4
The frac port is also contoured to minimize erosion effects of the exiting fracturing fluid and its entrained solids
Data Source
AI summary
A fracturing tool features spaced releasable packers with an outlet in between. The housing has relatively moving components for opening the frac port between the packers with weight set on the lower packer. Once the frac port is opened the upper packer is set and the pumping begins. The upper packer can be released so that tension can be pulled on the lower packer to close the frac port and open a through passage in the housing. In one embodiment the through passage can be located above the lower packer to a sand jet perforator to clean debris away from the lower packer if it is difficult to release the lower packer or to abrasively perforate through a tubular. The housing outlet can be below bottom packer to perform a treatment further downhole or to operate another tool. The straddle tool can be run in on coiled tubing.