Gravel Pack Completion Assembly External Fluid Return
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Solution Overview
Problem
Existing sand control operations in wellbores require the carrier fluid to return through the completion assembly central bore, which limits flexibility and efficiency, especially when dealing with well zones of varying lengths and complicates the design of the service tool.
Innovation Solution
A system where the carrier fluid is returned radially outward of the completion assembly central bore, allowing it to flow along a path external to the central bore during the gravel packing operation, decoupling the washpipe length from the well zone length and eliminating the need for a crossover port, thereby simplifying the service tool design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the carrier fluid returns through the completion assembly central bore, then the gravel pack can be formed, but the service tool design becomes complex and flexibility is limited
Solution Approach 1:
The patent extracts the carrier fluid return path from the completion assembly central bore and routes it through a separate annular flow path external to the central bore. This separation eliminates the need for complex internal crossover ports and washpipe configurations, simplifying the service tool design while maintaining gravel pack formation capability
Solution Approach 2:
The patent transitions the carrier fluid return path from a one-dimensional internal flow through the central bore to a two-dimensional annular flow path surrounding the central bore. This dimensional change allows the return flow to occur externally without interfering with the central bore functions, reducing service tool complexity
2Adaptability or versatility
If the washpipe length is made similar to the well zone length, then the carrier fluid can return through the central bore, but the service tool becomes less adaptable to varying well zone lengths
Solution Approach 1:
The annular flow path design allows the washpipe to serve multiple functions without being constrained to a specific length matching the well zone. The external return path can accommodate various well zone lengths while maintaining proper carrier fluid circulation, enhancing the service tool's versatility
3Ease of operation
If the carrier fluid returns through the completion assembly central bore, then gravel packing can be performed, but operational flexibility is reduced
Solution Approach 1:
The patent segments the flow paths by separating the gravel slurry injection path (through the central bore) from the carrier fluid return path (annular flow external to central bore). This segmentation allows independent optimization of each flow path, improving operational flexibility while simplifying the overall system configuration
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
This approach enhances operational flexibility, allows for efficient gravel packing in well zones of different lengths, and simplifies the service tool design by directing the return flow externally, reducing the complexity and length requirements of the washpipe.
Implementation Method 1
At the well zone, a carrier fluid is separated from the gravel slurry leaving gravel to form the gravel pack
Data Source
AI summary
A technique is provided for forming a gravel pack at a well zone. A completion assembly is positioned in a wellbore and cooperates with a service tool engaging the completion assembly. The completion assembly comprises a completion assembly central bore. A return is located radially outward of the central bore at a specific well zone or zones and comprises a flow path for returning a carrier fluid. The location of the return allows flow of the returning carrier fluid to remain outside of the completion assembly central bore at a specific well zone or zones.