Hydrostatically Insensitive Wellbore Testing Plug
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Solution Overview
Problem
Current wellbore cementing operations face challenges in performing full pressure checks on tubing strings after cementing, as traditional methods are time-consuming and costly, and may not be feasible with wet shoe implementations, limiting the ability to test casing integrity effectively.
Innovation Solution
A device comprising a body, piston, control valve, closure, and fixture is used to manage pressure within the wellbore, allowing for a wiper plug system that can seal and open fluid communication, enabling efficient pressure testing and maintaining fluid integrity during cementing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pressure testing methods are used after wellbore cementing, then casing integrity can be tested, but the process becomes time-consuming and costly
Solution Approach 1:
The patent incorporates a pressure testing mechanism directly into the plug assembly that is deployed during the cementing operation. The piston and control valve system is pre-positioned within the plug, allowing pressure testing to be performed immediately after plug deployment without requiring separate testing equipment or procedures. This preliminary integration eliminates the need for time-consuming post-cementing testing operations.
Solution Approach 2:
The invention combines multiple functions into a single integrated plug assembly: fluid separation, pressure control, and integrity testing. The control valve and piston mechanism are merged with the plug structure, allowing the same device that separates fluids during cementing to also perform pressure testing. This consolidation of functions reduces the number of separate operations and equipment needed, thereby reducing time and cost.
2Reliability
If traditional pressure testing methods are used after wellbore cementing, then casing integrity can be tested, but the process becomes costly
Solution Approach 1:
The plug assembly is designed with multi-functionality, serving both as a fluid separator during cementing and as a pressure testing device. The control valve and piston system can perform multiple operations: separating cement from spacer fluid, controlling pressure during testing, and enabling integrity verification. This universal design eliminates the need for separate specialized testing equipment, reducing overall operational costs.
Solution Approach 2:
The plug assembly performs pressure testing using its own integrated components rather than requiring external testing equipment. The piston and control valve system is self-contained within the plug, allowing it to conduct integrity testing autonomously as part of the normal cementing sequence. This self-service capability eliminates the need for additional costly testing operations.
3Ease of operation
If wet shoe implementation is used, then fluid communication is maintained, but the ability to perform full pressure checks is limited
Solution Approach 1:
The plug assembly divides the wellbore into separate zones using the piston and control valve mechanism. The piston can move to seal off different sections, allowing pressure testing to be performed in isolated zones even when wet shoe implementation maintains fluid communication elsewhere. This segmentation enables comprehensive pressure checks without compromising the fluid communication benefits of wet shoe design.
Solution Approach 2:
The control valve and piston system provides dynamic control over fluid communication and pressure containment. The valve can transition between open and closed states, and the piston can move to create sealed chambers, allowing the system to adapt between maintaining fluid communication and performing pressure tests. This dynamic capability resolves the contradiction between wet shoe operation and pressure testing requirements.
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 solution allows for efficient casing integrity testing and fluid management, reducing the need for costly and time-consuming processes, and enabling further operations like perforation gun deployment without re-entering the wellbore, thus enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
The control valve is disposed in communication between the wellbore and the piston chamber and is configured to capture wellbore pressure in the piston chamber as captured chamber pressure
Implementation Method 2
The piston is movable on the body from a first condition to a second condition and has a piston chamber. The closure is disposed on the body and is configured to transition from a closed condition to an open condition relative to the port in response to the movement of the piston
Implementation Method 3
The fixture releasably holds the closure in the closed condition on the body. The fixture is configured to release in response to an increased pressure differential on the piston above an initial pressure differential between the captured chamber pressure and the wellbore pressure
Data Source
AI summary
A plug for use in a wellbore has a piston that is movable on a body. A control valve is disposed in communication between the wellbore and a piston chamber and can capture wellbore pressure in the piston chamber. A closure on the body can transition from a closed condition to an open condition relative to the port in response to the movement of the piston. A fixture releasably holds the closure in the closed condition on the body. The fixture releases in response an increased pressure differential on the piston above an initial pressure differential between the captured chamber pressure and the wellbore pressure.