Long Lateral Completion System Friction Control

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Solution Overview

Problem

Conventional completion systems for wells with long lateral boreholes face challenges such as slow and unsafe insertion of production tubing, limited maximum horizontal insertion distance, and increased operational costs due to the need for larger and more complex rigs, which hinder efficient hydrocarbon production, especially in densely spaced well regions.

Innovation Solution

A long lateral completion system featuring a compact mast assembly, catwalk-pipe arm, and automated pipe handling mechanisms that allow for precise alignment and insertion of tubing with reduced rig footprint, enabling faster and safer operation, and extending the maximum length of lateral wells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional completion systems are used for long lateral boreholes, then the insertion of production tubing can be performed, but the insertion process is slow and unsafe

Engineering Contradiction:

Improveinsertion speedVSAvoidinsertion safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces conventional mechanical pipe handling systems with a controlled descent mechanism that uses friction and braking forces to regulate tubing insertion. The tubing is fed through a guide mechanism with controlled friction elements that act as a brake, allowing precise speed control and eliminating the need for complex mechanical handling equipment, thereby improving both safety and insertion speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a guide mechanism with friction elements as an intermediary between the tubing and the wellbore. This intermediary controls the descent speed by creating controlled friction, allowing the tubing to be inserted safely and at controlled rates without requiring direct mechanical handling by workers, thus improving both safety and efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Length of stationary object

If conventional rigs are used to insert production tubing, then the insertion can be completed, but the maximum horizontal insertion distance is limited

Engineering Contradiction:

Improvemaximum horizontal insertion distanceVSAvoidrig complexity

Core Design Contradiction:

Length of stationary objectVSDevice complexity

Solution Approach 1:

The patent segments the tubing insertion process into controlled sections, using a guide mechanism that can handle tubing in manageable portions. The tubing is fed through a series of guide elements and friction-controlled sections, allowing incremental insertion over long horizontal distances without requiring the entire tubing length to be handled simultaneously, thus extending the maximum insertion distance while keeping the system manageable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from vertical rig operations to a horizontal guide mechanism that follows the wellbore trajectory. The guide mechanism is positioned to accommodate horizontal lateral boreholes, changing the operational dimension from vertical to horizontal, thereby enabling insertion in long lateral wells without requiring excessively complex rigid vertical rig structures.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If conventional completion systems are used, then production tubing can be inserted, but operational costs increase due to larger and more complex rigs

Engineering Contradiction:

Improveoperational efficiencyVSAvoidrig size and complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts the essential function of tubing insertion from the complex conventional rig system, isolating it into a dedicated guide and controlled descent mechanism. By separating this specific function from the overall rig system, the invention eliminates the need for large, complex rigs, reducing equipment costs and operational complexity while maintaining insertion capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The tubing insertion system is designed to be self-regulating through controlled friction and gravity-based descent. The mechanism automatically controls the insertion speed and positioning without requiring complex active control systems or large crews, thereby reducing operational costs and simplifying the rig requirements while maintaining high productivity.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10113377B2Drive systems for use with long lateral completion systems and methods

Publication Date: 2018.10.30 AXIS ENERGY SERVICES LLC

AI summary

A completion system and method adapted for use in wells having long lateral boreholes includes a mast assembly, a pipe handling mechanism, a pipe arm, a pipe tub, a pump/pit combination skid, a rig carrier, and a control system. The mast assembly can extend in a generally vertical direction, e.g., perpendicular to the rig carrier and/or the earth's surface, such that the rig can be placed directly adjacent to a wellbore, and the top drive or a similar drive system can be engaged with and move along the mast while remaining above the wellbore. The top drive can be engaged with a support fixture that resists torque and rotation during operation. The support fixture can in turn be engaged with the mast to transfer torque forces to the mast while being vertically movable along the mast to enable positioning of the top drive.