Long Lateral Completion System Automation

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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 rig setups, which hinder efficient hydraulic fracturing and well production.

Innovation Solution

A long lateral completion system featuring a compact mast assembly, catwalk-pipe arm, and automated control van that allows for precise alignment and insertion of tubing with reduced rig footprint, enabling faster and safer operation, and extending the reach of wellbore completion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

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

Engineering Contradiction:

Improveinsertion speed of production tubingVSAvoidsafety during insertion

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The completion system is divided into modular components including a mast assembly, catwalk-pipe arm, and automated control van that can operate independently. This segmentation allows for specialized optimization of each component's function, improving both the speed and safety of tubing insertion operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Manual mechanical operations are replaced with automated control systems. The automated control van integrates electronic controls to manage the mast assembly and pipe handling operations, replacing manual mechanical processes with computer-controlled systems that improve safety and operational speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Length of moving object

If conventional completion systems are used, then well completion is possible, but the maximum horizontal insertion distance is limited

Engineering Contradiction:

Improvehorizontal insertion distance of tubingVSAvoidrig setup complexity

Core Design Contradiction:

Length of moving objectVSDevice complexity

Solution Approach 1:

The system transitions from a traditional vertical mast configuration to a compact mast assembly that operates in a different spatial dimension. The catwalk-pipe arm extends horizontally from the mast, creating a new operational dimension that enables longer lateral insertion distances without proportionally increasing overall rig complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The mast assembly is designed as a multi-functional component that serves multiple purposes: supporting the pipe arm, providing structural stability, and enabling automated pipe handling. This universal design reduces the need for separate specialized components, thereby reducing overall system complexity while achieving extended insertion capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If conventional completion systems are used, then well completion can be performed, but operational costs increase due to larger and more complex rig setups

Engineering Contradiction:

Improveoperational efficiency of well completionVSAvoidrig footprint and setup complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple functional components are merged into integrated assemblies. The mast assembly combines structural support, pipe handling, and control functions into a single unified structure. The catwalk-pipe arm integrates pipe support and positioning functions. This merging reduces the total number of separate components and simplifies the overall rig setup, reducing operational complexity and costs while maintaining high productivity.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If larger and more complex rig setups are used, then well completion can be achieved, but the rig footprint increases

Engineering Contradiction:

Improvecapability for well completion operationsVSAvoidrig footprint

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The system employs dynamic, movable components rather than fixed static structures. The pipe arm can be positioned and adjusted as needed, and the mast assembly can be configured for different operational requirements. This dynamic design allows the rig to adapt to various well completion scenarios without requiring a permanently large footprint, optimizing the balance between capability and space requirements.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS8915310B2Long lateral completion system and method

Publication Date: 2014.12.23 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 control system can be used to automate operations of the completion system to facilitate rapid and safe make-up and breaking of tubular connections.