Multi-Resettable Packer Stroker Tool for Well Unloading
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Solution Overview
Problem
Existing ESP systems face challenges in unloading wells efficiently due to complex logistics, inefficiencies in setting and unsetting packer systems, temperature range limitations, and incompatibility with high hydrogen sulfide (H2S) environments.
Innovation Solution
A bottom hole assembly (BHA) with a multi-resettable packer assembly and an electrical submersible pump (ESP) is deployed, featuring a stroker tool for compressing and decompressing the packer, and a power and communications bus for controlling the system, enabling efficient well unloading and natural flow initiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-use setting tool is used to set the packer, then the packer can be set successfully, but the tool requires redress at surface reducing operation efficiency
Solution Approach 1:
The setting tool is designed to reset itself automatically after setting the packer. The slips rotate and engage with gear teeth on the setting mandrel, causing the setting tool to rotate and retract the piston automatically, eliminating the need for manual redress at surface and enabling continuous operation
Solution Approach 2:
The setting tool transitions from a static single-use device to a dynamic multi-resettable system. The slips can engage and disengage repeatedly, the piston can extend and retract multiple times, and the tool can be reset at depth without tripping out, transforming it into an adaptable reusable system
2Productivity
If coiled tubing nitrogen pumping is used to unload the well, then the kill fluid can be removed, but the process is time consuming and requires complex logistics
Solution Approach 1:
The patent replaces the mechanical coiled tubing nitrogen pumping system with an electrical submersible pump (ESP) system. The ESP directly pumps the kill fluid out of the wellbore, eliminating the need for complex nitrogen injection logistics and significantly reducing the time required for well unloading
Solution Approach 2:
The ESP extracts the kill fluid directly from the wellbore through the production tubing, removing the need for indirect nitrogen injection methods. This direct extraction approach simplifies the unloading process and reduces operational time
3Device complexity
If the ESP system is used for well unloading, then surface equipment is reduced, but the system cannot tolerate large temperature changes and high H2S environments
Solution Approach 1:
The ESP system parameters are modified to withstand extreme conditions. The motor and pump components are designed with enhanced temperature tolerance and corrosion resistance to operate in high H2S environments and large temperature variations, expanding the system's environmental adaptability
Solution Approach 2:
The ESP system utilizes composite materials and protective coatings that provide both mechanical strength and chemical resistance. These materials enable the system to tolerate high H2S concentrations and extreme temperature changes while maintaining operational reliability
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
The system enhances operational efficiency by reducing the need for frequent packer setting and unsetting, tolerates varying temperatures, and operates safely in high H2S environments, facilitating effective well unloading and natural flow initiation.
Implementation Method 1
a packer assembly, the multi-resettable packer assembly comprising: a first multi-resettable packer having a first packer ring and a second packer ring
Implementation Method 2
a stroker tool configured to compress and decompress the first multi-resettable packer to seal and unseal, respectively, against an inner surface of the production tubing
Implementation Method 3
a port sub coupled below the first packer ring on the first multi-resettable packer, wherein the port sub is configured to hydraulically connect the production tubing to the ESP
Implementation Method 4
the inner mandrel having at least one intake port proximate the first end configured to allow fluid from outside the inner mandrel to an inner bore of the inner mandrel
Implementation Method 5
a stroker tool configured to compress and decompress the first multi-resettable packer... and a piston configured to extend from and retract into the stroker tool
Data Source
AI summary
System and method for a bottom hole assembly (BHA) in production tubing including an electrical submersible pump (ESP), multi-resettable packer assembly, sensor, power and communications bus, and control system. The multi-resettable packer assembly includes a multi-resettable packer, a port sub hydraulically connecting production tubing to the ESP, an inner mandrel inside the multi-resettable packer axially movable within the multi-resettable packer and port sub, and a stroker tool configured to compress and decompress the multi-resettable packer to seal and unseal an inner surface of production tubing. The stroker tool includes slips to grip the inner surface and a piston that extends from and retracts into the stroker tool. The sensor is configured to measure operating data including a pressure measurement. The power and communications bus powers and transmits signals to the BHA. The control system monitors operating data and controls the stroker tool via the power and communications bus.