Multi-zone Cemented Fracturing System with Wiper Plugs
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Solution Overview
Problem
Current multi-zone cementing and fracturing systems face challenges in efficiently isolating and treating multiple zones of a subterranean formation during hydraulic fracturing, as existing technologies struggle to effectively deploy and release cement slurry and proppant across multiple fracture valves, leading to incomplete isolation and reduced production efficiency.
Innovation Solution
A method and system that involves deploying a liner string with fracture valves and wiper plugs, using a dart to drive cement slurry through the annulus between the liner string and the wellbore, and releasing wiper plugs to open ports, allowing for precise control of cement placement and proppant distribution across multiple zones, enhancing isolation and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a liner string with multiple fracture valves is deployed for staged fracturing, then multiple zones can be isolated and treated sequentially, but the complexity of deploying and releasing cement slurry and proppant across multiple zones increases
Solution Approach 1:
The system divides the wellbore into multiple isolated zones using a liner string with multiple fracture valves positioned at different depths. Each zone can be independently treated by opening its respective fracture valve, enabling staged fracturing operations without interfering with other zones.
Solution Approach 2:
The liner string is deployed inside the existing wellbore structure, creating a nested configuration where the liner string with its multiple fracture valves is positioned within the wellbore. This allows the cementing and fracturing system to operate within the existing well infrastructure while adding multi-zone capability.
2Reliability
If cement slurry is pumped through the workstring to isolate zones, then proper zonal isolation can be achieved, but the time and complexity of the cementing operation increases
Solution Approach 1:
The liner string is pre-equipped with multiple fracture valves and wiper plugs positioned at specific locations before deployment. The wiper plugs are initially held in place by retainers, allowing the system to be prepared in advance for sequential zone isolation without requiring complex in-situ adjustments during the cementing operation.
Solution Approach 2:
The system uses self-contained wiper plugs with integrated retainers and release mechanisms that automatically function during the cementing operation. The wiper plugs are released by pressure differentials or mechanical actions inherent to the cementing process itself, reducing the need for external intervention and complex control systems.
3Manufacturing precision
If wiper plugs are used to release and drive cement slurry through the annulus, then precise control of cement placement is improved, but the device complexity and operational difficulty increase
Solution Approach 1:
The wiper plugs serve as intermediary elements between the pumped cement slurry and the fracture valves. These plugs are driven by the cement slurry pressure and mechanically interact with the fracture valves to release them, enabling precise control of cement placement and zone isolation without requiring complex external control mechanisms.
Solution Approach 2:
The system uses hydraulic pressure from the pumped cement slurry to drive the wiper plugs through the annulus and to trigger the release of fracture valves. The pressure differential created during cementing operations automatically actuates the wiper plugs and valve release mechanisms, simplifying operation while maintaining precision.
4Adaptability or versatility
If multiple fracture valves are installed on the liner string, then multiple zones can be treated, but the risk of incomplete isolation and reduced production efficiency increases
Solution Approach 1:
Each fracture valve on the liner string is equipped with its own dedicated wiper plug and retainer mechanism, creating localized isolation systems for each zone. This ensures that the operation and status of one fracture valve does not affect the isolation integrity of other zones, allowing independent verification and control of each zone's isolation completeness.
Data Source
AI summary
A method of cementing a liner string into a wellbore includes deploying a liner string into a wellbore; pumping cement slurry into a workstring; and pumping a dart through the workstring, thereby driving the cement slurry into the liner string. The dart engages a first wiper plug and releases the first wiper plug from the workstring. The dart and engaged first wiper plug drive the cement slurry through the liner string and into an annulus formed between the liner string and the wellbore. The dart and engaged first wiper plug land onto a first fracture valve. The dart releases a first seat into the first wiper plug. The dart engages a second wiper plug connected to the first fracture valve and releases the second wiper plug from the first fracture valve.