Multi-zone gravel pack tool with selective valves
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Solution Overview
Problem
Current wellbore gravel packing systems require multiple sequential treatments and trips to isolate desirable and undesirable zones, leading to inefficiencies and potential erosion of the wellbore walls.
Innovation Solution
A multi-zone single treatment gravel pack system with a tool string comprising an inner and outer string member and a passage between them, featuring selectively deployable packing elements and valves that allow for fluid connection and isolation of zones in a single operation, enabling simultaneous gravel packing of multiple zones without multiple trips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sequential treatments are performed to isolate and gravel pack different zones, then each zone can be treated individually, but the number of trips into the wellbore increases and time is lost
Solution Approach 1:
The patent combines multiple zonal isolation and gravel packing operations into a single integrated tool string that can treat multiple zones simultaneously in one trip. The tool string includes multiple selectively deployable packing elements and valves that enable independent control of each zone while performing all operations during a single wellbore entry.
Solution Approach 2:
The tool string is segmented into multiple independent functional units, each capable of isolating and treating a specific zone. Each segment includes packing elements and valve mechanisms that can be activated independently to provide zonal control without requiring separate trips for each zone.
2Strength
If gravel pack is applied across all zones including undesirable zones, then structural integrity is enhanced uniformly, but the complexity of subsequent isolation increases
Solution Approach 1:
The system performs preliminary zonal isolation by deploying packing elements to specific zones before gravel packing begins. This preliminary action creates isolated segments that allow gravel to be placed only in desirable zones, preventing the need for complex post-treatment isolation operations.
Solution Approach 2:
The system employs dynamically controllable valves that can be opened or closed to direct gravel flow to specific zones as needed. This dynamic control enables selective gravel placement in desirable zones while keeping undesirable zones isolated, simplifying the overall isolation process compared to uniform gravel packing of all zones.
3Ease of operation
If multiple treatments are performed sequentially to isolate zones, then precise zonal control is achieved, but erosion of wellbore walls occurs due to multiple trips
Solution Approach 1:
The patent merges multiple zonal control operations into a single tool string that can isolate and treat multiple zones during one continuous operation. This eliminates the need for repeated tool insertions and withdrawals that cause mechanical erosion of wellbore walls through friction and impact.
Solution Approach 2:
The system maintains continuous operation within the wellbore during a single trip, performing all necessary isolation and gravel packing operations without interruption or withdrawal. This continuous action prevents the repetitive mechanical stress on wellbore walls that would occur with multiple separate trips.
Data Source
AI summary
A gravel pack system includes a tool string having an inner string member, an outer string member, and a passage arranged between the outer string member and the inner string member. A packing element is provided on the outer string member. A first valve is coupled to one of the outer string member and the inner string member outwardly of the packing element in a downhole direction. The first valve fluidically connects the passage and the open hole wellbore. The first valve is configured and disposed to shift from a closed position to an open position. A second valve is coupled to one of the outer string member and the inner string member outwardly of the packing element in an uphole direction. The second valve selectively fluidically connects the passage and the open hole wellbore. The second valve shifts from an open position to a closed position.