Multistage Fracturing Valve Clusters With Pressure-Driven Sleeve Control
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Solution Overview
Problem
Conventional multistage fracturing methods face challenges such as time-consuming operations, plug defects, perf erosion, and the need for complex and costly systems with precise ball drop processes, which are inefficient and require multiple tools for opening frac valves in a specific order.
Innovation Solution
A downhole system with frac valves having identical profiles and a plugging device that uses a shiftable sleeve to incrementally engage and open valves in any sequence, allowing for flexible stimulation of formation stages without the need for intervention tools or unique plugs, and enabling reliable, efficient, and cost-effective multistage fracturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multistage fracturing methods are used with multiple frac valves and precise ball drop processes, then the formation zones can be stimulated in a controlled sequence, but the operational time is excessive and the process is time-consuming
Solution Approach 1:
The system employs a self-service mechanism where the frac fluid itself activates the valve opening sequence through pressure-driven piston movement. The frac fluid pressure automatically triggers the shiftable sleeve to move between grooves and open the appropriate frac valve, eliminating the need for external intervention tools, precise ball drop timing, or complex mechanical counting mechanisms. This self-activating process dramatically reduces operational time while maintaining reliable sequential control.
2Measurement precision
If multiple unique plugs and intervention tools are used to open frac valves in a specific order, then precise valve activation can be achieved, but the device complexity and costs increase significantly
Solution Approach 1:
The system employs a universal shiftable sleeve mechanism that can activate any frac valve in the sequence through a single standardized component. The sleeve moves between multiple grooves to trigger different valves as needed, eliminating the requirement for multiple unique plugs, intervention tools, or specialized activation devices. This multi-functional approach maintains precise valve activation while dramatically simplifying the overall system architecture and reducing costs.
Solution Approach 2:
The system uses pressure as a controllable parameter to activate valves in the desired sequence. By adjusting the frac fluid pressure, the piston moves to different positions, which in turn moves the shiftable sleeve to engage different frac valves. This parameter-based control method replaces complex mechanical sequencing systems with a simple, adaptable pressure-driven mechanism that reduces device complexity while maintaining activation precision.
3Productivity
If conventional frac operations are performed with multiple tools and crew resources, then the fracturing process can be completed, but the operational costs and resource requirements become ultra-competitive and burdensome
Solution Approach 1:
The system merges multiple functions into a single integrated mechanism. The shiftable sleeve combines valve activation, stage counting, and sequence control functions that previously required separate tools and intervention crews. By consolidating these functions into one component that operates automatically with the frac fluid, the system reduces the number of tools needed and minimizes crew resource requirements, thereby lowering operational costs while maintaining productivity.
Data Source
AI summary
A downhole system for multistage fracturing having at least a first cluster of valves. The first cluster of valves has a frac valve. The first cluster of valves also has a flex valve. A single plugging device is operable to pass through all of the valves of the first cluster of valves and leave all of them closed.