Zone Isolation Packer Disconnect for Single Trip Retrieval
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Solution Overview
Problem
Existing multi-zone fracturing and gravel packing systems face challenges when the inner string gets stuck in a zone isolation packer, requiring costly and complex procedures to retrieve, often resulting in abandoning the well or making multiple trips to extract the stuck string.
Innovation Solution
A completion assembly with a top packer and zone isolation packers separated by screens, featuring a disconnect mechanism that allows for the release of all packers in a single trip if the inner string gets stuck, enabling the shearing and removal of the stuck portion with a subsequent retrieval of the top packer and all other packers down to the stuck zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the inner string is pulled until it shears apart and the wellbore is abandoned in favor of a deviated bore, then the stuck inner string is removed, but the well is abandoned and requires expensive offset drilling
Solution Approach 1:
The completion assembly is segmented into multiple zone isolation packers that can be independently released. When the inner string gets stuck, the system can release and retrieve individual zone packers or groups of packers below the stuck point, rather than requiring complete well abandonment. This segmentation allows selective removal of problematic components while preserving the rest of the well structure.
Solution Approach 2:
The system enables recovery of the outer completion assembly and zone isolation packers that would otherwise be discarded when the inner string sticks. By providing a mechanism to release and retrieve packers below the stuck point, the system recovers expensive completion components and preserves the wellbore for continued production, rather than discarding the entire well.
2Ease of operation
If the top packer is grabbed and rotated to release zone isolation packers one by one through multiple trips, then the stuck inner string can be retrieved, but the procedure becomes extremely costly and time-consuming
Solution Approach 1:
The zone isolation packers are pre-configured with release mechanisms that can be activated from the surface. Before the inner string gets stuck, the system is prepared with the capability to release packers on demand. When sticking occurs, the predetermined release mechanism allows for efficient retrieval without requiring multiple trips and manual intervention at each packer location.
Solution Approach 2:
The top packer is designed with multi-functionality, serving both as the initial setting point for the completion assembly and as the control point for releasing all zone isolation packers below it. This universal design allows a single operation at the top packer to trigger the release of multiple downstream packers, eliminating the need for separate trips to each individual packer location.
3Ease of manufacture
If a lateral well is drilled above the stuck packer to abandon the original hole, then the stuck pipe is left in place, but the original wellbore is lost and requires significant offset drilling
Solution Approach 1:
The system extracts the stuck inner string and associated zone isolation packers from the wellbore using the predetermined release mechanism. By enabling the release and retrieval of packers below the stuck point through the top packer, the system removes the problematic components in situ, allowing the original wellbore to be preserved and reused, rather than requiring extraction via offset drilling.
Data Source
AI summary
A completion assembly of a top packer and zone isolation packers separated by screens has a disconnect in a selected zone to be fractured or gravel packed that is armed before such a procedure starts. Initially when the assembly of the outer completion and the inner string are properly located and all the screens valved off, all the packers are pressure set and the packer set release device associated with each packer is armed. Before starting a fracturing or gravel packing operation from a given zone isolation packer, a disconnect for that zone packer is armed so that if the inner string sticks in that packer, the inner string is sheared and removed and another trip is used to grab the top packer and pick up. Such picking up releases all the packers down to the one armed disconnect. The disconnect releases bringing up the remnant of the inner string stuck in the packer just above the actuated disconnect.