Packer Setting via Check Valve and Ball Seating
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Solution Overview
Problem
The oilfield industry faces inefficiencies and mechanical failures in setting packers in well bore completion assemblies due to the need for frequent repositioning and pressurization of setting tools, which are prone to leaks and failures, making the process time-consuming and costly.
Innovation Solution
A check valve system is used to control fluid flow, allowing a setting ball to seat and increase pressure on packers for setting, eliminating the need for a wash string or other setting tools, and enabling packer setting without mechanical failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wash string and setting tool are used to set packers one-by-one, then packers can be set in the well bore, but the process becomes very time-consuming and inefficient
Solution Approach 1:
The completion string is segmented into multiple zones with individual packers, and the setting mechanism is segmented into multiple ball seats distributed along the string. Each ball seat can be activated independently by dropping a setting ball, allowing parallel setting of multiple packers without moving the entire setting tool assembly.
Solution Approach 2:
The setting balls are prepared and dropped into the completion string before the packers are set. The balls travel down the string and automatically seat at the appropriate ball seats, initiating the setting action for each packer in advance without requiring sequential tool repositioning.
2Reliability
If a wash string is used for setting packers, then packers can be set, but the wash string is subject to frequent mechanical failures such as pressure leaks
Solution Approach 1:
The complex wash string assembly with cups, collets, and pressure testing mechanisms is extracted and replaced with a simple base pipe. The setting function is achieved through passive ball seating and pressure differential, eliminating the need for complex mechanical setting tools that are prone to failure.
Solution Approach 2:
The setting balls are simple, inexpensive objects that can be easily replaced if lost or damaged. Rather than investing in expensive, complex setting tools that require maintenance and repair, the system uses simple disposable balls that solve the setting problem without mechanical complexity.
3Reliability
If the setting tool must be repositioned and pressurized numerous times to set all packers, then all packers can be set, but the process becomes very inefficient and costly
Solution Approach 1:
The setting process continues uninterrupted as setting balls are dropped sequentially and travel continuously down the completion string, seating at their respective ball seats and activating packers in sequence without stopping the overall setting operation. This eliminates the need to retrieve and reposition setting tools between packers.
4Reliability
If pressure testing is conducted on long wash strings with many joints, then pressure leaks can be detected, but the process becomes very difficult and time-consuming
Solution Approach 1:
The pressure testing function is extracted from the complex multi-joint wash string and simplified to pressure testing a single continuous base pipe. The absence of joints and mechanical components in the base pipe makes pressure testing straightforward and reliable, eliminating the difficulty of testing long strings with multiple connection points.
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
This method allows for rapid and reliable setting of multiple packers without mechanical failures, reducing time and cost by eliminating the need for wash strings and other prone-to-failure tools, and simplifying pressure testing.
Implementation Method 1
it is moved into the open position when the pressure of the reservoir fluid is greater than the pressure inside the base pipe by a predetermined amount
Implementation Method 2
a setting ball is passed through the inside of the base pipe and sealingly seats in a seat sub, thereby preventing fluid from flowing out of the end of the base pipe
Implementation Method 3
The check valve is biased into the closed position
Data Source
AI summary
Apparatus and methods for setting one or more packers in a well bore. A check valve is provided that controls flow of fluids into and out of an inflow control device on a base pipe in a production string. With the check valve in the closed position, a setting ball is passed through the inside of the base pipe and sealing seats in a seat sub, thereby preventing fluid from flowing out of the end of the base pipe. Increasing the pressure inside the base pipe causes the packers to set. Decreasing the pressure inside the base pipe creates a differential between the pressure inside the base pipe and the pressure of the surrounding reservoir that is sufficient to overcome the bias on the check valve and move the check valve into the open position, thereby allowing reservoir fluid to flow into the base pipe for production.