Ported Collar Valves for Multi-Zone Fracturing
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Solution Overview
Problem
Current well completion techniques for multi-zone wells face challenges such as sand interference, excessive fluid usage, and cost issues with sand jet perforating, and limitations in the number of zones that can be fractured due to ball size constraints in sliding sleeve systems, which increase processing time, fluid consumption, and environmental concerns.
Innovation Solution
A wellbore completion system featuring a casing assembly with ported collars and valves that open via pressure differential, allowing for efficient fracturing across multiple zones without the need for ball drops, reducing fluid consumption, and minimizing the reduction in casing inner diameter, while enabling the use of coiled tubing for fracturing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sand jet perforating is used to create openings through casing and formation, then perforating effectiveness is improved, but sand accumulates in the well bore annulus interfering with fracturing and requiring lengthy cleaning operations
Solution Approach 1:
The invention extracts and removes the harmful sand particles from the well bore annulus using a sand removal device that circulates fluid through the annulus to flush sand out of the system, preventing sand accumulation interference with subsequent fracturing operations
Solution Approach 2:
The sand removal operation is performed as a preliminary step before fracturing, proactively removing sand from the annulus to prevent interference with the fracturing process, rather than attempting to clean sand after it has accumulated and caused problems
2Reliability
If sand jet perforating is used to create openings through casing and formation, then perforating effectiveness is improved, but excessive fluid is consumed to cut perforations and circulate or pump sand
Solution Approach 1:
The invention extracts and removes the harmful sand particles from the well bore annulus using a sand removal device that circulates fluid through the annulus to flush sand out of the system, preventing sand accumulation interference with subsequent fracturing operations
Solution Approach 2:
The invention discards sand from the system through the sand removal device that flushes sand out of the well bore, rather than attempting to recover and reuse the sand-laden fluid, reducing overall fluid consumption compared to methods that require pumping sand back into zones
3Adaptability or versatility
If sliding sleeve assemblies with balls are used to open ports in multiple zones, then multi-zone fracturing capability is improved, but the number of zones is limited to about 11-12 due to ball size constraints and processing time increases
Solution Approach 1:
The invention replaces the mechanical ball-and-sleeve system with an electronically controlled valve system that can be operated remotely, eliminating the need for physical ball drops and allowing for faster, more flexible opening of ports in multiple zones without being constrained by ball size increments
Solution Approach 2:
The invention makes the port opening system dynamic and adjustable through electronic control, allowing ports to be opened on demand in any zone without being limited by fixed ball size increments, enabling faster multi-zone fracturing operations with greater flexibility
4Adaptability or versatility
If sliding sleeve assemblies are installed on inner diameter of casing, then multi-zone fracturing capability is improved, but inner diameter of casing is significantly reduced
Solution Approach 1:
The invention replaces the mechanical ball-and-sleeve system with an electronically controlled valve system that can be operated remotely, eliminating the need for physical ball drops and allowing for faster, more flexible opening of ports in multiple zones without being constrained by ball size increments
Solution Approach 2:
The invention segments the control system into electronically controlled valves that can be independently operated for each zone, allowing for precise control of port opening without requiring large mechanical components that would reduce casing inner diameter
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
Enables efficient fracturing across multiple zones with reduced fluid consumption and operational time, minimizing environmental impact, and maintaining a larger inner casing diameter, thus improving the efficiency and cost-effectiveness of the fracturing process.
Implementation Method 1
The valves are configured to open when a pressure differential is created between the fracture ports and the valve vent holes
Data Source
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AI summary
A ported completion and method for use in fracturing multi-zone wells. A casing assembly having a plurality of casing lengths and one or more collars positioned so as to couple together the casing lengths. The collars may be a tubular body having an inner flow path, one or more fracture ports configured to provide fluid communication between an outer surface of the collar and the inner flow path, one or more valve holes intersecting the fracture ports, one or more valve vent holes positioned to provide fluid communication between the valve holes and the inner flow path, and one or more valves positioned in the valve holes for opening and closing the fracture ports. The valves are configured to open when a pressure differential is created between the fracture ports and the valve vent holes. The valve vent hole may be an annulus around the perimeter of the tubular body.