Pressure-Activated Completion Tool with Burst Plugs

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Solution Overview

Problem

Current hydraulic fracturing systems are expensive and inefficient, with existing pressure-activated tools prone to being plugged or blocked by debris, limiting the effectiveness of fluid flow and fracturing processes.

Innovation Solution

A pressure-activated completion tool apparatus featuring a tubular body with burst ports and a movable inner sleeve that slides to open flow-ports when exposed to hydraulic pressure, using incompressible fluid to activate burst plugs and ensure reliable multistage completions without debris obstruction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydraulic pressure is used to burst open completion tools, then the fracturing process can be activated, but only one out of multiple openings will burst and pressure is lost

Engineering Contradiction:

Improvereliability of burst openingVSAvoidpressure loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The completion tool is divided into multiple independent burst disks, each capable of bursting independently. This segmentation ensures that if one burst disk opens, the others remain intact and can still function, eliminating the problem of total pressure loss and improving system reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system is designed with redundant burst disks as a backup mechanism. This beforehand cushioning ensures that even if one burst disk fails or opens prematurely, other burst disks remain available to perform the fracturing function, maintaining system reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of operation

If exposed vent holes are used for hydraulic actuation, then pressure activation is achieved, but they are prone to being plugged or blocked by debris

Engineering Contradiction:

Improvehydraulic actuation capabilityVSAvoidresistance to debris blockage

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Burst disks made of flexible thin film materials are used instead of rigid vent holes. These flexible membranes can deform and are less susceptible to complete blockage by debris, while still allowing hydraulic pressure to pass through for actuation. They provide a more reliable flow path that resists plugging.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The burst disks are designed to dynamically respond to pressure changes, bursting open when pressure exceeds a threshold. This dynamic behavior allows the system to automatically overcome minor debris obstructions through pressure-driven deformation and opening, maintaining actuation capability while resisting blockage.

Inventive Principle:

Principle #15Dynamics

3Productivity

If current fracing systems are used, then hydraulic fracturing can be performed, but they are expensive and inefficient

Engineering Contradiction:

Improvefracturing efficiencyVSAvoidsystem cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The burst disks are designed as disposable, low-cost components that are replaced rather than repaired. This approach reduces overall system cost by using inexpensive materials for the burst disks while maintaining high efficiency through reliable, single-use operation. The simplicity of the disposable design eliminates complex maintenance and reduces operational costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The complex, expensive mechanisms from current fracing systems are removed and replaced with simple burst disk technology. By extracting only the essential function (pressure-activated opening) and implementing it through simple, inexpensive burst disks, the system achieves high efficiency at lower cost.

Inventive Principle:

Principle #2Taking out (Extraction)

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

The solution provides a safer, more reliable, and cost-effective hydraulic fracturing method with increased flow areas and reduced risk of debris blockage, enabling efficient fracturing of subterranean formations.

Implementation Method 1

a movable inner sleeve that can slide along the inside of the tubular body when exposed to hydraulic pressure from a first position to a second position

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Implementation Method 2

using incompressible fluid to activate burst plugs and ensure reliable multistage completions without debris obstruction

Methodology Applied

Scientific EffectIncompressible fluid:

Data Source

PatentUS10458221B2Pressure activated completion tools and methods of use

Publication Date: 2019.10.29 EXXONMOBIL TECHNOLOGY & ENGINEERING CO

AI summary

Methods and apparatus of pressure activated completion tools for hydraulic fracturing and related processes are provided. In some embodiments, the hydraulic fracturing apparatuses for accessing a subterranean formations can include a tubular body to be fluidly connected in-line with a completion string, the tubular body having at least one burst port configured to receive burst inserts (burst plugs), and a movable inner sleeve that can slide along the inside of the tubular body when exposed to hydraulic pressure from a first position to a second position. The tubular body can also have flow-port(s) that are blocked when the movable inner sleeve is in the first position and opened when the movable inner sleeve slides to the second position.