Programmable Plug Control of Sliding Sleeves in Multistage Fracturing
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Solution Overview
Problem
Current multistage fracturing methods in the Oil and Gas industry lack precision and flexibility in accessing and controlling well formation zones during hydraulic fracturing, as existing valve and plug systems are cumbersome and require expensive equipment for efficient operation.
Innovation Solution
A Programmable Plug System comprising a microprocessor-controlled Programmable Plug assembly and Sliding Sleeve Valves, which autonomously detects and engages with pre-programmed Sliding Sleeve Valves to open or close them, using sensors, mechanical dogs, and actuators for precise zone access and isolation, allowing for efficient fracturing operations without the need for expensive coil tubing units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional plugs and perforations or valve systems are used for accessing well formation, then formation access can be achieved, but the system lacks precision and flexibility in controlling zone access during hydraulic fracturing
Solution Approach 1:
The plug system is pre-programmed with target depth information and valve identification codes before being deployed. The microprocessor contains pre-stored data about the wellbore configuration, valve locations, and fracturing parameters, enabling the system to automatically navigate to and control specific zones without requiring complex real-time adjustments or expensive coil tubing equipment.
2Productivity
If expensive coil tubing units are used for efficient fracturing operations, then operational efficiency is improved, but operational costs and equipment requirements increase
Solution Approach 1:
The programmable plug system is self-contained with an onboard microprocessor, memory, and control mechanisms that enable it to autonomously navigate the wellbore, identify target zones using sensor detection of valve shape features, and execute fracturing operations according to pre-programmed instructions. This self-service capability eliminates the need for expensive external coil tubing units and complex surface equipment while maintaining high operational efficiency.
3Measurement precision
If a programmable plug system with microprocessor and sensors is implemented, then precision and efficiency of zone control is improved, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical navigation and positioning mechanisms with electronic sensing and computational control. The microprocessor uses sensor detection of valve shape features, combined with pre-programmed depth and position data, to automatically determine and execute precise engagement with target zones, eliminating the need for mechanically complex positioning systems.
Data Source
AI summary
A Programmable plug system for accessing and isolating formations during hydraulic fracturing, consisting of a Programmable Plug and plurality of Sliding Sleeve Valves installed in the casing string of a wellbore, wherein Programmable Plug travels, downwards or upwards through the casing and Sliding Sleeve Valves, wherein during its travel the Programmable Plug detects and counts each sleeve using on-board sensors, electronics and software and wherein the Programmable Plug utilizes detected information to locate, activate and engage itself into the Sliding Sleeve Valves, one at a time, from the top or from the bottom, without locking in, according to programmed sequence (to open, close or bypass) stored in the on-board memory. When engaged to the Sliding Sleeve Valve from the top, the Programmable Plug opens the Sliding Sleeve Valve by applying the pump pressure from the surface, thus providing access to the zone adjacent to the Sliding Sleeve Valve while sealing and isolating the zones below the Sliding Sleeve Valve. Applying pressure in opposite direction, or pulling on by the wire line or slick line winch connected to the Programmable Plug causes the Programmable Plug to disengage itself and travel up the casing string towards next Sliding Sleeve Valve where setting, actuation, and opening is repeated for that Sliding Sleeve Valve. To close open Sliding Sleeve Valve, Programmable plug engages Sliding Sleeve from the bottom side and pushed up by well pressure from the bottom or pulled upwards by the slick line or wire line winch, thus closes the Sliding Sleeve Valve.