Movable Cover Screen System for Proppant Flow Back Restriction
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Solution Overview
Problem
During hydraulic fracturing operations, proppant flow back into the wellbore is a significant issue, leading to reduced efficiency and increased costs, as existing systems fail to effectively restrict the flow of solid particles back into the tubular from the formation.
Innovation Solution
A proppant flow back restriction system comprising a tubular with a cover that shifts from a first position to uncover ports, allowing fluid communication, and then to a third position to deploy a screen over the ports, preventing solid particles greater than a threshold size from flowing back into the tubular, utilizing mechanical, hydraulic, or signal-actuated mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a cover is used to cover ports during well operations, then proppant flow back is restricted, but fluid communication through the ports is blocked
Solution Approach 1:
The cover is designed to be movable rather than fixed, allowing it to transition between covering and uncovering the ports based on operational requirements. The cover can be positioned to cover ports during production to prevent proppant flow back, and uncovered during fracturing operations to allow fluid communication, thus resolving the contradiction between restricting proppant flow back and maintaining fluid communication capability
Solution Approach 2:
The cover is pre-positioned to cover the ports before fracturing operations begin. This preliminary positioning prevents proppant from entering the wellbore during subsequent production phases, while the system is designed to allow easy removal or repositioning of the cover when fluid communication is needed for fracturing operations
2Object-affected harmful factors
If a screen is deployed over the ports to filter proppant, then proppant flow back is restricted, but the system complexity increases
Solution Approach 1:
The screen is integrated with the cover assembly, combining the filtering function with the existing port coverage mechanism. This merging approach allows the screen to be deployed and removed as a single unit with the cover, preventing proppant flow back without requiring a completely separate filtering system, thus minimizing the increase in overall system complexity
Solution Approach 2:
The screen acts as an intermediary component between the port and the wellbore environment. It provides the necessary filtration function to restrict proppant flow back while being easily installable and removable, serving as a mediator that adds minimal complexity to the overall system while effectively solving the proppant intrusion problem
3Productivity
If the cover shifts positions to uncover ports for fluid flow, then fluid communication is enabled, but proppant may flow back into the tubular
Solution Approach 1:
The cover's dynamic positioning capability allows it to be uncovered during fracturing operations to enable fluid communication, and then repositioned to cover the ports during production phases to prevent proppant flow back. This dynamic adjustment resolves the contradiction by allowing the system to adapt its configuration based on the operational phase
4Object-affected harmful factors
If a screen is used to prevent proppant flow back, then particle filtration is improved, but maintenance costs increase
Solution Approach 1:
The screen is installed in advance as part of the port coverage system before production begins. This preliminary installation ensures that proppant is prevented from entering the wellbore during the entire production phase, avoiding the need for costly remedial operations or well cleanouts that would be required if proppant intrusion occurred
Solution Approach 2:
The screen is designed to be self-contained within the cover assembly, requiring minimal intervention for installation and removal. This design allows the screening function to operate autonomously during production, preventing proppant flow back without requiring ongoing maintenance or complex repair operations, thus reducing overall maintenance costs
Data Source
AI summary
A proppant flow back restriction system includes a tubular extending through a wellbore and having a port disposed along the tubular. The system also includes a screen positioned along the tubular. The system further includes a cover disposed in an interior region of the tubular, where the cover is shiftable from a first position to a second position, and from the second position to a third position. The cover covers the port while the cover is in the first position, and uncovers the port while the cover is in the second position. The cover also engages the screen while shifting from the second position to the third position to shift the screen over the port.