Reverse Flow Downhole Tool Actuation for Fracture Stages
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Solution Overview
Problem
Existing oil and gas extraction methods face limitations in the number of fracture stages due to the size of actuating elements and wellbore casing, leading to restricted access and production potential, with prior art systems not utilizing stored energy in connected regions for useful work.
Innovation Solution
A multiple tool reverse flow system in a wellbore casing using catch-and-release tools and catch-and-engage tools, where restriction elements pass through in a downstream direction and engage to actuate sleeves in an upstream direction, leveraging stored energy for actuating sliding sleeve valves and allowing reverse flow to enable more fracture stages without size limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional ball-activated sliding sleeve tools are used, then the wellbore can be treated with fracture stimulation, but the number of fracture stages is limited due to the size of actuating elements and wellbore casing
Solution Approach 1:
The patent inverts the traditional actuation direction by using reverse flow to move restriction elements upstream instead of downstream. This allows the restriction element to be caught by catch-and-release tools positioned upstream, enabling actuation of sliding sleeves in reverse order and increasing the number of treatable stages without size constraints
Solution Approach 2:
The patent introduces catch-and-release tools as intermediary devices that temporarily retain restriction elements during reverse flow. These tools act as mediators between the restriction element and the sliding sleeve actuation mechanism, enabling precise control over which sleeves are opened at each stage
2Measurement precision
If coil tubing and ball counting mechanisms are used, then the system can track and actuate sliding sleeves, but the device complexity and operational time increase
Solution Approach 1:
The system uses the natural reverse flow of fluid through the wellbore to automatically move restriction elements upstream without requiring external coil tubing or complex counting mechanisms. The restriction elements self-propel through the system driven by pressure differentials, eliminating the need for additional tracking equipment
Solution Approach 2:
The patent removes the coil tubing and ball counting mechanisms from the system entirely, replacing them with a passive reverse flow mechanism. This extraction of complex components simplifies the overall system while maintaining the ability to track and actuate sliding sleeves through the natural flow dynamics
3Adaptability or versatility
If traditional downstream actuation is used, then the system can operate with simple tool design, but out-of-order fracturing operations cannot be performed
Solution Approach 1:
The patent creates a dynamic system where the direction of actuation can be reversed based on operational requirements. By utilizing reverse flow, the system can adaptively change the sequence of sleeve actuation, allowing out-of-order fracturing operations while maintaining relatively simple tool design through the use of passive flow-driven mechanics
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 system allows for increased fracture stages and improved well production by utilizing stored energy for actuating tools, eliminating the need for coil tubing and accurate ball counting, and enabling out-of-order fracturing operations and degradable elements for efficient hydrocarbon extraction.
Implementation Method 1
flowing back the restriction element in an upstream direction; reversing a flow direction in the wellbore casing from a downstream direction to an upstream direction
Data Source
AI summary
A seat forming apparatus for use in a downhole tool comprising a driving member and a seating restriction. The driving member and the seating restriction are mechanically disposed within an outer housing of the downhole tool. When the driving member drives into the seating restriction, the seating restriction or the driving member bend or buckle inwards to form a seat in the downhole tool. The inner diameter of the seat is configured to allow a restriction element to be seated in the seat.