Remotely Actuated Screenout Relief Valves for Hydraulic Fracturing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Hydraulic fracturing in hydrocarbon wells often results in proppant accumulation, leading to 'screenout' events that block fluid flow and are costly and time-consuming to resolve, especially when they occur in horizontal sections of the casing conduit without a mechanism for fluid re-establishment.

Innovation Solution

The implementation of remotely actuated screenout relief valves that detect operational parameters indicative of a screenout event, allowing for the introduction of a flush fluid stream to displace proppant from the casing conduit, thereby re-establishing fluid flow and preventing further blockages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If proppant is flowed into fractures through casing openings, then fracture support and hydrocarbon production are improved, but screenout events occur that block fluid flow and increase operational cost and time

Engineering Contradiction:

Improvefracture supportVSAvoidscreenout blockage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The relief valve is pre-installed in the casing string at a location downhole from the perforations, positioned to automatically activate when proppant accumulation occurs. This preliminary placement allows the valve to respond immediately to screenout conditions without requiring surface intervention or complex detection systems.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The relief valve operates autonomously based on pressure differential across the valve body. When proppant blocks the perforations, the pressure upstream of the valve increases relative to downstream pressure, automatically triggering the valve to open and divert proppant into the casing conduit, clearing the blockage without external control.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If traditional screenout response methods are used, then blockages can be cleared, but significant operational resources and time are required

Engineering Contradiction:

Improvescreenout resolutionVSAvoidoperational time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention replaces complex mechanical intervention systems (wireline tools, perforation re-creation equipment) with a simple pressure-driven mechanical valve system. The valve uses the existing pressure differential in the wellbore to activate, substituting sophisticated surface operations with a passive downhole mechanical response.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If no relief mechanism is provided in horizontal casing sections, then device complexity is reduced, but screenout events cannot be resolved and fluid flow is permanently blocked

Engineering Contradiction:

Improvecasing mechanismVSAvoidfluid flow continuity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The relief valve divides the casing conduit into two functional zones: an upper zone with perforations for proppant discharge into the formation, and a lower zone with the relief valve providing an alternative pathway. This segmentation allows the system to handle screenout events locally without affecting the entire wellbore system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The relief valve acts as an intermediary element that provides an alternative flow path when the primary perforation path is blocked. It mediates between the proppant slurry flow and the formation, allowing proppant to be diverted into the casing conduit and transported to a different discharge location or removed from the system.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This solution enables quick and efficient resolution of screenout events by remotely actuating valves to clear proppant blockages, reducing operational costs and time by maintaining fluid flow through the subterranean formation.

Implementation Method 1

the relief valve may be actuated automatically, or autonomously, in response to a screenout event based on a pressure differential across the relief valve

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS10689962B2Remotely actuated screenout relief valves and systems and methods including the same

Publication Date: 2020.06.23 EXXONMOBIL UPSTREAM RESEARCH COMPANY(US)

AI summary

Remotely actuated screenout relief valves, systems and methods are disclosed herein. The methods include providing a proppant slurry stream that includes proppant to a casing conduit that is defined by a casing string that extends within a subterranean formation. The methods further include detecting an operational parameter that is indicative of a screenout event within the casing conduit. Responsive to the detecting, the methods include providing a flush fluid stream to the casing conduit, opening the remotely actuated screenout relief valve, and displacing the proppant from the casing conduit into the subterranean formation with the flush fluid stream via the remotely actuated screenout relief valve. The methods may further include closing the remotely actuated screenout relief valve. The systems include hydrocarbon wells that include the remotely actuated screenout relief valve and/or hydrocarbon wells that include controllers that are configured to perform at least a portion of the methods.