Self-releasing Plug for Subterranean Well Flow Control

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Solution Overview

Problem

Current technologies face challenges in effectively regulating fluid flow in subterranean wells, particularly in preventing water or gas coning, minimizing undesired fluid production, and maximizing desired fluid production or injection, as they lack efficient mechanisms to adapt to changing fluid compositions and velocities.

Innovation Solution

A flow control system that includes a variable flow resistance system and a self-releasing plug mechanism, which adjusts resistance based on fluid characteristics such as viscosity and velocity, and automatically shuts off flow when an unacceptable ratio of undesired to desired fluids is detected, using a degradable support structure to release the plug and prevent further flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a fixed flow resistance system is used, then the device structure is simple, but it cannot adapt to changing fluid compositions and velocities

Engineering Contradiction:
Improveadaptability to fluid composition changesVSAvoiddevice structure complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies the dynamics principle by making the flow resistance variable rather than fixed. The support structure is designed to degrade over time, dynamically changing the flow resistance characteristics. This allows the system to adapt to changing fluid compositions and velocities without requiring complex control mechanisms, resolving the contradiction between adaptability and device complexity.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the physical-chemical parameters of the support structure by using degradable materials. As the support structure degrades, its mechanical properties change, which in turn changes the flow resistance parameters. This parameter change approach enables adaptation to varying fluid conditions while maintaining relatively simple device structure.

Inventive Principle:
Principle #35Parameter changes

2Extent of automation

If continuous monitoring and manual intervention is used, then flow regulation precision is high, but operation complexity and human intervention are required

Engineering Contradiction:
Improveautomation of flow controlVSAvoidease of flow control operation
Core Design Contradiction:
Extent of automationVSEase of operation

Solution Approach 1:

The patent applies the self-service principle by designing a system that automatically responds to fluid composition changes without requiring external monitoring or manual intervention. The degradable support structure self-adjusts the flow resistance based on the fluid it contacts, and the plug automatically seals the wellbore when degradation reaches a critical point. This achieves high automation while maintaining ease of operation.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The system incorporates implicit feedback through the degradation process. The support structure's degradation rate is directly influenced by the fluid composition it contacts, creating a natural feedback mechanism. When undesired fluids are present, they accelerate degradation, which then triggers the sealing action, automatically regulating flow without external control systems.

Inventive Principle:
Principle #23Feedback

3Extent of automation

If degradable support structure is used, then automatic flow shutdown is achieved, but structure reliability decreases

Engineering Contradiction:
Improveautomatic flow shutdown capabilityVSAvoidsupport structure reliability
Core Design Contradiction:
Extent of automationVSReliability

Solution Approach 1:

The patent applies beforehand cushioning by designing the degradable support structure with controlled degradation characteristics. The structure is engineered to maintain its load-bearing capacity and flow control function throughout the intended operational period, then gradually degrade to trigger the shutdown mechanism. This pre-planned degradation path ensures reliability during operation while enabling automatic shutdown when needed.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The support structure is designed as a temporary, disposable component that fulfills its function for a specific operational period and then degrades to enable shutdown. This approach accepts reduced long-term reliability of the support structure itself, but achieves the broader system goal of automatic flow control and prevents continuous operation under adverse conditions.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

4Productivity

If flow resistance is increased to prevent coning, then desired fluid production is maximized, but fluid flow velocity increases which accelerates structure degradation

Engineering Contradiction:
Improvedesired fluid productionVSAvoidsupport structure service life
Core Design Contradiction:
ProductivityVSDuration of action of moving object

Solution Approach 1:

The patent uses feedback through the degradation mechanism to balance productivity and service life. The increased flow velocity and undesired fluid composition accelerate degradation, which naturally limits the operational period and triggers shutdown before excessive production of undesired fluids occurs. This creates a self-regulating system where the degradation rate serves as a feedback signal.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The system changes parameters over time through controlled degradation. Initially, the support structure provides high flow resistance to maximize desired fluid production. As degradation progresses, the resistance decreases and flow velocity increases, accelerating degradation further until shutdown occurs. This time-dependent parameter change allows optimized productivity during the service period while automatically limiting total exposure to adverse conditions.

Inventive Principle:
Principle #35Parameter changes

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 effectively regulates fluid flow by increasing resistance to undesired fluids, preventing coning and maximizing desired fluid production or injection, and automatically shutting off flow when necessary, thereby enhancing well operation efficiency without human intervention.

Implementation Method 1

a structure which supports the plug, but which releases the plug in response to degrading of the structure by the fluid composition

Methodology Applied
Scientific EffectDegradation:

Data Source

PatentUS8851180B2Self-releasing plug for use in a subterranean well
Publication Date: 2014.10.07 HALLIBURTON ENERGY SERVICES INC
  • US8851180B2 patent drawing
  • US8851180B2 patent drawing
  • US8851180B2 patent drawing

AI summary

A flow control system for use in a subterranean well can include a flow chamber through which a fluid composition flows, and a plug which is released in response to an increase in a ratio of undesired fluid to desired fluid in the fluid composition. Another flow control system can include a flow chamber through which a fluid composition flows, a plug, and a structure which supports the plug, but which releases the plug in response to degrading of the structure by the fluid composition. Yet another flow control system can include a flow chamber through which a fluid composition flows, and a plug which is released in response to an increase in a velocity of the fluid composition in the flow chamber.