Retrievable Smart Fracturing Plug with Real-Time Sensor Data
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Solution Overview
Problem
Operators in hydraulic fracturing rely heavily on experience rather than real-time data due to the complexity of interpreting vast amounts of data, leading to inefficient well completions and potential detrimental effects.
Innovation Solution
The implementation of a smart sensor system that includes a fracturing plug, gun, setting tool, and sensors to measure and transmit parameters such as temperature and pressure in real-time, allowing for better control of the fracturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operators rely on real-time fracturing data to control the hydraulic fracturing process, then the quality of well completion should improve, but the complexity of data interpretation makes it difficult for operators to properly control the process
Solution Approach 1:
The patent introduces an automated control system that acts as an intermediary between the sensors collecting fracturing data and the operators. This system automatically interprets the complex real-time data from multiple sensors (pressure, temperature, flow rate) and generates actionable control recommendations, eliminating the need for operators to directly interpret complex data while maintaining reliable well completion quality
2Ease of operation
If operators rely on their own knowledge and experience to interpret real-time fracturing data, then they can control the fracturing process, but this leads to detrimental effects on well completion due to inability to properly interpret the wealth of data
Solution Approach 1:
The control system performs self-service by automatically analyzing fracturing data and generating control recommendations without requiring operator interpretation. The system monitors parameters such as pressure, temperature, and flow rate continuously and autonomously determines optimal control actions, freeing operators from the burden of data interpretation while ensuring reliable well completion through consistent automated decision-making
Solution Approach 2:
The patent implements a closed-loop feedback system where sensors continuously monitor fracturing parameters and the control system automatically adjusts operational variables based on real-time data. This feedback mechanism ensures that control decisions are based on actual process conditions rather than operator experience alone, improving both ease of operation and reliability of well completion quality
3Adaptability or versatility
If multiple variables of the hydraulic fracturing process are monitored and altered, then better control of the process should be achieved, but the complexity of the process makes it difficult for operators to alter variables based on real-time data
Solution Approach 1:
The control system dynamically adjusts multiple fracturing variables (injection rate, pump pressure, fluid composition) in real-time based on sensor data and changing formation conditions. The system continuously optimizes these variables throughout the fracturing process, enabling adaptability to different stages and conditions without requiring operators to manually manage the complexity of multiple interacting variables
Data Source
AI summary
Systems and methods are provided for a fracturing process and in particular, to providing a fracturing system including a fracturing plug configured to seal a wellbore to prevent fluid from passing through the wellbore, a gun configured to generate a perforation cluster, wherein the perforation cluster allows fluid exchange between the wellbore and a subterranean formation, a setting tool configured to initiate setting of the fracturing plug and firing of the gun to generate the perforation cluster, and a sensor configured to measure parameters proximate to the wellbore, wherein the sensor is retrievable after a fracturing process, measuring the parameters proximate to the wellbore with the sensor and transmitting the parameters measured by the sensor to an operator.