Straddle Frac Packer Bypass Flow Path

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Solution Overview

Problem

Current straddle frac systems require maintaining tension on the work string to set packers, which is not allowed in some jurisdictions, and cannot move the work string without killing the well, preventing debris clearance before production initiation.

Innovation Solution

A frac system with a first compression set packer and a second packer assembly that includes a bypass inlet fluidically connected to a frac port, allowing fluid flow without disengaging the packer, enabling packer setting and fluid flow without maintaining tension on the work string.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the work string is kept in tension to set packers, then the packers can be properly set and secured, but the work string cannot be moved without killing the well, preventing debris clearance operations

Engineering Contradiction:

Improvepacker setting reliabilityVSAvoidwork string mobility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The system divides the work string into multiple segments with independent tensioning capabilities. A first tensioning device sets the bottom packer while a second tensioning device sets the top packer, allowing the work string to be released and moved for debris clearance operations without compromising packer setting reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a bypass flow path as an intermediary mechanism that allows fluid to flow around the packer assembly. This enables the work string to be moved and the well to be cleared of debris without requiring continuous tension maintenance, while the bypass ensures proper fluid flow paths are established

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the work string is moved after setting packers to clear debris, then debris clearance can be performed, but jurisdictions prohibit moving the work string without killing the well

Engineering Contradiction:

Improvedebris clearance capabilityVSAvoidwell killing risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system establishes bypass flow paths and sets packers in a specific sequence before moving the work string. The bypass inlet is opened and fluid flow is established prior to work string movement, ensuring that proper flow paths exist to prevent well killing during the move operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system transitions from a static tension-maintained state to a dynamic state where the work string can be moved. The bypass mechanism and independent tensioning devices enable the system to adapt its configuration, allowing work string movement for debris clearance while maintaining well integrity through controlled fluid flow paths

Inventive Principle:

Principle #15Dynamics

3Reliability

If multiple pick up and set down operations are performed to set packers in tension, then the packers can be properly set, but the operation time and complexity increase significantly

Engineering Contradiction:

Improvepacker setting accuracyVSAvoidoperation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The packer setting operation is segmented into independent tasks performed by separate tensioning devices. The first tensioning device sets the bottom packer while the second tensioning device sets the top packer, eliminating the need for multiple pick up and set down operations and reducing overall operation time while maintaining setting accuracy

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple packer setting operations into a single continuous operation. Both packers are set during one run of the work string into the well, rather than requiring separate operations, thereby reducing time loss while ensuring proper setting accuracy through the use of independent tensioning devices

Inventive Principle:

Principle #5Merging (Combining)

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

Enables the setting of packers without continuous tension and allows fluid flow for debris clearance and fracturing operations without killing the well, facilitating safer and more efficient well operations.

Implementation Method 1

the bypass inlet is fluidically connected to the frac port through a bypass flow path and is selectively opened without disengaging the second packer

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

applying a compressive force to a packer, expanding the packer with the compressive force

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS11725479B2System and method for performing a straddle frac operation

Publication Date: 2023.08.15 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A frac system includes a first packer assembly having a first compression set packer and a first indexing member, and a second packer assembly arranged upstream of the first packer assembly. The second packer assembly includes a second packer, a second indexing member, a bypass inlet arranged upstream of the second packer, and a frac port arranged downstream of the second packer. The bypass inlet is fluidically connected to the frac port through a bypass flow path and is selectively opened without disengaging the second packer.