Two-Part Dissolvable Flow-Plug for Controlled Well Removal
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Solution Overview
Problem
Existing downhole flow-plugs lack sufficient control and efficiency in removal, as dissolvable plugs rely on specific solvents that can cause issues with equipment or formations, and mechanical removal methods are limited, leading to productivity reduction and potential need for re-completion when issues arise.
Innovation Solution
A two-part dissolvable flow-plug system using different dissolvable materials for the retaining and plugging components, allowing for controlled dissolution and mechanical removal options, with the plugging component being pushed out by fluid flow once the retaining component is dissolved, and the ability to use different solvents for each component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single-material dissolvable flow-plug is used, then the plug can be removed by dissolution with a specific solvent, but the operator has little control over the removal process and the solvent may cause issues with equipment or formations
Solution Approach 1:
The flow-plug is divided into two distinct components: a plugging component and a retaining component. Each component can be made of different dissolvable materials with different dissolution rates and solvent requirements. This segmentation allows the operator to control the removal process by selecting which component dissolves first and under what conditions, thereby reducing unwanted solvent impact on equipment and formation.
Solution Approach 2:
Different portions of the flow-plug (plugging component vs. retaining component) are assigned different material properties and dissolution characteristics. The plugging component may use a material resistant to certain solvents while the retaining component uses a material that dissolves readily in those same solvents, enabling localized control over dissolution behavior to protect sensitive equipment and formation areas.
2Adaptability or versatility
If multiple dissolvable flow-plugs are used in a completion, then flow can be regulated at multiple locations, but the solvent takes the path of least resistance and dissolves the first plug encountered, preventing dissolution of remaining plugs
Solution Approach 1:
Each flow-plug in the completion is segmented into plugging and retaining components with different dissolution characteristics. The retaining component dissolves first to allow solvent passage, while the plugging component remains intact to continue providing flow control. This enables sequential dissolution of multiple plugs without the solvent taking shortcuts, maintaining productivity across all completion zones.
Solution Approach 2:
The dissolution parameters (solvent type, temperature, pressure, dissolution rate) are optimized differently for the plugging versus retaining components. By adjusting these parameters, the system ensures that retaining components dissolve to allow solvent flow through all zones, while plugging components maintain their integrity until desired removal, thereby preserving well productivity.
3Ease of operation
If a dissolvable flow-plug is used, then the plug can be removed without affirmative action, but the operator cannot correct issues if the solvent causes problems with equipment or formation
Solution Approach 1:
The segmented design allows partial dissolution scenarios where only the retaining component dissolves while the plugging component remains. This provides an intermediate state that allows operator intervention to correct issues before complete removal occurs, combining passive removal capability with correction flexibility.
Solution Approach 2:
The retaining component is designed to dissolve first as a preliminary action, allowing the operator to assess whether the plugging component needs to be removed or if correction is needed. This staged approach enables preliminary passive removal while retaining the option for corrective action.
4Ease of operation
If a mechanical removal mechanism is used, then the plug can be removed actively, but the mechanism may fail or damage the well, leaving little recourse except re-completion
Solution Approach 1:
The design replaces complex mechanical removal mechanisms with a chemical dissolution system. The dissolvable materials provide a reliable, failure-free removal method that eliminates mechanical wear, jamming, or breaking risks associated with mechanical retrieval tools, thereby improving reliability while maintaining active removal capability.
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 system provides controlled fluid flow regulation, minimizes equipment impact, and allows for efficient removal of the flow-plug without re-completion, maintaining productivity by ensuring all plugs are dissolved without clogging issues.
Implementation Method 1
The retaining component and the plugging component may each comprise a different dissolvable material and may be dissolved through the use of different solvents and/or at different rates of dissolution
Data Source
AI summary
Well systems for plugging and unplugging a flow path in a subterranean formation are provided. An example well system comprises a flow path comprising a two-part dissolvable flow-plug. The two-part dissolvable flow-plug comprises a retaining component and a plugging component adjacent to the retaining component. The retaining component comprises a dissolvable material. The flow path is in fluid communication with a tubing. The retaining component is configured to retain the plugging component in a fixed position.