Well Barrier Plug and Disconnect System for Drilling Operations
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Solution Overview
Problem
Well site drilling operations face challenges with cavernous formations that lead to severe loss rates, logistical issues, and well control problems, requiring effective solutions to plug and disconnect from the drilling assembly without causing safety and financial concerns.
Innovation Solution
A well barrier plug and disconnect system utilizing a liner hanger and valve combination, where the liner hanger acts as a seal and anchor in the wellbore casing, and the valve is used to isolate the wellbore environment, allowing for controlled disconnection of the drilling assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional drilling operations continue in cavernous formations, then drilling progress can be maintained, but severe loss rates and well control issues occur
Solution Approach 1:
The system divides the drilling assembly into separable sections using a disconnect device. The upper and lower drilling assemblies can be disconnected and separated, allowing the upper assembly to be retrieved while the lower assembly remains in place. This segmentation enables continued drilling operations without requiring complete well plugging, thereby maintaining productivity while reducing substance loss.
Solution Approach 2:
A barrier device acts as an intermediary element between the upper and lower drilling assemblies. This barrier can be set to seal against the wellbore wall, creating an isolation zone that prevents mud loss into cavernous formations while allowing drilling operations to continue. The barrier serves as a mediator that addresses the loss problem without stopping productivity.
2Loss of substance
If the wellbore is plugged to prevent loss, then substance loss is reduced, but drilling operations must be discontinued
Solution Approach 1:
The disconnect device enables segmentation of the drilling assembly into upper and lower sections. When loss problems occur, the upper assembly can be disconnected and retrieved while the lower assembly with the barrier remains in place to continue drilling. This segmentation allows loss prevention without complete operational discontinuation, maintaining productivity.
Solution Approach 2:
The barrier device is preliminarily positioned within the drilling assembly before encountering severe loss conditions. This preliminary placement allows the barrier to be quickly deployed when needed, enabling rapid isolation of the loss zone without requiring complete well plugging and operational shutdown.
3Reliability
If a barrier device is deployed to isolate the wellbore, then well control is improved, but device complexity increases
Solution Approach 1:
The system merges the barrier device and disconnect device into a single integrated assembly. The barrier, disconnect mechanism, and sealing elements are combined into one unified system that can be deployed as a single unit. This merging reduces overall complexity compared to having separate barrier and disconnect systems, while maintaining improved well control reliability.
Solution Approach 2:
The barrier device is designed with multi-functionality, serving both as a sealing element to prevent mud loss and as part of the disconnect mechanism. The same structural components perform multiple functions: the barrier seals against the wellbore wall while also being integrated with the disconnect assembly. This universality reduces the number of separate components needed, thereby reducing device complexity while maintaining reliability.
Data Source
AI summary
A well barrier plug and disconnect system for use during drilling operations in wellbore environments. The system comprises of a liner hanger, valve, and a drilling assembly coupled to a liner hanger running tool. The system is used to performing drilling operations in downhole wellbore environments with high risk of uncontrollable losses, cavernous zones, karst formations, or well control issues. In the event the well is on uncontrollable losses or a well control issue occurs, the liner hanger can be set into the downhole wellbore casing and a valve connected below the liner hanger can be closed creating a barrier plug in the well. Further disconnecting the liner hanger running tool from the liner hanger, valve, and drilling assembly allows retrieval of the upper drilling assembly section from the well.