Wellbore Isolation Device with Dual Valve Flow Diversion
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Solution Overview
Problem
Current wellbore isolation devices face challenges in effectively sealing the wellbore during cementing operations, particularly in preventing surge and swab effects and ensuring debris removal, while allowing fluid circulation before and after setting.
Innovation Solution
The wellbore isolation device incorporates a primary and secondary valve system that allows fluid flow through a central passage until the secondary valve seals, enabling the device to function as a cement squeeze packer, with a packer assembly and radial flow ports for efficient sealing and debris removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wellbore isolation device seals the wellbore during cementing operations, then zonal isolation is achieved, but surge and swab effects occur and debris removal is hindered
Solution Approach 1:
The wellbore isolation device is segmented into multiple functional zones: an upper portion with a first seal element for zonal isolation, and a lower portion with a second seal element and debris removal mechanism. This segmentation allows the device to simultaneously achieve reliable sealing while preventing surge and swab effects through the lower seal element's interaction with the formation face.
Solution Approach 2:
A bridge plug is introduced as an intermediary component between the wellbore isolation device and the formation face. The bridge plug serves as a mediator that prevents direct contact between the isolation device and formation, thereby eliminating surge and swab effects while maintaining zonal isolation through the packer's seal elements.
2Reliability
If a wellbore isolation device seals the wellbore tightly, then zonal isolation is improved, but fluid circulation before and after setting is obstructed
Solution Approach 1:
The wellbore isolation device employs dynamic seal elements that can adjust their sealing characteristics. The first seal element in the upper portion is designed to provide zonal isolation when set but allows fluid circulation when in the running or released state, enabling dynamic transition between circulation and isolation functions.
Solution Approach 2:
The device operates in periodic cycles: during the running phase, fluid can circulate through the device; during the setting phase, zonal isolation is established; and during the released phase, fluid circulation is restored. This periodic action allows both fluid circulation and reliable sealing to be achieved at different operational stages.
3Reliability
If a packer assembly is set against the wellbore wall, then zonal isolation is achieved, but debris accumulation obstructs the setting process
Solution Approach 1:
The device incorporates a debris removal mechanism in the lower portion that actively removes debris before the packer assembly is set. This preliminary action of debris removal prevents accumulation that would otherwise obstruct the setting process and compromise zonal isolation reliability.
Solution Approach 2:
The debris removal mechanism extracts debris from the wellbore environment before the packer setting operation. By taking out the harmful debris particles through the lower seal element's interaction with the formation face, the setting process can proceed without obstruction.
Data Source
AI summary
A method includes conveying a wellbore isolation device into a wellbore, the wellbore isolation device including a primary valve arranged within a central flow passage. A fluid is then circulated through the central flow passage and into a tubing attached to a downhole end of the wellbore isolation device and in fluid communication with the central flow passage. The primary valve is moved from a first position to a second position and thereby diverts the fluid into an annulus defined between the wellbore and the wellbore isolation device. The primary valve may then be moved to seal the central flow passage and thereby prevent the fluid from flowing into the annulus or into the tubing.