Wellbore Pack-Off Detection Using Caving and Debris Modeling
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Solution Overview
Problem
Downhole debris accumulation in wellbores causes pack offs, leading to immobility or inaccessibility of downhole tools, resulting in costly delays and potential damage during wellbore operations.
Innovation Solution
A system using software models to estimate downhole pressure, debris, and caving volume to determine a pack off indicator, such as the pack off volume percent, which is output via a user interface to aid in adjusting wellbore operations, reducing the need for additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional equipment is deployed into the wellbore to detect pack off conditions, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces physical sensing equipment with a software-based simulation model that uses computational algorithms to predict pack off conditions. The system substitutes mechanical/deployment complexity with software processing of existing operational parameters, eliminating the need for additional downhole sensors while maintaining detection capability
Solution Approach 2:
The patent creates a virtual copy or simulation model of the wellbore environment that replicates pack off conditions through software. Instead of physically measuring in the actual wellbore, the system generates a digital representation that mirrors real-world conditions, allowing detection without additional physical equipment
2Reliability
If downhole tools are deployed to address pack off issues, then reliability is improved, but loss of time increases due to tool deployment and retrieval
Solution Approach 1:
The patent performs preliminary detection and prediction of pack off conditions using software simulation before actual pack off occurs. By identifying potential issues in advance through computational modeling of operational parameters, the system enables proactive decision-making that prevents tool deployment and associated time losses
Solution Approach 2:
The patent implements continuous monitoring of wellbore operational parameters with real-time feedback through the simulation model. The system processes incoming data streams, updates the virtual wellbore state, and provides immediate alerts when pack off conditions are predicted, enabling timely operational adjustments without tool deployment
3Productivity
If higher fluid circulation rates are used to prevent pack off, then productivity is improved, but use of energy increases
Solution Approach 1:
The patent enables dynamic adjustment of fluid circulation rates based on real-time simulation predictions of pack off risk. Instead of maintaining constantly high circulation rates, the system modulates flow velocity dynamically - increasing only when and where pack off is predicted - thereby maintaining productivity while reducing overall energy consumption
Solution Approach 2:
The patent changes operational parameters (fluid circulation rate, flow velocity) based on simulation outputs that predict pack off conditions. The system optimizes these parameters by adjusting them only when necessary according to predicted risk levels, achieving the same productivity protection with lower energy input compared to constant high-rate circulation
Data Source
AI summary
A system can generate, via a software model, downhole pressure estimations and downhole debris estimations using caving parameters. Additionally, the system can generate, via the software model, settled caving volume percent estimations using the caving parameters. The system can determine a pack off volume percent using the downhole pressure estimations, the downhole debris estimations, and the settled caving volume percent estimations. The system can output, via a user interface, the pack off indicator and a subset of the caving parameters for use in adjusting a wellbore operation. The user interface can provide a plot of the pack off volume percent horizontally offset with respect to a plot of the subset of the caving parameters and a depth of the wellbore.