Wellbore Plug Isolation System with Conformal Seating
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Solution Overview
Problem
Existing oil and gas extraction methods face challenges in positioning ball seats at desired locations without predefined sleeve locations, isolating multiple hydraulic fracturing zones without milling operations, and ensuring unrestricted well production fluid flow, while preventing premature plug settings that hinder further wellbore operations.
Innovation Solution
A wellbore isolation plug system that includes a setting tool to deploy a large inner diameter restriction sleeve member and restriction plug element, allowing for selective placement and removal without milling, and enabling unrestricted fluid flow by using a wellbore setting tool to form a conforming seating surface for the plug element, which can degrade over time for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional plugs with predefined sleeve locations are used, then plug positioning is simplified, but the ability to position plugs at desired locations without predefined sleeves is lost
Solution Approach 1:
The system divides the wellbore isolation function into two separate components: a reusable setting tool that positions and deploys plugs, and disposable or removable plug elements. This segmentation allows the setting tool to be precisely controlled to place plugs at any desired location, while the plug elements themselves remain simple isolation components.
Solution Approach 2:
The setting tool acts as an intermediary device that bridges the gap between the operator's positioning requirements and the actual plug placement. It provides the mechanical means to accurately position and deploy plugs at specific wellbore locations without requiring predefined sleeve structures in the casing.
2Productivity
If traditional milling operations are used to remove plugs, then complete plug removal is achieved, but operational time and cost increase
Solution Approach 1:
The plug elements are designed as disposable or easily removable components that serve their isolation function temporarily during wellbore treatment operations. After use, they can be abandoned in the wellbore or removed through simple retrieval methods without requiring time-consuming milling operations, thus improving productivity and reducing time loss.
Solution Approach 2:
The system enables selective discarding of plug elements after they have fulfilled their isolation purpose. Rather than attempting to recover and reuse all plug components, the design allows for efficient abandonment of spent plugs, eliminating the need for complex removal operations and significantly reducing operational time.
3Reliability
If small inner diameter plugs are used, then isolation effectiveness is improved, but fluid flow restriction during production increases
Solution Approach 1:
The plug system incorporates dynamic elements that allow the inner diameter to change based on operational requirements. During isolation operations, the plug maintains a smaller effective diameter for sealing, while during production, the system transitions to a larger diameter configuration to minimize flow restriction, thus resolving the contradiction between isolation effectiveness and fluid flow capability.
Solution Approach 2:
The system changes the physical parameters of the plug structure, specifically the inner diameter, to match different operational phases. The plug design allows transformation from a compact isolation configuration to an expanded flow-permissive configuration, optimizing both isolation reliability and production flow without compromise.
Data Source
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AI summary
A wellbore plug isolation system and method for positioning plugs to isolate fracture zones in a wellbore is disclosed. The system includes a wellbore casing laterally drilled into a hydrocarbon formation, a wellbore setting tool (WST) that sets a large inner diameter (ID) restriction sleeve member (RSM), and a restriction plug element (RPE). The WST is positioned along with the RSM at a desired wellbore location. After the WST sets and seals the RSM, a conforming seating surface (CSS) is formed in the RSM. The CSS is shaped to engage/receive RPE deployed into the wellbore casing. The engaged/seated RPE isolates heel ward and toe ward fluid communication of the RSM to create a fracture zone. The RPE's are removed or left behind prior to initiating well production without the need for a milling procedure. A large ID RSM diminishes flow constriction during oil production.