Zone Isolation Cementing System with Settable Packers

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Solution Overview

Problem

Current cementing techniques in the drilling and completion industry face challenges in effectively isolating and supporting different zones within a borehole, particularly due to variations in formation strength and pressure, which can lead to inadequate cement distribution and zone isolation.

Innovation Solution

A zone isolation cementing system comprising a tubular with flow-controlled ports and settable packers, allowing for staged delivery of cement slurry through secondary conduits and distributor manifolds to isolate and support distinct zones within the borehole, ensuring optimal cement placement and zone separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional cementing techniques are used to deliver cement slurry into the borehole annulus, then the cementing operation can be completed, but inadequate cement distribution and zone isolation occur due to variations in formation strength and pressure

Engineering Contradiction:

Improvecement placement precisionVSAvoidzone isolation reliability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The system divides the borehole into multiple isolated zones using settable packers positioned at different depths. Each zone can be cemented independently through separate flow-controlled ports, allowing precise cement placement in each zone while maintaining reliable isolation between zones with different formation strengths and pressure characteristics.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system provides different cementing conditions for different zones by using zone-specific flow-controlled ports and packers. Each zone can receive cement slurry with appropriate density and volume tailored to its specific formation characteristics, improving both cement placement precision and zone isolation reliability.

Inventive Principle:

Principle #3Local quality

2Device complexity

If a single stage cementing operation is performed, then the operation is simpler, but hydrostatic stress from the cement column can damage weaker formations

Engineering Contradiction:

Improvecementing system complexityVSAvoidhydrostatic stress on formation

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The cementing operation is divided into multiple stages with settable packers creating isolated zones. Cement slurry is pumped into each zone separately through flow-controlled ports, eliminating the need for a single long cement column. This reduces hydrostatic stress on weaker formations while maintaining manageable system complexity through modular zone isolation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Settable packers are deployed beforehand to isolate zones before cementing begins. This preliminary action allows the cementing operation to proceed zone-by-zone, preventing the formation of a continuous high-pressure cement column that would exert damaging hydrostatic stress on weaker formations throughout the borehole.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If cement slurry is pumped down the casing and into the annulus without zone isolation, then the cementing process is straightforward, but cement distribution is inadequate in specific zones

Engineering Contradiction:

Improvecementing operation simplicityVSAvoidcement distribution uniformity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system uses multiple flow-controlled ports positioned at different depths, each connected to specific zones through isolated segments created by settable packers. This allows cement slurry to be distributed uniformly within each isolated zone while maintaining relatively simple operation through sequential zone-by-zone cementing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Settable packers act as intermediaries that isolate zones and control cement slurry flow paths. These packers enable precise cement distribution within each zone by preventing cement from bypassing isolated sections, while the overall operation remains manageable through systematic zone isolation and control.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables precise cement placement and zone isolation, reducing hydrostatic stress on weaker formations and improving the overall integrity of the cement sheath, thereby enhancing the stability and efficiency of the cementing operation.

Implementation Method 1

a first settable packer disposed exteriorly of the tubular and arranged longitudinally between the first flow-controlled port and the first distributor manifold

Methodology Applied

Scientific EffectCement setting:

Data Source

PatentUS9771774B2Zone isolation cementing system and method

Publication Date: 2017.09.26 BAKER HUGHES CO

AI summary

A zone isolation cementing system includes a tubular having a longitudinal axis and a first flow-controlled port, a first conduit having a first end and a second end, the first end fluidically connected to the first flow-controlled port, a first distributor manifold arranged to deliver cement slurry exteriorly of the tubular, the second end of the first conduit fluidically connected to the first distributor manifold, and a first settable packer disposed exteriorly of the tubular and arranged longitudinally between the first flow-controlled port and the first distributor manifold.