Abrasive Jet Tool Injection System for Wear Reduction
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Solution Overview
Problem
Current methods for injecting abrasive fluids at high pressures in abrasive jet perforating tools are inefficient and costly, as they require specialized pumps and result in short tool life due to abrasive wear, and existing techniques for mixing abrasives into high-pressure fluid streams are ineffective at pressures above 2,000 psi.
Innovation Solution
A system and method for injecting high-pressure abrasive fluid into an abrasive jet tool using a combination of low-pressure abrasive and high-pressure non-abrasive pumps, with valves and vessels designed to handle abrasive fluids, allowing the abrasive to be inserted downstream of the high-pressure pump, reducing wear on equipment and enabling the use of less expensive pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If specialized pumps are used to inject abrasive fluids at high pressures, then the fluid can be delivered at sufficient pressure for perforating, but the equipment wear increases and operational costs increase
Solution Approach 1:
The system divides the fluid delivery process into two separate pumps: a low-pressure pump that delivers abrasive slurry and a high-pressure pump that delivers non-abrasive fluid. This segmentation allows each pump to operate within optimal pressure ranges, preventing excessive wear on the low-pressure pump while still achieving the necessary high pressure at the jet tool through combination of the two pump outputs.
Solution Approach 2:
A mixing chamber acts as an intermediary between the two pumps and the abrasive jet tool. The mixing chamber combines the low-pressure abrasive slurry and high-pressure non-abrasive fluid, allowing the abrasive particles to be accelerated to full velocity before impacting the target. This intermediary structure enables the system to achieve high pressure without requiring the low-pressure pump to withstand abrasive wear.
2Stress or pressure
If abrasive fluid is mixed into high-pressure stream at pressures above 2,000 psi, then the abrasive can be delivered to the jet tool, but the mixing becomes ineffective
Solution Approach 1:
The abrasive slurry is mixed at low pressure before being delivered to the high-pressure pump system. This preliminary mixing action ensures that the abrasive particles are properly suspended and distributed in the fluid stream before the pressure is increased. The low-pressure mixing environment allows for effective mixing without the turbulence and energy loss that occur when trying to mix at high pressures.
Solution Approach 2:
The system separates the mixing function from the high-pressure delivery function. The low-pressure pump handles mixing and delivery of abrasive slurry, while the high-pressure pump handles the non-abrasive fluid delivery. This segmentation allows mixing to occur at optimal low pressure conditions while still achieving high pressure delivery at the jet tool through the combination of both pump outputs.
3Productivity
If abrasive jet perforating tools are designed with multiple jets and complex configurations, then the perforating effectiveness may improve, but the device complexity increases
Solution Approach 1:
The abrasive jet tool is designed to utilize the natural flow dynamics and pressure differential to self-regulate the jet operation. The tool body and jet arrangement are configured so that the abrasive slurry and non-abrasive fluid automatically mix and deliver effectively without requiring complex control mechanisms. The design allows the system to serve itself by using the pressure differential between the two fluid streams to maintain proper flow patterns and jet performance.
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 approach extends tool life, reduces operational costs by eliminating the need for specialized pumps, and enhances the effectiveness of abrasive jet perforating by ensuring abrasives reach full velocity before impacting the target, improving cutting performance.
Implementation Method 1
Abrasive jet perforating uses fluid slurry pumped under high pressure to perforate tubular goods around a wellbore, where the tubular goods include tubing, casing, and cement. Since sand is the most common abrasive used, this technique is also known as sand jet perforating (SJP).
Implementation Method 2
High pressure non-abrasive fluid is sent by a high pressure non-abrasive pump through a first high pressure valve to a first high pressure vessel. The first, second, and third high pressure valves are rotated to allow the high pressure non-abrasive fluid to push the abrasive slurry through the first high pressure vessel to an abrasive jet tool.
Implementation Method 3
Abrasive jet perforating uses fluid slurry pumped under high pressure to perforate tubular goods around a wellbore. Sand laden fluids were first used to cut well casing in 1939. Abrasive jet perforating was eventually attempted on a commercial scale in the 1960s.
Implementation Method 4
ensuring abrasives reach full velocity before impacting the target, improving cutting performance
Data Source
AI summary
A system for injecting high pressure abrasive fluid into an abrasive jet tool in a wellbore comprises an abrasives hopper; a slurry tank connected to the abrasives hopper; a low pressure abrasive pump connected to the slurry tank; a first high pressure vessel connected to the low pressure pump through a first high pressure valve; a high pressure non-abrasive pump connected to the first high pressure vessel through a second high pressure valve; and an abrasive jet tool connected to the first high pressure vessel through a third high pressure valve.