Abrasive Perforating Tool Flow Control Mechanism

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Solution Overview

Problem

Existing abrasive perforating tools face challenges in horizontal wellbores due to fill material gathering around the outer diameter of the bottom hole assembly during reverse circulation, leading to inefficient clean-out operations, as gravity-assisted flow is not effective and annular velocity may not be sufficient to sweep debris to the end of the tool.

Innovation Solution

A multi-cycle abrasive perforating tool that cycles between flow-through and perforating modes, utilizing a piston and mandrel mechanism with seals to ensure fluid flow through a central opening in flow-through mode and lateral jetting ports in perforating mode, preventing split flow and optimizing fluid direction for effective clean-out and perforation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If reverse circulation is used for clean-out, then fluid can be pumped down the coiled tubing and up the annulus, but fill material gathers around the outer diameter of the bottom hole assembly in horizontal wellbores

Engineering Contradiction:

Improveclean-out operationVSAvoidfill material gathering

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent inverts the traditional reverse circulation approach by using a plunger and seat mechanism to force fluid through the central opening in one direction, then reversing the flow path through the same central opening in the opposite direction. This controlled inversion prevents fill material from gathering around the BHA outer diameter by maintaining centralized flow through the tool rather than allowing annular flow that would deposit material on the BHA surface.

Inventive Principle:

Principle #13The other way round (Inversion)

2Productivity

If conventional abrasive perforating is used, then casing can be perforated, but clean-out function is insufficient in horizontal wellbores

Engineering Contradiction:

Improveperforation efficiencyVSAvoidclean-out effectiveness

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent creates a multi-functional tool that combines abrasive perforating capability with effective clean-out functionality in a single device. The same central opening and plunger mechanism that enable controlled fluid direction for perforation also provide the clean-out function by directing high-velocity fluid to sweep debris. This universal design eliminates the need for separate perforating and clean-out tools, particularly benefiting horizontal well operations where both functions are needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If fluid flow is not directed through central opening in flow-through mode, then split flow occurs, but proper fluid direction is lost

Engineering Contradiction:

Improvefluid flow controlVSAvoidfluid flow direction

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent introduces a plunger as an intermediary component that acts as a mediator between the fluid source and the jetting ports. The plunger, working with the seat and seals, controls and directs fluid flow through the central opening, preventing split flow. This intermediary mechanism ensures reliable fluid direction by physically blocking alternative flow paths and channeling all fluid through the intended route, whether in flow-through mode or perforating mode.

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

The tool ensures efficient clean-out and perforation by maintaining fluid flow through the central opening during flow-through mode and directing it through lateral jetting ports during perforating mode, effectively managing debris removal and casing perforation without relying on gravity or high annular velocity.

Implementation Method 1

Abrasive perforating tools utilize custom lateral jetting ports that allow a fluid containing abrasive particles, e.g., sand, to be pumped downhole through the working string at high pressures and then out of the jetting ports. The abrasive fluid erodes through the surrounding casing at a designated depth, then through the cement and out into the surrounding rock formation.

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Gradient

Data Source

PatentUS10927648B2Apparatus and method for abrasive perforating and clean-out

Publication Date: 2021.02.23 WORKOVER SOLUTIONS INC

AI summary

A perforating tool and method of use in a wellbore. The perforating tool is placed at the end of a coiled tubing or other conveyance string. The perforating tool comprises a tubular housing providing an elongated bore through which fluid flows. The tubular housing has jetting ports used for hydraulic perforating. The tool operates in a flow-through mode when working fluid is pumped into the tubular housing at a first flow rate, with all of the fluid flowing through the end of the tool. The perforating tool operates in a perforating mode when the working fluid is pumped into the bore of the tubular housing at a second flow rate. In this mode, all of the working fluid flows through the jetting ports. The perforating tool may include a sequencing mechanism responsive to a sequence of flow rates to cycle the tool through operating modes.