Abrasive Slurry Tool for Downhole Opening Precision

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Solution Overview

Problem

Existing methods for creating openings in downhole structures, such as 'windows' in production tubing, result in inconsistent and rough shapes, making sealing difficult due to unknown shapes and edge roughness, and abrasive slurry tools face issues like settling and machinery wear under high pressure.

Innovation Solution

An abrasive slurry tool with a high-pressure assembly and a low-pressure assembly in fluid communication, featuring a nozzle assembly and a low-pressure holding tank for rechargeable abrasive fluid, which emits high-pressure abrasive fluid to create precise openings, adjustable for direction and proximity, and uses a thixotropic fluid for suspension and pumpability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If standard milling equipment is used to create openings in production tubing, then openings can be created, but the opening shape is inconsistent and edges are rough, making sealing difficult

Engineering Contradiction:

Improveopening shape consistencyVSAvoidsealing difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical milling system with a high-pressure abrasive slurry injection system. The mechanical cutter is substituted by a nozzle assembly that injects abrasive-laden fluid at high pressure (up to 10,000 psi) to erode material away, creating smooth, consistent openings suitable for sealing while avoiding the rough edges produced by mechanical cutting.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters by using high-pressure abrasive fluid instead of mechanical force. The high pressure (up to 10,000 psi) combined with abrasive particles in the slurry creates a controlled erosion process that produces consistent opening shapes and smooth edges, fundamentally changing how the opening is created from mechanical removal to fluid-mediated erosion.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If abrasive slurry is used to cut openings in the downhole environment, then cutting can occur, but the abrasive material settles and machinery wears under very high operating pressure

Engineering Contradiction:

Improvecutting capabilityVSAvoidabrasive material settling and machinery wear

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent segments the abrasive slurry delivery system into a surface-supplied high-pressure pump system and a downhole nozzle assembly. The pump is located at the surface where it can be optimized for pressure generation, while the nozzle at the downhole location delivers the abrasive slurry. This segmentation allows the system to achieve high pressure without requiring the entire downhole tool to withstand extreme pressures, reducing machinery wear.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses a gas lift or pneumatic system as an intermediary to deliver the abrasive slurry to the downhole location. Instead of pumping abrasive slurry directly through the tool at high pressure (which causes settling and wear), the gas lift acts as a mediator to transport the slurry, allowing the tool to operate at lower pressures while still achieving effective cutting.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If high-pressure abrasive fluid is used to create openings, then precise and consistent openings can be created, but the tool requires complex high-pressure assemblies and surface-supplied fluids

Engineering Contradiction:

Improveopening precisionVSAvoidtool assembly complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent incorporates a self-contained abrasive slurry delivery system within the tool that can be recharged downhole. The tool includes a holding tank that can be refilled with abrasive slurry at the wellhead without requiring complex surface-supplied fluid delivery systems. This self-service capability simplifies the overall system by eliminating the need for complex high-pressure fluid delivery infrastructure while maintaining opening precision.

Inventive Principle:

Principle #25Self-service

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 effectively creates consistent and precise openings with adjustable precision and speed, reducing the need for high-horsepower pumps and surface-supplied fluids, maintaining fluid suspension and reducing wear on machinery, enabling efficient sealing and cutting in downhole environments.

Implementation Method 1

actuating the tool to emit high pressure abrasive fluid at the target structure

Methodology Applied

Scientific EffectHigh-pressure fluid flow: Pressure Gradient

Implementation Method 2

abrasively affecting the target structure

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 3

uses a thixotropic fluid for suspension and pumpability

Methodology Applied

Scientific EffectThixotropy: Thixotropy

Data Source

PatentUS8047291B2Tool and method for abrasive formation of openings in downhole structures

Publication Date: 2011.11.01 BAKER HUGHES CO

AI summary

An abrasive slurry tool, the tool being attachable to a running string, the tool including a high-pressure assembly, the assembly including a nozzle assembly; and a low-pressure assembly in abrasive fluid communication with the high-pressure assembly, the low-pressure assembly comprising a low pressure holding tank configured to carry recharge abrasive fluid with the tool and method.