Downhole Agitation Motor Valve System
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Solution Overview
Problem
Conventional downhole drilling systems face challenges in reducing friction on tool strings, particularly in horizontal drilling, where coiled tubing is prone to buckling and friction lock-up, and existing pulsation devices lack controlled, tunable pressure pulses and compatibility with coiled tubing.
Innovation Solution
A downhole agitation motor valve system and method that provides oscillating fluid flow using a pulsation valve system with a valve mandrel, oscillating valve head, and stationary valve head, aligned cyclically to reduce friction and advance tool strings, incorporating a rotor-driven design for efficient fluid flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If coiled tubing is used for downhole operations, then flexibility and ease of deployment are improved, but susceptibility to buckling and friction lock-up increases
Solution Approach 1:
The patent employs a pulsation valve system that generates mechanical vibrations and pressure pulses within the coiled tubing. The oscillating valve head creates controlled vibrations that prevent buckling by maintaining dynamic motion and reduce friction lock-up through vibrational forces that overcome static friction between the tubing and wellbore wall.
Solution Approach 2:
The pulsation valve system operates by periodically opening and closing the oscillating valve head, creating cyclic pressure pulses. This periodic action generates alternating flow patterns that prevent the coiled tubing from settling into a buckled configuration and continuously disrupt friction lock-up through repeated vibrational cycles.
2Force
If conventional cavitation devices are used to create pulsation, then vibration assistance for advancement is achieved, but controlled and tunable pressure pulses cannot be provided
Solution Approach 1:
The oscillating valve head is designed to dynamically adjust its position and oscillation characteristics based on operating conditions. The valve can be positioned at different angular positions and oscillate with varying amplitudes and frequencies, enabling controlled and tunable pressure pulse generation while maintaining the vibrational assistance needed for tool string advancement.
Solution Approach 2:
The system allows for parameter changes in the pressure pulses by adjusting the oscillation amplitude, frequency, and duty cycle of the valve head. These parameter adjustments enable tailored pressure pulse characteristics that can be optimized for different well conditions, formation types, and tool string configurations while maintaining effective vibration assistance.
3Ease of operation
If rotational and stationary valve flow heads are used, then fluid flow control is achieved, but separation between rotating and stationary valve members occurs under increased pressure
Solution Approach 1:
The patent merges the rotating and stationary valve functions into a single oscillating valve head that performs both functions. The oscillating valve head combines the flow control capabilities of a stationary valve with the dynamic positioning of a rotating valve, eliminating the interface between separate rotating and stationary members that would be prone to separation under pressure.
Solution Approach 2:
The oscillating valve head is nested within the valve body housing, with the oscillating mechanism contained within a compact structure. This nested design allows the valve to withstand high pressures while maintaining precise flow control, as the oscillating components are protected and constrained within the robust valve body.
4Device complexity
If direct on and off fluid flow is used in valve systems, then simple flow control is achieved, but increased pressure pulses damage the valve and downstream tools
Solution Approach 1:
Instead of direct on-off flow control, the system uses periodic action through the oscillating valve head that creates controlled pressure pulses. The oscillating valve opens and closes in a regulated manner, generating pressure waves that propagate through the fluid to reduce friction and assist advancement, while the periodic nature of the pulses prevents the damaging shock loads associated with abrupt flow changes.
Solution Approach 2:
The oscillating valve head creates pressure pulses that act as a cushioning mechanism before the main flow changes occur. These preliminary pressure waves prepare the fluid and tool string for upcoming flow changes, reducing the impact of pressure surges and preventing damage to the valve and downstream tools by cushioning the transition rather than allowing abrupt on-off changes.
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 system effectively reduces friction and advances tool strings by generating controlled pressure pulses, enhancing the ability to drill through challenging formations without causing damage to the valve or downstream tools, and is compatible with coiled tubing.
Implementation Method 1
providing oscillating fluid flow to a pulsation and/or agitation device
Implementation Method 2
generate controlled pressure pulses
Implementation Method 3
reducing friction acting on a tool string by oscillating fluid flow
Data Source
AI summary
A pulsation valve system and method can include a valve mandrel, an oscillating valve and a stationary valve. The valve mandrel can be operably coupled to and downstream of a rotor of a drilling motor. The oscillating valve can be attached to and rotatable with the valve mandrel. The stationary valve can be positioned adjacent and stationary with respect to the oscillating valve head. The stationary valve can include a stationary valve bore defined therethrough. The oscillating valve can include an oscillating valve bore defined therethrough that is alignable with the stationary valve bore at a predetermined rotational position. A valve mandrel cavity allows fluid to travel from the oscillating valve bore and down toward a tool. Rotation of the oscillating valve creates a cyclic obstruction with the stationary valve bore, that results in an agitation force on the drilling motor or bottom hole assembly.