Annular Casing Packer Collar Stage Tool Cementing
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Solution Overview
Problem
Conventional cementing tools require costly and time-consuming operations due to the need for multiple plug drops and the risk of premature rupture of rupture discs, which can lead to contamination and inefficiencies in cementing processes.
Innovation Solution
A stage tool that mechanically sets and expands a packer element by transmitting a load after a setting plug lands on a seat, eliminating the need for rupture discs and reducing the number of necessary plug drops, with confirmation of seat shifts by fluid pressure changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cementing tools use multiple plug drops and rupture discs for each stage operation, then the cementing process can be completed, but the operation time increases and the risk of premature rupture disc puncture occurs
Solution Approach 1:
The patent eliminates rupture discs from the cementing tool design, removing the component that causes premature puncture risks. The tool uses a mechanical setting mechanism with seats and plugs instead, where plugs are dropped into seats to trigger packer expansion without relying on rupture discs for pressure containment.
Solution Approach 2:
The cementing tool is divided into multiple stages with separate seats and plugs for each stage operation. Each stage has its own setting mechanism that can be independently activated by dropping a plug into the corresponding seat, allowing sequential cementing operations without requiring multiple separate tool deployments.
2Productivity
If conventional cementing tools require multiple plug drops for each stage operation, then the cementing process can be completed, but the equipment cost and operation complexity increase
Solution Approach 1:
The cementing tool incorporates multiple seats and corresponding plugs within a single tool assembly, allowing multiple stage operations to be performed with one tool deployment. The tool can sequence through multiple cementing stages by dropping plugs into different seats, eliminating the need for separate tool deployments or complex manual intervention for each stage.
Solution Approach 2:
The seats and plugs are pre-configured within the cementing tool before deployment. The mechanical setting mechanism is prepared in advance with all necessary components in place, so that when the tool is deployed, the plug drops automatically trigger the predetermined sequence of packer expansions and cementing operations without requiring complex real-time decision-making or additional equipment.
3Reliability
If rupture discs are used in conventional cementing tools to contain pressure, then pressure containment is achieved, but premature puncture can occur leading to contamination
Solution Approach 1:
The patent removes rupture discs from the system entirely, replacing them with a mechanical setting mechanism using seats and plugs. This eliminates the source of premature puncture and potential contamination, as the mechanical plug-seat interaction provides pressure containment without the fragility of rupture discs.
Solution Approach 2:
The mechanical seat and plug design provides a controlled, predictable pressure containment mechanism that avoids the unpredictable premature failure mode of rupture discs. The plug drops into the seat in a controlled manner, providing cushioning and gradual pressure build-up rather than sudden rupture, preventing contamination from premature failure.
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 solution reduces equipment costs, minimizes the risk of premature rupture disc puncture, and decreases operation time by eliminating the need for multiple plug drops, enhancing the efficiency and reliability of cementing processes.
Implementation Method 1
The packer element may be any suitable size, shape and configuration, and may expand, contract, set, un-set, or both, based on the mechanical load applied to the stage tool after a plug has landed on a seat
Data Source
AI summary
The present disclosure relates to multiple stage operations, and more particularly to systems and methods for performing second stage cementing operations with a stage tool. A stage tool comprises: a mandrel; an opening seat; a closing seat; a plurality of ports; a closing sleeve; and a packer element, wherein the opening seat is attached to an interior surface of the mandrel, wherein the closing seat is attached to the interior surface of the mandrel, wherein the plurality of ports is configured to allow fluid communication between the interior surface of the mandrel and an exterior surface of the mandrel, wherein the closing sleeve is disposed on the exterior surface of the mandrel and coupled to the closing seat, wherein the packer element is disposed on the exterior surface of the mandrel.