Annulus Flow Control Tool Bypass Mechanism

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Solution Overview

Problem

Existing well operations face challenges in controlling fluid flow through the annulus, particularly when disconnecting tubulars, which can lead to the 'U-tubing' effect, causing fluid displacement and air entry, thereby affecting subsequent operations.

Innovation Solution

The introduction of an annulus flow control tool with a tubular inner mandrel, a displaceable sleeve, and external annular seals that can move between bypass open and closed positions in response to pressure differentials, allowing for controlled fluid flow through a bypass flow path.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If tubulars are disconnected during well operations, then operational flexibility is improved, but fluid displacement and air entry occur due to the U-tubing effect

Engineering Contradiction:

Improvetubular disconnectionVSAvoidfluid flow control

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The annulus flow control tool serves as an intermediary device installed in the tubular string to mediate between the need for tubular disconnection and the need to prevent U-tubing. The tool includes a bypass flow path with controllable openings that allow operators to disconnect tubulars while maintaining annulus flow control, preventing harmful fluid displacement and air entry

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The annulus flow control tool incorporates dynamically controllable bypass flow path openings that can be opened or closed as needed. This dynamic control allows the system to adapt to different operational states - allowing flow during normal operations and blocking flow during tubular disconnection to prevent U-tubing, thereby resolving the contradiction between operational flexibility and fluid flow control reliability

Inventive Principle:

Principle #15Dynamics

2Reliability

If annulus flow is blocked to prevent U-tubing, then fluid flow control is improved, but operational flexibility deteriorates

Engineering Contradiction:

Improvefluid flow controlVSAvoidoperational flexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The bypass flow path with controllable openings provides dynamic flow control, allowing the system to switch between blocked and open states based on operational needs. This resolves the contradiction by enabling both reliable flow control (when blocked) and operational flexibility (when opened for tubular disconnection)

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If bypass flow path is opened to allow annulus flow, then operational flexibility is improved, but U-tubing effect occurs causing fluid displacement

Engineering Contradiction:

Improvetubular disconnectionVSAvoidfluid displacement

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The controllable bypass flow path openings enable dynamic control where the flow path can be opened to allow tubular disconnection operations and then closed to prevent U-tubing and fluid displacement during subsequent operations, resolving the contradiction between operational flexibility and prevention of harmful fluid displacement

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The tool acknowledges that opening the bypass flow path enables tubular disconnection (beneficial) but converts the potential harm of U-tubing into a controlled situation by providing the ability to close the flow path afterward, transforming the harmful fluid displacement issue into a manageable operational parameter

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 effectively prevents the 'U-tubing' effect by blocking fluid flow through the annulus during tubular disconnection, ensuring consistent operation and preventing air entry into the tubular string.

Implementation Method 1

at least one external annular seal configured to sealingly engage the well surface

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

a bypass flow path configured to allow fluid flow through the annulus when the external annular seal is in the bypass open position

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 3

The external annular seal may be adapted to displace in response to a pressure differential between a bypass open position and a bypass closed position

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS12241336B2Control of annulus return flow in well operations

Publication Date: 2025.03.04 WEATHERFORD TECHNOLOGY HOLDINGS LLC

AI summary

An annulus flow control tool can include an inner mandrel with a longitudinal bypass flow path, a sleeve on the inner mandrel, the sleeve being displaceable on the inner mandrel between bypass open and bypass closed positions, and at least one annular seal carried externally on the sleeve. A method of controlling annulus flow can include connecting an annulus flow control tool in a tubular string, the annulus flow control tool including a bypass flow path and at least one external annular seal, deploying the tubular string into the well, sealingly engaging a well surface with the annular seal, flowing a fluid through the tubular string into the well, thereby causing another fluid in an annulus between the tubular string and the well surface to flow through the bypass flow path, and closing the bypass flow path, the annulus flow control tool thereby blocking flow through the annulus.