Bi-diameter Wiper Cup Tracking via Pressure Spikes
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Solution Overview
Problem
Current wiper dart designs require multiple wiper cups with varying outer diameters to effectively wipe the inside of tool joints and pipe sections, leading to increased costs, complexity, and potential supply chain issues, as well as challenges in tracking the location of the wiper dart within the wellbore.
Innovation Solution
A wiper dart equipped with a single bi-diameter wiper cup that has two different outer diameters, allowing it to effectively wipe both the inside of tool joints and pipe sections, and a method to track its location by observing detectable pressure spikes as it traverses from pipe sections into tool joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wiper cups with varying outer diameters are used to wipe both tool joints and pipe sections, then the wiping effectiveness is improved, but the device complexity and cost increase
Solution Approach 1:
The wiper cup is designed with a bi-diameter configuration where a single cup performs the wiping function for both tool joints and pipe sections. The cup has a first diameter for wiping tool joints and a second diameter for wiping pipe sections, allowing one component to replace multiple specialized components while maintaining effective wiping across different geometries
Solution Approach 2:
Multiple wiping functions that previously required separate wiper cups are merged into a single bi-diameter wiper cup. The cup integrates two different diameter surfaces on one component, combining the functionality of what would otherwise be two or more separate parts into a unified structure
2Reliability
If multiple wiper cups with varying outer diameters are used to wipe both tool joints and pipe sections, then the wiping effectiveness is improved, but the manufacturing cost increases
Solution Approach 1:
Multiple wiping functions that previously required separate wiper cups are merged into a single bi-diameter wiper cup. The cup integrates two different diameter surfaces on one component, combining the functionality of what would otherwise be two or more separate parts into a unified structure
Solution Approach 2:
The wiper cup is designed with a bi-diameter configuration where a single cup performs the wiping function for both tool joints and pipe sections. The cup has a first diameter for wiping tool joints and a second diameter for wiping pipe sections, allowing one component to replace multiple specialized components while maintaining effective wiping across different geometries
3Device complexity
If a single bi-diameter wiper cup is used, then the device complexity is reduced, but the ability to effectively wipe both tool joints and pipe sections may be compromised
Solution Approach 1:
The wiper cup is designed with a bi-diameter configuration where a single cup performs the wiping function for both tool joints and pipe sections. The cup has a first diameter for wiping tool joints and a second diameter for wiping pipe sections, allowing one component to replace multiple specialized components while maintaining effective wiping across different geometries
Solution Approach 2:
Different regions of the wiper cup have different diameters optimized for specific surfaces. The first diameter region contacts tool joints while the second diameter region contacts pipe sections, allowing each local area of the cup to be specifically tailored for its intended wiping surface
4Loss of information
If traditional wiper dart design is used, then the location tracking is difficult, but the device structure is simpler
Solution Approach 1:
The system uses pressure sensors to detect pressure spikes generated when the wiper cup transitions from pipe sections to tool joints. This pressure feedback is transmitted to the surface where it is processed to determine the wiper dart's location, creating a closed-loop information system that provides real-time tracking without adding mechanical complexity to the wiper dart itself
Solution Approach 2:
Pressure spikes serve as an intermediary signal that indirectly indicates the wiper dart's location. Instead of directly measuring position, the system detects pressure changes caused by the wiper cup interacting with different pipe geometries, using these pressure variations as a proxy for location information
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 bi-diameter wiper cup design reduces the number of wiper cups required, simplifying the wiper dart and potentially lowering costs, while the pressure spike tracking method allows for more accurate location monitoring of the wiper dart within the wellbore.
Implementation Method 1
observing detectable pressure spikes as the wiper cup traverses from each drill pipe section into each tool joint
Data Source
AI summary
A wiper dart having a bi-diameter wiper cup can be used to help track the location of the dart in a pipe string. As the wiper dart is pumped through the pipe string, a first mean pump pressure will exist as the wiper cup travels through drill pipe sections having a larger inner diameter than a tool joint and a second mean pump pressure will exist as the wiper cup travels through the tool joints. The wiper cup can have a geometric shape selected such that a detectable pressure spike can be observed when the wiper cup reaches a transition section located between one end of a pipe section and the tool joint. By counting the number of pressure spikes, an operator can accurately track the location of the wiper dart as it is being pumped through the pipe string.