Breachable Obstruction Stage Tool for Deviated Well Cementing
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Solution Overview
Problem
Current hydraulically-operated stage tools face challenges in deviated wells due to issues with opening and closing mechanisms, particularly in high bend radius wells, and often have lower burst and collapse pressure ratings, which can lead to tool failure during cementing operations in development wells requiring high pressures.
Innovation Solution
A stage tool design featuring a breachable obstruction, such as a rupture disc, and a secondary closure mechanism that includes a piston and chamber to manage fluid pressure, allowing for controlled communication between the tool's bore and the wellbore annulus, and a closure sleeve that can be moved to seal off the exit port, along with rotational catches to prevent rotation and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hydraulically-operated stage tool is used in deviated wells, then the tool can be operated in high bend radius wells, but the opening and closing mechanisms face operational challenges
Solution Approach 1:
The patent inverts the traditional opening mechanism by using a breachable obstruction (rupture disc) that fails open under pressure rather than a mechanism that opens closed. This inversion simplifies operation in deviated wells by eliminating complex opening mechanisms that struggle in high bend radius conditions.
Solution Approach 2:
The patent extracts the opening function from the mechanical mechanism and transfers it to the breachable obstruction system. The rupture disc is positioned at the exit port and opens automatically when internal pressure exceeds the disc's burst pressure, removing the need for mechanical opening components that are difficult to operate in deviated wells.
2Strength
If conventional stage tools are used, then the structure is simpler, but the burst and collapse pressure ratings are lower leading to tool failure
Solution Approach 1:
The patent segments the tool structure into distinct functional components: a reinforced housing for pressure containment, a breachable obstruction for controlled opening, a closure sleeve for sealing, and rotational catches for positional control. This segmentation allows each component to be optimized for its specific function, achieving high pressure ratings while maintaining manageable complexity.
Solution Approach 2:
The housing is designed with composite construction combining high-strength materials to withstand burst and collapse pressures. The integration of multiple materials with different properties (strength, flexibility, sealability) enables the tool to achieve superior pressure ratings compared to conventional single-material constructions.
3Ease of operation
If a breachable obstruction is added to control fluid communication, then cement slurry flow is controlled, but the device complexity increases
Solution Approach 1:
The breachable obstruction system is self-activating based on internal pressure conditions. When cement slurry pressure exceeds the rupture disc's burst pressure, the disc automatically opens without requiring external control mechanisms. This self-service approach simplifies operation while the added component provides precise flow control.
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 design improves the ability to operate in deviated wells by allowing for controlled cement slurry communication and sealing, while increasing the tool's resistance to burst and collapse pressures, making it suitable for high-pressure applications.
Implementation Method 1
a breachable obstruction, such as a rupture disc or other temporary closure, preventing fluid communication through the exit port. In response to a first fluid pressure component in the housing's bore, however, the breachable obstruction opens fluid communication through the exit port
Implementation Method 2
a secondary closure mechanism that includes a piston and chamber to manage fluid pressure
Data Source
Figure 1A~1B
Figure 2~2D
Figure 3A~3B
AI summary
A stage tool operable with a plug is used for cementing a tubing string in a wellbore annulus. The tool can have a housing with a closure sleeve movably disposed in the internal bore of the housing. When pressure is applied downhole to the tool, a breachable obstruction on an exit port of the tool's bore opens and allows fluid such as cement slurry to communicate to the wellbore annulus. When cementing through the open tool finished, a plug deployed downhole lands on a seat in the closure sleeve, and applied fluid pressure in the tool's bore against the seated plug closes the closure sleeve relative to the housing's exit port. Rotational catches between the housing's bore and the closure sleeve prevent the closure sleeve from rotating. Preferably, an intermediate sleeve is used in the housing's bore and has rotational catches on each end. When the closure sleeve moves closed, the intermediate sleeve is also moved to engage between the catches on the end of the closure sleeve and the catches on a shoulder of the housing's bore. In further arrangements, a hydraulic mechanism on the tool can facilitate movement of the closure sleeve in response to a fluid pressure component.