Bypass Device for Drilling Fluid Diversion and ECD Control

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Solution Overview

Problem

In drilling wellbores, particularly in highly deviated wells, cuttings tend to settle and not efficiently flow to the surface due to inadequate circulating fluid flow rate, and there is a need to reduce equivalent circulation density (ECD) at the wellbore bottom.

Innovation Solution

A bypass device with a fluid passage is used, equipped with sensors to detect flow rate and pressure differential, and a controller that activates the bypass to divert drilling fluid from the drill string to the annulus when specific parameters are met, ensuring efficient hole cleaning and ECD control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If drilling fluid is supplied through the drill string to the bottom, then the drill bit can effectively disintegrate rock formation, but in highly deviated wells the cuttings tend to settle at the low side and flow rate becomes inadequate for efficient cuttings removal

Engineering Contradiction:

Improvecuttings removal efficiencyVSAvoidfluid flow rate

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

The drilling fluid flow path is segmented into two separate paths: (1) through the drill string to the drill bit for rock disintegration, and (2) through the bypass device directly into the annulus for cuttings removal. This segmentation allows independent optimization of each flow path's function and rate.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bypass device acts as an intermediary component that diverts a portion of the drilling fluid from the drill string into the annulus. This intermediary mechanism enables controlled fluid diversion to improve cuttings transport without compromising the primary drilling function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If drilling fluid flow rate is increased to improve cuttings removal, then hole cleaning efficiency improves, but equivalent circulation density (ECD) at the wellbore bottom increases

Engineering Contradiction:

Improvehole cleaning efficiencyVSAvoidequivalent circulation density (ECD)

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

Instead of increasing total fluid flow rate, the bypass device implements partial action by diverting only a portion of the drilling fluid into the annulus. This partial diversion improves hole cleaning efficiency while avoiding the excessive ECD increase that would result from increasing overall flow rate.

Inventive Principle:

Principle #16Partial or excessive action

3Productivity

If a bypass device is added to divert fluid to the annulus, then hole cleaning and ECD control improve, but device complexity increases

Engineering Contradiction:

Improvehole cleaning efficiencyVSAvoidbypass device structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The bypass device is designed with multi-functionality to justify its added complexity: it serves as a flow divider, a cuttings removal enhancer, an ECD control mechanism, and potentially a stabilization device. This universal application of a single component optimizes its value-to-complexity ratio.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution enhances fluid flow through the annulus, improving hole cleaning and reducing ECD, allowing for better cuttings removal and efficient drilling operations by diverting a portion of the drilling fluid based on real-time parameters.

Implementation Method 1

activating the bypass device when the selected drilling parameter and one of the second flow rate and the differential pressure are present during the defined time period to divert a portion of the drilling fluid from the bypass device to the annuls

Methodology Applied

Scientific EffectFluid flow diversion:

Implementation Method 2

a first sensor configured to determine one of a flow rate and a pressure differential between the fluid in the bypass device and the annulus

Methodology Applied

Scientific EffectPressure differential detection:

Data Source

PatentUS9103180B2Drilling apparatus including a fluid bypass device and methods of using same

Publication Date: 2015.08.11 BAKER HUGHES CO

AI summary

In one aspect, the disclosure provides a method of drilling a wellbore, which method, in one embodiment, includes the features of drilling the wellbore with a drill string that includes a bypass device having a fluid passage therethrough by supplying a fluid through the bypass device, wherein the drilling fluid circulates to the surface via an annulus between the drill string and the wellbore; defining a time period (locking time); initiating a selected drilling parameter; detecting downhole the selected drilling parameter and one of the second flow rate and a differential pressure; and activating the bypass device when the selected drilling parameter and one of the second flow rate and the differential pressure are present during the defined time period to divert a portion of the drilling fluid from the bypass device to the annuls. In one aspect, the selected drilling parameter is rotation of a member associated with the bypass device.