Cementing Stage Tool With Rupture-Disk Flow Control
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Solution Overview
Problem
Existing cementing stage tools struggle to selectively control fluid communication between a tubular string bore and an annulus during cementing operations, necessitating improvements for efficient cement placement and minimization of post-operation cleanup.
Innovation Solution
A cementing stage tool with an opening sleeve and rupture disks that respond to pressure differentials to allow controlled fluid communication, enabling plug displacement and cement flow management, reducing cement residue in the tubular string.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cementing stage tools are used to control fluid communication between tubular string bore and annulus, then cement placement control is improved, but cement residue in the tubular string increases
Solution Approach 1:
The tool performs preliminary actions by establishing fluid communication control before cement injection, using the opening plug and opening sleeve mechanism to prepare the flow path in advance. This allows the system to control cement placement while minimizing residue by having the communication path ready before the harmful cement flow occurs.
Solution Approach 2:
The opening plug acts as an intermediary element that mediates between the tubular string bore and the annulus. It provides a controlled interface for fluid communication, allowing cement to be placed where needed while preventing unwanted cement residue in the tubular string through the selective opening and closing of the flow path.
2Loss of substance
If fluid communication is prevented between flow passage and annulus, then cement residue is minimized, but cement placement efficiency decreases
Solution Approach 1:
The system dynamically controls fluid communication by transitioning between closed and open states. The opening sleeve can be displaced to open positions to allow efficient cement placement when needed, and closed positions to minimize residue. This dynamic adjustment optimizes both productivity and substance loss prevention.
Solution Approach 2:
The tool uses hydraulic pressure differentials to control the opening and closing of fluid communication paths. Pressure applied to the opening sleeve causes it to displace to open positions, enabling efficient cement placement. When pressure is released, the sleeve returns to closed positions to minimize residue, using hydraulic forces to optimize both efficiency and substance conservation.
3Loss of substance
If opening sleeve is held in closed position, then cement residue is reduced, but operation complexity increases
Solution Approach 1:
The opening sleeve mechanism is self-actuating through pressure differentials. When cementing pressure is applied, the opening sleeve automatically displaces to open positions without requiring external intervention. After cementing, it automatically returns to closed positions, reducing residue. This self-service operation simplifies the overall process despite the sophisticated control mechanism.
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
Facilitates controlled cement placement by minimizing cement residue in the tubular string, ensuring efficient operation and reduced post-cementing cleanup efforts.
Implementation Method 1
a rupture disk configured to prevent fluid flow between the flow passage and the housing port and permit fluid flow between the flow passage and the housing port in response to a predetermined pressure differential applied from the flow passage to the housing port
Data Source
AI summary
A method of cementing a tubular string in a wellbore can include applying a predetermined pressure differential from a flow passage extending axially through the tubular string to an annulus surrounding the tubular string, thereby opening a rupture disk of a cementing stage tool connected in the tubular string, and then flowing a fluid through the flow passage and into the annulus via the rupture disk, thereby displacing an opening plug into engagement with an opening sleeve of the cementing stage tool. A cementing stage tool can include a longitudinal flow passage, an outer housing assembly, an opening sleeve that prevents fluid flow between the flow passage and a housing port in a run-in configuration, and a rupture disk that permits fluid flow between the flow passage and the housing port in response to a predetermined pressure differential applied from the flow passage to the housing port.