Multi-cycle Circulating Tool Port Alignment Mechanism
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Solution Overview
Problem
There is a need for a reliable circulating tool that can be opened and closed multiple times to efficiently circulate fluid in a wellbore, particularly for wellbore cleanout operations, carrying drill cuttings, and sealing the formation.
Innovation Solution
A circulating tool comprising a bottom sub, mandrel, activation piston, port piston, inner sleeve, and index sleeve, which allows for selective alignment of ports to control fluid flow, enabling the tool to open and close multiple times by using pressure to move the components and align the ports for fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional circulating tool is used, then fluid can be circulated in the wellbore, but the tool cannot be reliably opened and closed multiple times
Solution Approach 1:
The circulating tool is divided into multiple segments including a body, inner sleeve, port piston, and activation piston that can move independently. This segmentation allows each component to perform specific functions during opening and closing cycles, enabling reliable repeated operation without excessive complexity in any single component.
Solution Approach 2:
The tool employs dynamic elements including the inner sleeve that can rotate to different positions, the port piston that moves axially, and the activation piston that responds to pressure changes. These dynamic components allow the tool to transition between open and closed states reliably multiple times while maintaining manageable complexity through coordinated motion rather than complex mechanical linkages.
2Reliability
If the circulating tool uses multiple moving components to enable repeated opening and closing, then reliability improves, but the device complexity increases
Solution Approach 1:
The tool features nested components where the inner sleeve is positioned within the body, the port piston moves within the inner sleeve, and the activation piston operates within the body cavity. This nesting arrangement allows multiple moving parts to coexist in a compact configuration, achieving reliable repeated opening and closing while minimizing the space and complexity required for each component.
Solution Approach 2:
The activation piston is actuated by hydraulic pressure from drilling fluid, and the port piston responds to pressure differential between the interior cavity and exterior. This pneumatic-hydraulic actuation mechanism replaces complex mechanical linkages with pressure-driven motion, enabling reliable repeated operation while reducing mechanical complexity.
3Productivity
If the tool aligns ports to control fluid flow, then fluid circulation is achieved, but the mechanism becomes more complex
Solution Approach 1:
The inner sleeve can rotate to different angular positions to dynamically align or misalign the inner sleeve port with the body port and mandrel port. This dynamic rotation provides efficient fluid circulation control by simply changing the angular position rather than using complex valve mechanisms, achieving high productivity with relatively simple port alignment.
Solution Approach 2:
The inner sleeve serves multiple functions: it acts as a structural component of the tool body, provides a rotating connection to the port piston, and controls fluid flow through port alignment. This multi-functionality reduces the need for separate dedicated components for each function, achieving efficient fluid circulation while minimizing overall device complexity.
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 tool effectively circulates fluid into the wellbore, allowing for reliable and repeated operation by aligning the mandrel, inner sleeve, and bottom sub ports to facilitate fluid flow, enhancing wellbore cleanout and sealing capabilities.
Implementation Method 1
supplying pressure to move an activation piston in a first direction and moving an inner sleeve in a second direction in response to moving the activation piston
Implementation Method 2
aligning the mandrel port and the inner sleeve port, thereby allowing fluid to flow out of the circulating tool
Data Source
AI summary
A method and apparatus for circulating fluid in a wellbore includes a bottom sub having a bottom sub port and a mandrel, wherein the mandrel substantially forms an inner bore of the circulating tool and includes a mandrel port. The circulating tool may also include an activation piston that is movable in a first direction and a port piston movable in a second direction when the activation piston moves in the first direction. The circulating tool may further include an inner sleeve coupled to the port piston and movable with the port piston, the inner sleeve having an inner sleeve port in selective communication with the mandrel port. When the inner sleeve port is in communication with the mandrel port at least partially, circulating fluid is allowed to flow through the bottom sub port to the wellbore.