Continuous Circulation Tool for Drilling Mud Pressure Control
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Solution Overview
Problem
Current drilling systems face challenges in maintaining continuous circulation of drilling mud during the make-up or break-out of drill pipe sections, leading to pressure fluctuations and increased risk of 'kicks' and formation damage, especially when dealing with varying formation pressures and poor drilling mud properties.
Innovation Solution
A method and apparatus that utilize a continuous circulation tool with a closure mechanism to selectively control drilling mud flow through a sub, allowing for continuous circulation by directing mud flow from a housing into the sub and back to the wellbore, using a powered extendible member and a tubular manipulation apparatus to facilitate connection and disconnection of drill pipe sections while maintaining fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a fill valve or mud saver valve is used to contain pressure in the drill string during make-up or break-out of drill pipe, then pressure is substantially maintained in the well, but circulation of drilling fluid is stopped and pressure changes occur causing increased risk of kicks
Solution Approach 1:
The patent implements continuous circulation of drilling fluid through the drill string during make-up and break-out operations by using a circulation tool with a bypass passage. The bypass passage allows mud to flow continuously from the drill string through the circulation tool and back, eliminating the need to stop circulation for valve connections. This continuous action prevents pressure fluctuations and kick risks while maintaining well pressure control.
2Ease of operation
If drilling mud circulation is stopped during make-up or break-out of drill pipe, then valve connection can be performed, but drilled cuttings sink and pressure changes occur
Solution Approach 1:
The circulation tool maintains continuous mud circulation through the drill string during valve connection operations. The bypass passage ensures that drilling mud continues to flow and suspend cuttings throughout the make-up and break-out processes, preventing cuttings from sinking while allowing valve operations to proceed without interrupting circulation.
3Stability of the object's composition
If additional fluid weighting is used to maintain cuttings suspension, then cuttings remain in suspension, but viscosity increases requiring more pumping power and causing over pressuring of the wellbore
Solution Approach 1:
Instead of increasing fluid weighting to maintain cuttings suspension, the patent uses continuous circulation through the bypass passage to keep cuttings suspended. This approach maintains cuttings suspension without requiring additional weighting agents, thereby avoiding increased viscosity and the need for higher pumping power that would otherwise cause wellbore over-pressuring.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A method for facilitating continuous circulation of drilling mud during construction and maintenance of a well, the method comprising the steps of moving a housing (102) of a continuous circulation tool (100) to a sub (10) having a bore (14) therethrough, the sub (10) in or for connection in a string of tubular s in the well and selectively allowing drilling mud to flow between the housing (102) and a side opening (13) in the sub (10), the continuous circulation tool (100) further comprising a closure apparatus (40), activating a closure mechanism (41,44) to insert a closure member (42) of the closure apparatus (40) through the side opening (13) in the sub (10) to isolate of drilling fluid through at least a portion of the bore (14). Also disclosed in a system for continuous circulation wellbore operations, the system comprising a continuous circulation tool (100) positionable in fluid communication with a wellbore tubular string comprising a sub (10) therein, the continuous circulation tool (100) for selectively closing off flow to the wellbore tubular string, tubular manipulation apparatus (202) adjacent the sub, and the tubular manipulation apparatus comprising one of tong, tongs, tong and back-up, tong and spinning wrench, and iron roughneck.