Continuous Flow Drilling System Spoolpiece Valve
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Solution Overview
Problem
Current drilling methods interrupt fluid circulation when adding or removing drill string sections, leading to formation damage, wellbore instability, and increased costs due to mud weight adjustments, as well as challenges in maintaining continuous cuttings removal.
Innovation Solution
A continuous flow drilling system that maintains drilling fluid circulation by injecting fluid at a first rate through a tubular string with a port, allowing for remote plug operation to add or remove sections while maintaining fluid flow, using a float valve and hydraulic actuator to control fluid pressure and flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If drill string sections are added or removed by stopping drilling and interrupting fluid circulation, then tubular joints can be connected or disconnected, but formation damage occurs, wellbore stability deteriorates, and operational time increases
Solution Approach 1:
The patent employs a spoolpiece with a valve assembly that enables continuous drilling fluid circulation during drill string modifications. The valve can be closed to isolate the drill string from the annulus, allowing tubular joints to be added or removed while maintaining fluid flow through the spoolpiece and into the annulus, thus preventing formation damage and wellbore instability that would occur with circulation interruption
Solution Approach 2:
The spoolpiece acts as an intermediary device between the drill string and the annulus. It provides a separate fluid pathway that allows drilling fluid to continue circulating in the annulus even when the drill string is disconnected or modified, serving as a mediator that maintains wellbore stability during operations that would otherwise require circulation shutdown
2Adaptability or versatility
If drilling fluid circulation is interrupted to add or remove tubular joints, then drill string configuration can be modified, but mud weight adjustments become necessary and operational costs increase
Solution Approach 1:
The spoolpiece with integrated valve assembly maintains continuous drilling fluid circulation in the annulus during drill string modifications. By closing the valve to isolate the drill string while keeping the annulus flow path open, the system eliminates the need to stop circulation, adjust mud weight, and restart pumps, thereby reducing operational time and costs while maintaining drill string configuration flexibility
3Reliability
If relatively viscous drilling fluid is used to maintain cuttings suspension during flow cessation, then cuttings can remain suspended, but more power is required to pump the fluid
Solution Approach 1:
The spoolpiece system maintains continuous drilling fluid circulation throughout the wellbore, eliminating periods of flow cessation. By keeping the fluid constantly moving through both the drill string and annulus, cuttings remain suspended without requiring increased fluid viscosity, thus avoiding the additional pumping power that would be needed to circulate thicker fluids
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
Enables uninterrupted drilling fluid circulation during drill string modifications, reducing formation damage and operational costs, while effectively conveying cuttings and maintaining wellbore stability.
Implementation Method 1
a clamp operable to engage an outer surface of the housing and seal the port, the clamp comprising a hydraulic actuator operable to remove the plug from the port and install the plug into the port
Implementation Method 2
using a float valve and hydraulic actuator to control fluid pressure and flow rates
Implementation Method 3
The drilling fluid and cuttings returns to the surface via an annulus formed between the drill string and the wellbore
Implementation Method 4
The drilling fluid exits the drill bit and carries cuttings from the drill bit
Data Source
AI summary
In one embodiment, a method for drilling a wellbore includes injecting drilling fluid into a top of a tubular string disposed in the wellbore at a first flow rate. The tubular string includes: a drill bit disposed on a bottom thereof, tubular joints connected together, a longitudinal bore therethrough, and a port through a wall thereof. The drilling fluid exits the drill bit and carries cuttings from the drill bit. The cuttings and drilling fluid (returns) flow to the surface via an annulus defined between the tubular string and the wellbore. The method further includes rotating the drill bit while injecting the drilling fluid; remotely removing a plug from the port, thereby opening the port; and injecting drilling fluid into the port at a second flow rate while adding a tubular joint or stand of joints to the tubular string. The injection of drilling fluid into the tubular string is continuously maintained between drilling and adding the joint or stand to the drill string. The method further includes remotely installing a plug into the port, thereby closing the port. The first and second flow rates may be substantially equal or different.