Crossover Joint Connecting Eccentric and Concentric Flow Paths
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Solution Overview
Problem
Current sand control systems in open-hole completions face challenges with premature sand bridging and incomplete gravel pack distribution due to inadvertent loss of carrier fluid, leading to exposure of wellbores to sand and fines infiltration, especially in inclined or irregular boreholes.
Innovation Solution
A crossover joint is introduced to connect eccentric and concentric flow paths, allowing for fluid communication between sand screens and packers, enabling gravel slurry bypass and maintaining wellbore integrity by using a crossover joint with primary and secondary flow paths that fluidly connect eccentric and concentric flow paths, ensuring complete gravel pack distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sand control system is used in open-hole completions, then sand and fines infiltration is prevented, but premature sand bridging occurs and gravel pack distribution becomes incomplete
Solution Approach 1:
The flow path is segmented into primary and secondary pathways. The primary flow path carries gravel slurry directly through the center, while secondary flow paths around the perimeter provide alternative routes. This segmentation ensures that even if carrier fluid is lost in certain areas, gravel can still reach all regions through multiple pathways, preventing incomplete gravel pack distribution.
Solution Approach 2:
A crossover joint with eccentric geometry acts as an intermediary component connecting different flow path configurations. The crossover joint includes a body with a primary flow path through its center and secondary flow paths in its perimeter, allowing gravel slurry to transition between different flow regimes and ensuring complete gravel pack distribution throughout the annulus.
2Ease of operation
If carrier fluid is used to transport gravel slurry, then gravel pack installation is enabled, but inadvertent loss of carrier fluid causes premature sand bridging
Solution Approach 1:
The system is designed with secondary flow paths and crossover joints in place before gravel slurry injection begins. This preliminary configuration ensures that if carrier fluid is lost during injection, gravel can still flow through alternative pathways, preventing premature sand bridging and ensuring complete gravel pack distribution without requiring perfect carrier fluid retention.
3Productivity
If eccentric flow paths are used in sand screens, then flow distribution is improved, but connection to concentric packers becomes complex
Solution Approach 1:
The crossover joint is designed as a universal connector that can interface with both eccentric sand screens and concentric packers. The joint includes a body with both primary flow path (for eccentric connection) and secondary flow paths (for concentric connection), allowing a single component to bridge different flow path configurations and enable complete gravel pack distribution.
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A wellbore apparatus and method comprising a first wellbore tool having a primary flow path and at least one secondary flow path and a second wellbore tool having a primary flow path and secondary flow path. A radial center of the primary flow path in the first wellbore tool is offset from a radial center of the primary flow path in the second wellbore tool which comprises a crossover joint connecting the first wellbore tool to the second wellbore tool having a primary flow path fluidly connecting the primary flow path of the first wellbore tool to the primary flow path of the second wellbore tool, and at least one secondary flow path fluidly connecting the at least one secondary flow path of the first wellbore tool to the at least one secondary flow path of the second wellbore tool.