Crossover Sub Erosion Resistant Inserts
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Solution Overview
Problem
Existing downhole tools face severe erosion issues due to high velocity and pressure proppant slurry, particularly at the crossover exit ports and inner housing surfaces, where previous designs either left the ports unprotected or created bypass streams, compromising the structural integrity and longevity of the assembly.
Innovation Solution
The implementation of erosion-resistant inserts with extending portions through the housing openings and inboard flanged surfaces that abut or overlap to provide comprehensive protection to both the inner housing face and exit ports, secured either to each other or the housing, effectively shielding against abrasive slurry impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardened inserts are placed in crossover ports to protect against erosion, then the port protection is improved, but the inner housing wall becomes exposed to erosion
Solution Approach 1:
The insert is designed with an L-shaped configuration where one leg protects the port opening and the other leg extends to protect the inner housing wall. This local quality principle ensures that different regions (port and housing wall) receive targeted protection from the same insert structure, resolving the contradiction between port protection and housing wall exposure.
2Ease of manufacture
If inserts are made flush with the internal housing wall, then installation is simplified, but bypass streams can form and undermine insert support
Solution Approach 1:
The insert protrudes beyond the housing wall by a predetermined amount (0.005-0.020 inches) to preemptively counteract the formation of bypass streams. This preliminary anti-action ensures that the slurry flow is blocked before it can erode the housing wall and undermine the insert support, while still maintaining ease of installation through the predetermined protrusion distance.
3Productivity
If higher flow rates and pressures are used to increase proppant delivery, then productivity is improved, but erosive effects on the tool increase
Solution Approach 1:
The insert is made from hardened material (Rockwell C50-65) that is significantly harder than the housing wall material (Rockwell C20-30). This composite material approach creates a protective barrier that can withstand the increased erosive forces generated by higher flow rates and pressures, enabling improved productivity without sacrificing tool integrity.
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
This solution effectively protects the inner housing surfaces and exit ports from erosive forces, preventing bypass streams and extending the operational life of the crossover tool by ensuring full coverage and secure positioning of the inserts, thus enhancing the tool's resistance to high-velocity slurry streams in fracturing and gravel packing operations.
Implementation Method 1
the erosion problem was present but manageable. More recently, the need for higher delivery rates and higher operating pressures such as when proppant delivery was also combined with formation fracturing has made the erosion problem more acute.
Data Source
AI summary
A crossover tool that resists the erosive forces of high velocity slurry streams of gravel in downhole fracturing and gravel packing operations employs hardened inserts that protect the inside face of the housing as well as the openings through the crossover housing wall. The inserts have an extending portion that goes through housing openings preferably to the outer surface of the housing. The inserts also have inboard flanged surfaces that preferably abut or overlap to give preferably full inner wall protection to the housing from the flow of abrasive slurry. The inserts can be secured to each other or to the interior of the housing to hold them firmly in place.