Crossover Tool Segmented Flow Path for Mud Pulse Telemetry
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Solution Overview
Problem
Existing crossover tools in frac-pack and gravel packing operations have restricted flow paths during circulation and reverse operations, leading to low signal-to-noise ratios in mud pulse telemetry, which hampers effective data transmission during completion operations.
Innovation Solution
A new crossover position is introduced between the circulation and reverse positions in the crossover tool, allowing flow to be redirected through the production tubing and upper annulus directly to a mud pulse transmitter, creating a discrete flow path that minimizes signal noise by avoiding the screens and gravel pack, and utilizing the Smart Collet to define this position for optimal data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flow path is restricted in existing crossover tools during circulation, then flow direction control is achieved, but signal-to-noise ratio in mud pulse telemetry deteriorates
Solution Approach 1:
The flow path is segmented into multiple independent channels: a restricted circulation path for gravel deposition and a separate unrestricted telemetry path for data transmission. The crossover tool includes distinct ports and passages that allow flow to be directed differently for circulation versus telemetry functions, resolving the contradiction by providing dedicated pathways for each function.
Solution Approach 2:
The crossover tool employs movable components such as sliding sleeves and shift tools that can dynamically reconfigure the flow path. By shifting the tool or moving internal components, the system transitions between circulation mode (restricted flow) and telemetry mode (unrestricted flow), allowing optimal conditions for each function at different operational stages.
2Measurement precision
If flow path is unrestricted in upper annulus during reverse operation, then signal-to-noise ratio improves, but flow control capability deteriorates
Solution Approach 1:
The flow path is segmented into multiple independent channels: a restricted circulation path for gravel deposition and a separate unrestricted telemetry path for data transmission. The crossover tool includes distinct ports and passages that allow flow to be directed differently for circulation versus telemetry functions, resolving the contradiction by providing dedicated pathways for each function.
Solution Approach 2:
The crossover tool employs movable components such as sliding sleeves and shift tools that can dynamically reconfigure the flow path. By shifting the tool or moving internal components, the system transitions between circulation mode (restricted flow) and telemetry mode (unrestricted flow), allowing optimal conditions for each function at different operational stages.
3Productivity
If crossover tool is used for gravel deposition, then packing operation is achieved, but data transmission capability deteriorates due to flow restrictions
Solution Approach 1:
The flow path is segmented into multiple independent channels: a restricted circulation path for gravel deposition and a separate unrestricted telemetry path for data transmission. The crossover tool includes distinct ports and passages that allow flow to be directed differently for circulation versus telemetry functions, resolving the contradiction by providing dedicated pathways for each function.
Solution Approach 2:
The crossover tool employs movable components such as sliding sleeves and shift tools that can dynamically reconfigure the flow path. By shifting the tool or moving internal components, the system transitions between circulation mode (restricted flow) and telemetry mode (unrestricted flow), allowing optimal conditions for each function at different operational stages.
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 configuration enhances signal-to-noise ratios during data transmission by providing an unrestricted flow path, enabling real-time data collection and transmission during gravel packing operations, even in deep wells, and allows for efficient communication of operational parameters like pressure and weight settings.
Implementation Method 1
Mud pulse telemetry has been used to transmit a variety of information to the surface
Data Source
AI summary
A completion tool for gravel packing screens incorporates an added position to allow redirection of flow to a signal transmission tool at the needed flow rates to optimize signal to noise ratios by creation of a discrete flow path that channels the desired flow directly to the device and using the production tubing and upper annulus as the balance of the flow circuit. The Smart Collet® has a landing location for this position which is preferably between the circulation and reverse positions of the crossover tool. The wash pipe assembly can have a shifting tool that closes the sleeve over the gravel exit ports for the information transmittal such ports can thereafter remain closed because the gravel packing is complete but for the reversing out of excess gravel which happens above the gravel exit ports.