Downhole Valve Using Degradable Element for Flow Control
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Solution Overview
Problem
In coiled tubing operations, the maximum pump rate of positive displacement motors is limited, restricting high flow rates needed for milling operations to lift debris, and existing multi-cycle circulation valves do not effectively manage fluid flow to prevent motor damage during high circulation demands.
Innovation Solution
A downhole tool with a degradable element that obstructs fluid flow through a valve seat, allowing high flow rates during circulation and reducing pressure on the motor, with the element degrading to restore normal operation, enabling repeated cycling between circulation and milling modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pump rate is increased to lift debris during milling operations, then the circulation efficiency is improved, but the motor may be damaged due to excessive pressure
Solution Approach 1:
The valve transitions between two operational states (circulation mode and milling mode) to dynamically adjust fluid flow distribution. During milling operations, the valve directs fluid through the motor at limited rates, while during circulation operations, it redirects fluid through the annulus to achieve high circulation rates without overpressuring the motor
Solution Approach 2:
The degradable element undergoes parameter changes through degradation processes (dissolution, disintegration, defragmentation) that alter its physical properties over time. This allows the element to transition from an obstructive state (preventing element passage) to a permissive state (allowing element and fluid passage), thereby changing the valve's operational mode
2Reliability
If a valve mechanism is added to manage fluid flow between circulation and milling modes, then motor protection is improved, but the device complexity increases
Solution Approach 1:
The degradable element automatically changes the valve's operational state through its degradation process without requiring external control mechanisms. The element's dissolution, disintegration, or defragmentation naturally triggers the transition from milling mode to circulation mode, eliminating the need for complex control systems, sensors, or actuators
Solution Approach 2:
The degradable element is designed as a temporary, consumable component that performs its function (controlling valve operation) and then degrades away. This disposable approach simplifies the overall device by replacing potential complex reusable mechanisms with a simple, temporary element that achieves the same protective function
3Ease of operation
If the degradable element is used to control valve operation, then the ease of operation is improved, but the loss of substance occurs due to element degradation
Solution Approach 1:
The degradable element is discarded through controlled degradation (dissolution, disintegration, or defragmentation) after serving its purpose of controlling valve operation. The element's mass is intentionally lost as it transitions from obstructing fluid flow to allowing free flow, enabling the valve to cycle between operational modes without requiring retrieval or replacement by complex mechanisms
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 high flow rates during milling operations while protecting the motor from excessive pressure, allowing for efficient debris removal and repeated use without mechanical retrieval, thus enhancing operational efficiency and safety.
Implementation Method 1
The valve is opened to direct the flow of the fluid around the hydraulic tool. Opening the valve utilizes pressure generated in response to the element obstructing the flow of the fluid through the valve seat passage
Implementation Method 2
At least a portion of at least one of the element and the valve seat is then degraded by an amount sufficient to permit the element to pass through the valve seat passage
Implementation Method 3
The element may undergo degradation in the form of dissolution, disintegration, and/or defragmentation
Data Source
AI summary
An element is deployed within tubing extending to a downhole tool. The downhole tool includes a hydraulic tool and a valve coupled between the conveyance string and the hydraulic tool. The valve includes a valve seat having a passage directing the fluid from the conveyance string to the hydraulic tool. Deploying the element includes landing the element on the valve seat such that the element substantially obstructs flow of the fluid through the valve seat passage. The valve is opened to direct the flow of the fluid around the hydraulic tool, wherein opening the valve utilizes pressure generated in response to the element obstructing the flow of the fluid through the valve seat passage. At least a portion of at least one of the element and the valve seat is then degraded by an amount sufficient to permit the element to pass through the valve seat passage.