Reusable Diverter Tool Flapper Valve for Surge Pressure Control
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Solution Overview
Problem
The existing diverter tools used for managing surge pressure while running casing into a wellbore are limited by their one-shot nature, which restricts their ability to operate correctly in non-vertical wellbores and cannot reopen to allow further circulation, leading to increased formation damage and operational inefficiencies.
Innovation Solution
A diverter tool with a bypass valve that can automatically open and close multiple times without user intervention, using a flapper assembly and shear sleeve mechanism to manage fluid flow and pressure, allowing for increased running speeds and reduced formation damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a one-shot diverter tool with hydrostatic pressure-actuated sleeve closure is used, then surge pressure can be reduced during initial casing run-in, but the tool cannot reopen to allow further circulation and may not operate correctly in non-vertical wellbores
Solution Approach 1:
The patent replaces the static hydrostatic pressure-actuated closure mechanism with a dynamic ball-and-flapper valve system that can automatically open and close multiple times based on real-time fluid flow conditions. The flapper valve responds to upward fluid flow by opening to allow circulation, and closes when flow stops or reverses, enabling adaptive surge pressure control throughout the entire casing running operation regardless of wellbore orientation.
Solution Approach 2:
The diverter tool incorporates a self-actuating mechanism where upward fluid flow itself triggers the opening of the flapper valve, eliminating the need for external control systems or hydrostatic pressure differentials that fail in non-vertical wellbores. The ball-and-flapper assembly automatically responds to flow conditions, making the tool adaptable to any wellbore orientation without requiring user intervention or complex control systems.
2Object-affected harmful factors
If casing is run at reduced speeds to decrease pressure on wellbore fluid, then surge pressure and formation damage are reduced, but the time required to obtain a producing wellbore increases
Solution Approach 1:
The reusable diverter tool with automatic flapper valve allows continuous circulation of fluid down through the casing and out through the diverter tool ports throughout the entire casing running operation. This continuous fluid circulation maintains pressure relief and surge pressure reduction without interruption, enabling faster running speeds while still protecting the formation, unlike one-shot tools that require stopping and resetting.
3Object-affected harmful factors
If a one-shot diverter tool is used, then initial surge pressure control is achieved, but multiple run-ins and tool servicing are required adding time and cost
Solution Approach 1:
The patent designs a universal diverter tool with a reusable ball-and-flapper valve mechanism that performs surge pressure control functions throughout the entire casing running operation without requiring removal or resetting. The tool can handle multiple casing strings and various wellbore orientations with a single installation, eliminating the need for multiple run-ins and tool servicing associated with one-shot diverter tools.
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
The tool effectively reduces surge pressure and allows for safe operation in various wellbore orientations by automatically controlling fluid communication, minimizing formation damage and operational costs through increased running speeds and flexibility.
Implementation Method 1
supplying fluid behind the closure device to move the closure device
Implementation Method 2
a rupture member disposed in the bore to block fluid communication
Data Source
AI summary
A closure device is provided to close a surge pressure reduction tool disposed in a deviated wellbore. The closure device may include a tubular body, a fin, and a rupture disk disposed in the tubular body. The closure device may be pumped downhole to close the tool.