Downhole Flow Control Tool for Solids Transport
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Solution Overview
Problem
In oil and gas exploration, high-pressure fluid circulation is necessary to maintain flow of drill cuttings and solids to the surface, which is costly and damages downhole components, and existing flow control tools do not effectively address accumulation of solids in deviated wells.
Innovation Solution
A downhole flow control tool with multiple fluid flow ports of varying sizes and a movable flow control member that allows selective fluid flow at different velocities and pressures to efficiently clear solids from the wellbore annulus, including inclined and circumferentially arranged ports for enhanced flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-pressure fluid circulation is used to maintain flow of drill cuttings and solids to surface, then solids transport is improved, but downhole components suffer wear and operational life is reduced
Solution Approach 1:
The tool divides the single fluid stream into multiple segregated jets through separate flow ports (first fluid flow ports and second fluid flow ports), each directing fluid at different velocities and angles to achieve solids transport without requiring excessively high overall pressure that would damage downhole components
Solution Approach 2:
Different regions of the tool body have different flow port characteristics - first fluid flow ports with smaller flow areas for high-velocity jets to clear blockages, and second fluid flow ports with larger flow areas for lower-velocity sustained circulation, allowing localized optimization of fluid delivery to match specific cleaning needs while preserving component life
2Productivity
If high-pressure fluid circulation is used to maintain flow of drill cuttings and solids to surface, then solids transport is improved, but energy consumption increases
Solution Approach 1:
The fluid circulation system is segmented into multiple flow paths with different pressure requirements, allowing the pump to operate at moderate overall pressure while still achieving effective solids transport through the coordinated action of multiple jets with varying velocities
Solution Approach 2:
The system changes fluid delivery parameters by providing multiple flow ports with different flow areas, enabling the same fluid stream to be delivered at different velocities and pressures to match different cleaning requirements, thereby reducing the need for excessively high pump pressures and associated energy consumption
3Device complexity
If a single flow port is used for fluid circulation, then device complexity is low, but adaptability to different flow requirements is limited
Solution Approach 1:
The single flow port is segmented into multiple flow ports (first and second fluid flow ports) with different characteristics, allowing the tool to adapt to different flow requirements by selectively opening different ports or combinations of ports based on the specific cleaning or circulation needs
Solution Approach 2:
The tool body is designed with multiple flow ports that can serve different functions - some ports optimized for high-velocity jetting to clear blockages, others for lower-velocity sustained circulation, enabling a single tool to handle multiple flow management scenarios without requiring different specialized 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 directs fluid flow to clear solids from the wellbore annulus, reducing wear on downhole components and maintaining effective circulation without excessive pressure, particularly in deviated wells, by utilizing higher velocity jets and boosted flow to clear blockages.
Implementation Method 1
the at least one first fluid flow port comprising an outlet having a first fluid flow area; at least one second fluid flow port extending through the main body wall for the selective flow of fluid from the body internal bore to the tool exterior, the at least one second fluid flow port comprising an outlet having a second fluid flow area greater than said first fluid flow area
Implementation Method 2
a flow control member mounted for movement relative to the body main bore between: a closed position in which both the at least one first and the at least one second fluid flow ports are closed, to thereby prevent flow of fluid from the body main bore to the tool exterior through said ports
Implementation Method 3
Providing a flow control tool having such first and second flow control ports permits selective jetting of fluid to the exterior of the tool at different velocities. This is because the velocity of fluid exiting the at least one first fluid flow port will be higher than the velocity of fluid exiting the at least one second fluid flow port
Data Source
AI summary
A downhole flow control tool 1, includes a flow control member in the form of a sleeve 8, and comprises a main body 2 having a longitudinal internal bore 3 extending therethrough, an upper end 4 having a box section 6, and a lower end 5 with a pin section 7, which enable connection of the tool 1 into a work string. The flow control sleeve 8 is mounted for movement relative to the bore 3 between at least a closed and one of several open positions. The tool body 2 includes several flow ports extending through a wall of the body 2 and spaced around a circumference of the body 2. The tool provides multiple fluid flow control options for directing and splitting fluid flow for example during a drilling operation to clear settled cuttings by suitable location of the tool.