Float Collar Bypass via Rupture Disk
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Solution Overview
Problem
Float collars and float shoes in wellbore operations often become plugged during completion operations, necessitating time-consuming removal or drilling out procedures, which delays well completion and increases rig time.
Innovation Solution
A float collar design featuring multiple auxiliary flow passages with rupture disks and a shearable seal, allowing fluid bypass when blockages occur, and a controller for actuating these features to maintain circulation and control well influx.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If float collars are used to prevent fluid influx and maintain well control, then well control reliability is improved, but the risk of plugging increases which requires time-consuming removal procedures
Solution Approach 1:
The float collar is divided into multiple independent flow paths: a central flow passage with check valves and auxiliary flow passages with rupture disks. This segmentation allows fluid to bypass blocked sections through alternative paths, maintaining well control without requiring removal of the entire float collar assembly.
Solution Approach 2:
Rupture disks are pre-installed in auxiliary flow passages and configured to burst at specific pressure differentials. This preliminary preparation ensures that when plugging occurs, bypass flow is immediately activated without requiring manual intervention, thus preventing loss of rig time.
2Reliability
If multiple check valves are installed in the float collar to enhance fluid flow control, then well control capability is improved, but the complexity of the device increases
Solution Approach 1:
Multiple flow control functions are merged into a single integrated float collar body. The central flow passage with check valves and auxiliary flow passages with rupture disks are combined in one device, allowing enhanced fluid control capability without requiring multiple separate components that would increase overall system complexity.
Solution Approach 2:
The float collar is designed as a multi-functional device that performs several functions simultaneously: check valve operation for backpressure, rupture disk activation for bypass flow, and contamination barrier functions. This multi-functionality reduces the need for separate devices while maintaining comprehensive well control capability.
3Productivity
If auxiliary flow passages with rupture disks are added to enable bypass flow, then productivity is improved by reducing trips, but the device complexity increases
Solution Approach 1:
The auxiliary flow passages with rupture disks are designed to activate automatically when plugging occurs, based on pressure differential across the float collar. This self-service mechanism eliminates the need for external control systems or manual intervention, improving productivity by reducing trips while adding only minimal structural complexity.
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
Reduces the number of trips required during completion operations by enabling direct circulation through the string and maintaining well control, even if float collars are plugged, thus reducing rig time and facilitating quicker production or injection well start-up.
Implementation Method 1
The rupture disk is configured to burst at a specified pressure differential
Implementation Method 2
A check valve is located within the central flow passage. The check valve is arranged such that a fluid flow travels in a downhole direction during operation of the float collar
Data Source
AI summary
A body defines a central flow passage. A check valve is located within the central flow passage. The check valve is supported by the body. The check valve is arranged such that a fluid flow travels in a downhole direction during operation of the float collar. An auxiliary flow passage is substantially parallel to the central flow passage and is defined by the body. The auxiliary flow passage includes an inlet upstream of the check valve and an outlet at a downhole end of the float collar. A rupture disk seals the inlet of the auxiliary flow passage. The rupture disk is configured to burst at a specified pressure differential.