Float Valve Turbulent Flow Vanes for Cement Buildup
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Solution Overview
Problem
Residual cement buildup around float valves in wet shoe applications can cause valve sticking, preventing fluid injection and leading to float equipment failures, which may necessitate expensive tubing-conveyed perforating operations.
Innovation Solution
A float tool with a housing, at least one valve, and one or more vanes is designed to control flow in tubing. The tool includes a turbulent flow device with angled or spiraling vanes that produce turbulence, helping to clear residual cement from the float tool and valve areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If float valves are used in wet shoe applications, then fluid flow control is achieved, but residual cement buildup causes valve sticking and equipment failure
Solution Approach 1:
The patent employs turbulent flow elements that create mechanical disturbance and vibration in the fluid stream passing through the float valve assembly. This turbulence prevents cement from settling and adhering to the valve components by continuously disrupting the fluid boundary layer where cement particles would otherwise accumulate, thereby preventing valve sticking while maintaining reliable flow control
Solution Approach 2:
The patent introduces dynamic flow characteristics through turbulent flow generators that create varying flow velocities and patterns. This dynamic flow regime prevents the static conditions that allow cement to settle and harden on valve surfaces, ensuring the float valve remains operational by maintaining continuous movement of the fluid medium through which the valve operates
2Ease of operation
If horizontal float equipment is used in lateral well sections, then cement can settle on the bottom of internal parts, but this causes valve sticking and injection failure
Solution Approach 1:
The turbulent flow elements create mechanical disturbance that counteracts gravitational settling of cement particles in horizontal orientations. By generating vibration and turbulence in the fluid stream, the system prevents cement from depositing on the bottom surfaces of internal components, maintaining injection capability despite the horizontal equipment orientation
Solution Approach 2:
The patent employs periodic turbulent flow patterns that create recurring disturbances in the fluid stream. This periodic action continuously disrupts any tendency for cement to settle on horizontal surfaces, ensuring that the internal parts remain clear of cement buildup and injection operations can proceed without failure
3Productivity
If float equipment failures occur due to cement buildup, then expensive tubing-conveyed perforating operations are required
Solution Approach 1:
By incorporating turbulent flow elements that generate mechanical vibration and disturbance, the system proactively prevents cement buildup on float valve components. This preventive approach maintains float equipment reliability and avoids the need for costly TCP operations, thereby preserving operational efficiency and reducing downtime
Solution Approach 2:
The patent implements preliminary protective measures by incorporating turbulent flow generators into the float equipment design before cementing operations begin. This preliminary action creates a flow regime that inherently prevents cement settlement, protecting the float valves from future failure and eliminating the need for expensive remedial TCP operations
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 turbulent flow device effectively reduces the risk of float equipment failure by clearing residual cement, ensuring uninterrupted fluid flow and reducing the need for costly TCP operations.
Implementation Method 1
At least a portion of the longitudinal bore has the one or more vanes, which are angled relative to the longitudinal bore. The one or more vanes are configured to produce turbulence in the flow in the downbore direction through the longitudinal bore.
Data Source
AI summary
A float tool is used for controlling flow in tubing. The float tool comprises a housing, at least one valve, and at least one inset. The housing is configured to install on the tubing and has a longitudinal bore therethrough. The at least one valve is disposed in the longitudinal bore. The at least one valve is configured to allow the flow in a downbore direction through the longitudinal bore and is configured to prevent flow in an upbore direction through the longitudinal bore. The at least one inset is disposed in the longitudinal bore and is disposed downbore of the at least one valve. The at least one inset defines an orifice therethrough. The orifice has one or more vanes angled relative to the longitudinal bore. The one or more vanes are configured to produce turbulence in the flow in the downbore direction through the longitudinal bore.