Flow Control Device for Cementing Operations
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Solution Overview
Problem
Current stage cementing operations require the drilling out of internal operating parts of stage cementing tools, which is inefficient and costly, as it necessitates the use of a drilling rig for further down-hole operations.
Innovation Solution
A flow control device with a housing, port sleeve, and movable sleeves that allow for axial movement and fluid communication control, enabling cementing without the need for drilling out internal components, utilizing a packer and float collar assembly to seal and supply cement effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stage cementing tools are used, then cementing operations can be performed, but drilling out of internal operating parts is required which increases operational complexity and cost
Solution Approach 1:
The tool is divided into modular components including a housing, port sleeve, first sleeve, and second sleeve that can be independently positioned and controlled. This segmentation allows each component to perform its specific function while enabling easy assembly and disassembly, eliminating the need for drilling out internal parts.
Solution Approach 2:
The patent employs movable sleeves (port sleeve, first sleeve, second sleeve) that can dynamically change position within the housing to control fluid flow paths. These dynamic components allow the tool to transition between different operational states (cementing mode, displacement mode, retrieval mode) without requiring drilling out, thereby simplifying subsequent operations.
2Productivity
If internal operating parts are drilled out for further operations, then access is achieved, but use of drilling rig is required which increases time and cost
Solution Approach 1:
The internal operating parts (sleeves and port structures) are designed to be extractable from the housing through axial movement. After cementing operations are complete, the second sleeve can be moved axially to open the port, and the first sleeve can be moved to allow removal of the port sleeve and second sleeve assembly, providing clean access without drilling and eliminating the need for a drilling rig.
Solution Approach 2:
The tool is pre-configured with movable sleeves and ports that can be opened and components removed in advance of any needed access operations. This preliminary design eliminates the need for time-consuming drilling operations later, as the path for component removal is already prepared through the axial movement capability of the sleeves.
3Adaptability or versatility
If sleeves are moved axially to control fluid flow, then cementing and displacement operations are enabled, but precise positioning is required
Solution Approach 1:
The patent employs seals (first seal between housing and port sleeve, second seal between port sleeve and second sleeve) as intermediary elements that automatically position and seal against the sleeve surfaces. These seals act as mediators that ensure proper positioning and fluid sealing without requiring high-precision machining, as the seals compensate for minor dimensional variations and self-align during assembly.
Solution Approach 2:
The sleeves and housing features are designed with localized precision requirements only at the critical sealing surfaces and port alignment areas, while other portions of the components can have standard tolerances. This local quality approach reduces overall manufacturing complexity while ensuring the necessary positioning precision where it is most needed for fluid control.
Data Source
AI summary
A flow control apparatus includes a housing having a bore extending and a port formed through a wall of the housing; and a port sleeve disposed in the housing and having a port in communication with the port of the housing. The apparatus also includes a first sleeve releasably attached to the housing, wherein the first sleeve is movable from a first position preventing axial movement of the port sleeve relative to the housing to a second position allowing axial movement of the port sleeve relative to the housing. The apparatus further includes a second sleeve releasably attached to the port sleeve, wherein the second sleeve is movable from a first position blocking fluid communication through the port of housing and the port of the port sleeve to a second position allowing fluid communication through the ports.