Flow Diversion Valve for Single-Trip Casing Removal
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Solution Overview
Problem
Conventional casing removal systems require multiple trips into the wellbore for pulling and cutting operations, increasing time and cost due to the need for separate tools and processes for each step.
Innovation Solution
A flow diversion valve system that allows simultaneous pulling of the casing with a hydraulically powered jack and cutting with a mud motor by diverting fluid flow to control the operation of downhole tools, enabling these operations to occur in a single trip by changing its flow control state based on the casing diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate tools and processes are used for pulling and cutting operations, then each operation can be performed with dedicated equipment, but multiple trips into the wellbore are required, increasing time and cost
Solution Approach 1:
The patent combines multiple downhole tools (jack for pulling, mud motor for cutting, flow diversion valve for control) into a single integrated tool assembly that can perform both pulling and cutting operations during one trip into the wellbore. The flow diversion valve coordinates fluid flow to sequentially activate different tools within the same assembly, eliminating the need for multiple separate trips while maintaining dedicated functionality for each operation.
2Loss of time
If a single tool assembly performs both pulling and cutting operations, then time and cost are reduced, but the device complexity increases due to multiple tools and flow control mechanisms
Solution Approach 1:
The flow diversion valve serves as an intermediary control mechanism that manages fluid distribution to multiple tools within the assembly. It sequentially directs hydraulic flow to the jack or mud motor based on operational requirements, enabling coordinated operation of multiple tools without requiring complex direct control systems for each component. This intermediary approach simplifies the overall control architecture while maintaining multi-functionality.
3Ease of operation
If the flow diversion valve restricts fluid flow, then the valve can control operation sequence, but the rate of fluid flow exiting the valve is reduced
Solution Approach 1:
The flow diversion valve employs movable actuation members that can dynamically adjust the flow path configuration in response to casing diameter changes. The valve transitions between different flow control states (restricting flow for tool activation vs. allowing full flow for motor operation) based on real-time operational conditions. This dynamic adjustment enables the valve to provide precise control while maintaining adequate flow rates for each operational phase.
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 for casing removal, saving time and money by allowing both pulling and cutting operations to be performed in a single downhole trip, thereby optimizing the efficiency of the casing removal process.
Implementation Method 1
at least one actuating member that extends beyond the outer diameter of the housing under the influence of a biasing force and is configured to be moved at least partially inwardly with respect to the housing against the biasing force when the flow diversion valve passes from a first casing to a second casing
Data Source
AI summary
A casing removal system includes a flow diversion valve. The flow diversion valve includes a flow switch that engages an upper end of an inner casing. When the flow switch engages the upper end of the inner casing, the flow diversion valve opens and at least a portion of the fluid flow through the casing removal system exhausts to the annulus. The remaining fluid flow below the flow diversion valve is insufficient to operate a mud motor that drives a casing cutter. In other embodiments, when the flow switch is not engaged with the inner wall of casing, the flow diversion valve prevents fluid flow to components that are downhole of the valve and when the flow switch is engaged with the inner wall of casing, the flow diversion valve allows for fluid flow to components that are downhole of the valve.