Downhole Flow Isolation Tool Assembly Design
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Solution Overview
Problem
Existing well treatment technologies, such as abrasive jet perforating, face challenges in efficiently combining fluid flow isolation with perforation tasks, requiring multiple trips and increasing completion costs due to limited tool life and high-pressure maintenance issues.
Innovation Solution
A flow isolation tool assembly and method that uses a cylindrically shaped flow tube with ball seats and shear pins to selectively block and re-establish fluid flow, allowing multiple tasks to be performed in a single trip by shifting the tube/seat assembly based on ball seating and pressure control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If abrasive jet perforating is used to perforate tubular goods, then fluid production is stimulated, but the tool life is measured in minutes and the process is not economically successful
Solution Approach 1:
The patent employs abrasive-resistant materials in the construction of the perforating tool and jet orifices, creating a composite structure that resists the erosive effects of abrasive fluid. This material composition enables the tool to withstand prolonged exposure to high-pressure abrasive slurry, extending tool life from minutes to hours or days, thereby achieving economic success in well treatment operations
2Stress or pressure
If high fluid pressures are used to cut casing, then perforation is achieved, but the pumps available at the time could not maintain these pressures for long periods
Solution Approach 1:
The patent utilizes advancements in pump materials and technology that enable the system to handle abrasive fluids under high pressures for longer periods. By changing the material parameters of the pump components to be more abrasive-resistant, the system can maintain high fluid pressures required for casing cutting and perforation throughout extended operation durations, overcoming the limitations of earlier pump technology
3Adaptability or versatility
If multiple trips are made to complete well treatment tasks, then each task can be performed, but completion costs increase
Solution Approach 1:
The patent integrates multiple functions into a single downhole tool assembly, including flow isolation capabilities, perforation, and milling operations. This multi-functional design allows the tool to perform various well treatment tasks during a single trip, eliminating the need for multiple separate interventions and thereby reducing completion costs while maintaining the adaptability to handle different operational requirements
4Ease of manufacture
If explosive shape charge perforators are used, then perforation is achieved with less expense, but the danger involved in storage, transport, and use of explosives increases
Solution Approach 1:
The patent replaces the explosive-based perforation system with a mechanically-driven abrasive jet system. Instead of using explosives that pose storage, transport, and usage dangers, the system employs high-pressure abrasive fluid slurry pumped through the tool to achieve perforation. This substitution maintains cost-effectiveness while eliminating the harmful safety risks associated with explosive materials
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
Enables efficient fluid flow isolation and re-establishment, reducing the number of trips and completion costs by allowing multiple tasks to be completed in a single well intervention, while maintaining tool longevity and safety by avoiding explosive use.
Implementation Method 1
an upper ball seat connected to the top of the flow tube; a lower ball seat connected to the bottom of the flow tube; a tapered inner diameter in the upper ball seat, acting as a ball valve; a tapered inner diameter in the lower ball seat, acting as a ball valve
Implementation Method 2
shear pins connecting the upper ball seat to the upper sub
Implementation Method 3
Abrasive jet perforating uses fluid slurry pumped under high pressure to perforate tubular goods around a wellbore, where the tubular goods include tubing, casing, and cement
Implementation Method 4
Sand laden fluids were first used to cut well casing in 1939
Data Source
AI summary
An apparatus for isolating fluid flow in a bottomhole tool assembly comprises a generally cylindrically shaped flow tube with a side, a top, and a bottom; an upper ball seat connected to the top of the flow tube; a lower ball seat connected to the bottom of the flow tube; a plurality of openings in the side of the flow tube; a tapered inner diameter in the upper ball seat, acting as a ball valve; a tapered inner diameter in the lower ball seat, acting as a ball valve, smaller than the tapered inner diameter in the upper ball seat; an upper sub attached to the bottomhole tool assembly; a lower sub attached to the bottomhole tool assembly; shear pins connecting the upper ball seat to the upper sub; and a limiting pin in the lower sub below the lower ball assembly.