Fluid-Powered Reaming Tool for Wellbore Completion String Placement
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Solution Overview
Problem
Existing completion strings in wellbore completion face challenges such as encountering obstructions, being stuck, and difficulty in rotating due to low torque capacity and friction losses, especially in long horizontal or deviated wellbores, which can lead to incomplete placement and damage to sensitive components.
Innovation Solution
A completion system with a fluid-powered reaming tool featuring a turbine drive unit and a geometric reaming structure, allowing for selective fluid communication and operation below pressures that activate hydraulic devices, enabling reaming without rotating the completion string, thus minimizing damage and facilitating placement in complex wellbores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the completion string is rotated to remove obstructions using a reaming tool, then obstructions can be removed and progression permitted, but the low torque capacity threads and friction losses prevent effective rotation, especially in long horizontal or deviated wellbores
Solution Approach 1:
The system separates the rotation function from the completion string by introducing an independent powered reaming tool that rotates autonomously via downhole motor or turbine, while the completion string remains stationary and serves only as a conduit for fluid and structural support
Solution Approach 2:
The system replaces the mechanical torque transfer mechanism (which relies on thread capacity) with a fluid-powered rotational system where hydraulic energy from downhole fluid drives the reaming tool's rotation independently of the completion string's mechanical strength
2Power
If fluid pressure is increased to power the reaming tool, then reaming effectiveness improves, but pressure-sensitive elements such as inflow control devices may be inadvertently activated
Solution Approach 1:
The system divides the fluid flow path into separate channels: one channel delivers high-pressure fluid exclusively to the reaming tool motor/turbine for powerful reaming operation, while another channel maintains lower pressure to prevent premature activation of inflow control devices and other pressure-sensitive elements
Solution Approach 2:
The system applies different pressure levels to different components: high pressure is localized to the reaming tool's power mechanism where it is needed for effective reaming, while lower pressure is maintained at components sensitive to pressure activation
3Productivity
If larger diameter completion string tubulars are used to improve hydrocarbon flow, then flow capacity increases, but torque capacity of the threads decreases making rotation more difficult
Solution Approach 1:
The system separates the functions of flow transport and reaming operation by making the completion string stationary for fluid conveyance while using an independent powered tool for reaming, eliminating the need for torque transfer through the completion string threads
Solution Approach 2:
The system replaces mechanical torque transfer through threads with fluid-powered rotation, allowing large-diameter completion strings optimized for flow capacity to be used without compromising the ability to perform reaming operations
Data Source
AI summary
A completion system comprises tubular components coupled together to form a completion string. In-flow control devices are provided to permit selective fluid communication between an internal bore of the completion string and the annulus. A reaming tool is provided at a leading end of the completion string and the reaming tool is run into the borehole with the completion string. The reaming tool comprises a fluid-powered drive unit, a reaming body and a reaming nose. In use, the completion string is located in the borehole and fluid is directed to the reaming tool to facilitate reaming of the borehole. A second tubular in the form of a washpipe may extend through an internal bore of the completion string for providing fluid to the reaming tool. The reaming tool is operable at a fluid pressure below a pressure which would activate the in-flow control devices.