Downhole Glass Disc Rupture via Wellhead Isolation
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Solution Overview
Problem
Existing methods for rupturing downhole glass discs in oil and gas wells are complex, time-consuming, and not designed to withstand high pressures, risking damage to wellhead Christmas trees and production tubing during the process.
Innovation Solution
A method involving the use of a wellhead isolation tool and simultaneous pressurization of the annulus between the casing and production strings to apply a controlled high pressure for disc rupture, indicated by a sudden pressure drop, with optional water hammer cycles to clear glass shards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is applied to rupture the glass disc, then the disc rupture effectiveness is improved, but the risk of damage to Christmas tree and production tubing increases
Solution Approach 1:
The system divides the pressure application into two separate pathways: one for the production tubing (through the disc) and one for the annulus (outside the tubing). The isolation tool segments the wellhead system, allowing independent pressure control in each zone. This enables high pressure application to rupture the disc while the annulus pressure protects the tubing from exceeding its burst rating.
Solution Approach 2:
The wellhead isolation tool acts as an intermediary device between the Christmas tree and the high-pressure disc rupture operation. It isolates the Christmas tree from the high pressures generated during disc rupture, protecting this sensitive equipment while enabling the necessary high pressure to be applied to the production tubing to rupture the glass disc.
2Reliability
If complex mechanical and hydraulic devices are used to rupture the glass disc, then the rupture capability is improved, but the device complexity and set-up time increase
Solution Approach 1:
The wellhead isolation tool serves multiple functions: it isolates the Christmas tree from high pressure, provides a pathway for annulus pressurization, enables production tubing pressurization, and protects tubing from damage. This multi-functional approach eliminates the need for multiple separate complex devices and reduces overall system complexity while maintaining reliable disc rupture capability.
Solution Approach 2:
The method uses hydraulic pressure applied through the isolation tool to rupture the glass disc. By utilizing fluid pressure rather than complex mechanical rupture devices, the system achieves reliable disc rupture with simpler equipment. The hydraulic approach allows controlled pressure application and easy pressure modulation without mechanical linkages or moving parts downhole.
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
This method provides a reliable, efficient, and safe means to rupture glass discs without complex downhole apparatus, protecting the wellhead and tubing while ensuring clear indication of disc removal and effective glass shard clearance.
Implementation Method 1
A high pumping pressure is applied to the production tubing in the well to rupture the glass disc
Implementation Method 2
The rupturing of the disc is indicated by a sudden drop in pressure
Implementation Method 3
fluid injections into the well are alternately rapidly started and stopped after the disc is ruptured in order to produce a water hammer effect to flush out any glass shards that remain in the disc holder
Implementation Method 4
A predetermined minimum pressure is maintained in the tubing/casing annulus during the pumping operation
Data Source
AI summary
A method for rupturing a glass disc in a well completion tool located downhole in a section of production tubing includes providing a wellhead isolation tool, or tree saver, to isolate the wellhead Christmas tree, adding a pressurized fluid to the tubing/casing annulus and pumping a disc rupturing fluid into the production tubing via the tree saver until the disc is ruptured. Following rupture, the pump can be rapidly stopped, or slowed, and started to create a water hammer effect that removes any glass shards remaining in the disc holder.