Hydraulic Motor Flow Control for Single-Trip Downhole Operations
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Solution Overview
Problem
Existing downhole drilling and milling operations in wellbores face challenges in efficiently orienting and setting anchors while preventing motor rotation, which limits the ability to perform milling or cutting operations effectively during a single trip.
Innovation Solution
A hydraulically-operated motor system with a flow control device that allows fluid to pass through to set the anchor while blocking fluid flow to the motor, and then switches to allow fluid flow to the motor to operate the cutting device, enabling efficient orientation, anchor setting, and milling/cutting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluid is allowed to flow through the motor to operate it, then the motor can perform milling/cutting operations, but the anchor cannot be hydraulically set
Solution Approach 1:
The fluid flow path is segmented into multiple routes using flow control devices. One route directs fluid through the motor for milling operations, while another route directs fluid to the anchor for setting. The segmentation allows independent control of each function through selective activation of different flow paths.
Solution Approach 2:
The system dynamically switches between different operational modes by adjusting fluid flow distribution. The flow control devices can change the direction and distribution of hydraulic fluid in real-time, enabling transition from anchor-setting mode to motor-operation mode and vice versa, providing dynamic adaptability to different operational requirements.
2Reliability
If fluid is blocked from flowing through the rotor, then the motor cannot operate, but fluid can flow to set the anchor
Solution Approach 1:
Flow control devices act as intermediaries between the hydraulic fluid source and the motor/anchor system. These devices mediate the fluid distribution by selectively opening or closing flow paths, enabling controlled transfer of hydraulic power to either the anchor setting mechanism or the motor without direct mechanical connection or interference.
3Reliability
If the rotor is mechanically locked to prevent rotation, then the cutting tool cannot be rotated, but the anchor can be set hydraulically
Solution Approach 1:
The system replaces mechanical locking mechanisms with hydraulic flow control. Instead of using mechanical devices to lock or unlock the rotor, the invention uses hydraulic pressure control and flow direction control to achieve the same effect. This substitution allows for more precise and controllable operation transitions.
4Productivity
If a single trip operation is required, then all operations must be performed in sequence without retrieving the tool, but fluid flow control becomes more complex
Solution Approach 1:
The hydraulic system is designed with multi-functionality, where the same hydraulic fluid source and control mechanisms serve multiple purposes: setting the anchor, operating the motor, and controlling various downhole tools. This universal hydraulic architecture reduces the need for separate dedicated systems for each function, managing complexity while enabling single-trip multi-operation capability.
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 the orientation, setting, and operation of anchors and cutting devices during a single trip, enhancing the efficiency and precision of downhole operations by selectively controlling fluid flow to the motor, thus improving the performance of milling and cutting operations in wellbores.
Implementation Method 1
supplying a fluid at first flow rate to flow the fluid through the rotor while preventing the fluid to flow to the motor to operate the motor; setting the anchor in the wellbore with the fluid flowing through the motor
Implementation Method 2
supplying the fluid at a second flow rate to flow the fluid to the motor to operate the motor to operate the cutting device
Data Source
AI summary
In one aspect an apparatus for performing a downhole operation is disclosed that in one non-limiting embodiment may include a downhole tool that contains a hydraulically-operated motor and a flow control device that in one position allows a fluid to pass through the motor while preventing the fluid to flow to the motor and in another position allows the fluid to flow to the motor to operate the motor.