Liner Wiper Plug Bypass Flow Path via Shear Dart
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Solution Overview
Problem
Conventional wellbore operation systems face challenges in establishing an alternate flow path after a liner wiper plug assembly has completed wiping and landed into a landing seat, limiting post-cementing flow maintenance.
Innovation Solution
A wiper dart with a releasable nose is designed to create an alternate flow path by using bypass ports and an axial shear stud mechanism, allowing the nose to detach under increased pressure and bypass the primary flow path, enabling fluid flow through an alternate route.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a liner wiper plug assembly is used to wipe cement from the liner, then cement placement efficiency is improved, but the ability to maintain flow after cement curing is compromised
Solution Approach 1:
The wiper plug assembly is divided into functionally independent segments: the wiper plug for cement displacement and the wiper dart for flow path creation. The dart can be released independently after the plug completes its wiping function, allowing the flow path to be opened while maintaining the plug in place for continued cementing operations.
Solution Approach 2:
The system transitions from a static blocked flow path to a dynamic configurable flow path. The wiper dart is initially positioned to block flow during cement placement, then can be released to open the flow path. This dynamic reconfiguration allows the system to adapt to different operational phases: cement placement versus post-cementing flow maintenance.
2Manufacturing precision
If the wiper dart blocks the flow path during cement placement, then cement displacement is effective, but post-cementing flow is obstructed
Solution Approach 1:
The wiper dart is pre-positioned to block the flow path during cement placement operations, ensuring effective cement displacement. After this preliminary function is completed, the dart can be released to open the flow path for post-cementing operations, allowing the system to transition from one operational mode to another.
Solution Approach 2:
The wiper dart serves its primary function of blocking flow during cement placement, then is discarded (released) from its blocking position to allow flow. The dart itself remains in the system but changes position, transitioning from a flow-blocking element to a flow-permitting configuration, enabling continued operations.
3Ease of operation
If increased pressure is applied to release the wiper dart, then flow path opening is achieved, but risk of premature release increases
Solution Approach 1:
The release mechanism responds to changes in pressure parameters. The wiper dart is held in place by a latch mechanism that maintains blocking pressure during cement placement. When a predetermined pressure threshold is reached (indicating cement placement completion), the latch releases, allowing the dart to move and open the flow path. This parameter-based control ensures reliable operation.
Solution Approach 2:
The system incorporates pressure feedback to control dart release. Pressure sensors or pressure-sensitive mechanisms monitor the pressure differential across the wiper plug. When pressure reaches a predetermined level indicating successful cement placement, this feedback triggers the latch release mechanism, allowing the dart to open the flow path. This feedback loop prevents premature release while ensuring timely opening.
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 solution ensures efficient cement placement and post-cement curing flow maintenance by establishing a secondary flow path, allowing continued fluid circulation through the wellbore without obstructing the primary sealing features.
Implementation Method 1
a wiper dart with a releasable nose is designed to create an alternate flow path by using bypass ports and an axial shear stud mechanism, allowing the nose to detach under increased pressure
Implementation Method 2
Pressure is then applied above the latched wiper dart, which initiates the release of the liner plug assembly from the liner hanger running tool
Data Source
AI summary
A system for establishing a bypass flow path includes a plug assembly having bypass ports extending from the exterior to the interior; a wiper dart to engage and seal the first flow path and bypass flow path, and initiate release of the plug assembly from a first position, the plug assembly having a dart nose attached to the dart body; once the plug has moved to a second position, pressure applied through the bypass ports communicates to the dart nose to cause detachment of the dart nose from the dart body; a first flow path extends through the central bore of the plug assembly when the wiper dart is not present; and a second flow path extends through the bypass ports on the plug assembly below the dart body to the detachable dart nose, once detached, the bypass flow path is established thru the bore below the dart body.