Mill Diverter Swellable Material Annular Seal
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Solution Overview
Problem
Existing mill diverters, such as whipstocks, face issues with fluid by-pass, which can lead to corrosive or erosive damage, improper cementing, increased fluid requirements, pressure loss, and ineffective debris removal during lateral wellbore formation, due to the inability to maintain a seal and control fluid flow.
Innovation Solution
Incorporating a swellable material positioned circumferentially around the tapered face of the mill diverter, which swells to create a radial seal, preventing fluid by-pass and maintaining pressure, while being resistant to corrosive and erosive fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mill diverter is used to form lateral wellbores, then the mill bit can create a window in casing and cement, but fluid by-pass occurs causing corrosive or erosive damage and pressure loss
Solution Approach 1:
The mill diverter incorporates a swellable material at the specific location where fluid by-pass occurs (around the tapered face and fishing mechanism). This material swells upon contact with drilling fluid to create a seal, providing localized protection against corrosive or erosive damage while maintaining the overall structural integrity and window creation capability of the diverter.
Solution Approach 2:
A swellable material acts as an intermediary between the drilling fluid and the mill diverter mechanisms. When the swellable material contacts the drilling fluid, it swells and creates a seal that prevents direct contact between the fluid and the diverter, thereby eliminating fluid by-pass damage while allowing the diverter to function properly.
2Productivity
If a mill diverter is used without fluid flow control, then lateral wellbores can be formed, but improper cementing and increased fluid requirements occur
Solution Approach 1:
The swellable material is positioned specifically around the tapered face and fishing mechanism to create a localized seal. This seal prevents fluid by-pass, ensuring that drilling fluid and cement remain contained in the intended zone, thereby preventing improper cementing and reducing overall fluid requirements while maintaining lateral wellbore formation productivity.
Solution Approach 2:
The swellable material provides automatic feedback-based flow control. Upon contact with drilling fluid, the material automatically swells to seal the annular space, preventing fluid by-pass. This self-regulating mechanism ensures proper fluid containment without requiring external control systems, thereby preventing improper cementing and optimizing fluid usage.
3Ease of operation
If a mill diverter is used without sealing mechanism, then the diverter can be positioned in the wellbore, but pressure loss and ineffective debris removal occur
Solution Approach 1:
The swellable material is positioned locally around the tapered face and fishing mechanism to create a seal. This localized sealing maintains the simplicity of diverter positioning while preventing pressure loss and enabling effective debris removal through the mill bit, thereby improving reliability without compromising ease of operation.
Solution Approach 2:
The swellable material automatically activates upon contact with drilling fluid, swelling to create a seal without requiring external intervention. This self-service mechanism prevents pressure loss and enables effective debris removal while maintaining the simplicity of diverter positioning, thereby improving reliability without adding operational complexity.
4Reliability
If a swellable material is added to the mill diverter, then fluid flow is prevented, but device complexity increases
Solution Approach 1:
The swellable material is a relatively simple, consumable component that is added to the mill diverter. It performs its sealing function during the drilling operation and can be left in the wellbore or retrieved with the fishing mechanism. This approach provides reliable fluid flow control without significantly increasing device complexity, as the swellable material is a straightforward additive rather than a complex mechanical system.
Solution Approach 2:
The mill diverter is enhanced by incorporating a swellable material, creating a composite structure that combines the mechanical diverter components with the sealing properties of the swellable material. This composite approach provides reliable fluid flow control while maintaining relatively simple device structure, as the swellable material integrates seamlessly with the existing diverter design.
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
The swellable material effectively seals the annular space, preventing fluid flow and pressure loss, protecting the diverter mechanisms and ensuring accurate fluid calculations and pressure control, thereby enhancing the reliability and efficiency of lateral wellbore formation operations.
Implementation Method 1
a swellable material, wherein the swellable material: (i) is positioned circumferentially around the body of the mill diverter adjacent to the tapered face; (ii) swells in the presence of a swelling fluid; and (iii) prevents substantially all of a fluid from flowing past the swellable material
Data Source
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AI summary
A method of preventing fluid flow past a tapered face of a mill diverter in a wellbore comprises: positioning the mill diverter in the wellbore, wherein the mill diverter comprises: a body; the tapered face, wherein the tapered face is located at one end of the body; and a swellable material, wherein the swellable material: is positioned circumferentially around the body of the mill diverter adjacent to the tapered face; swells in the presence of a swelling fluid; and prevents substantially all of a fluid from flowing past the swellable material after the swellable material has swelled; and causing or allowing the swellable material to swell. The swellable material can also prevent a loss of pressure in the wellbore above the swellable material or prevent a first fluid having a first density from mixing with a second fluid having a second density after the swellable material has swelled.