Modular Insert Float System for Casing Compatibility
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Solution Overview
Problem
Current float valves used in hydrocarbon well cementing operations require matching threads and materials, leading to difficulties in installation and potential damage to the wellbore formation due to excessive pressure, and fail to provide sufficient flow area without pressure drop or reliable sealing against backflow.
Innovation Solution
A modular insert float system with interchangeable casing anchor and seal assemblies, including lower and upper valve assemblies, that can be flexibly installed within casings of varying thread types and materials, featuring flapper valves and sliding sleeves to manage fluid flow and pressure, allowing for auto-fill during installation and sealing against backflow during cementing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If float valves are inserted into the casing bore, then matching threads and materials are no longer required, but excessive installation pressure is generated that can damage the wellbore formation
Solution Approach 1:
The system performs preliminary actions by providing expansion control mechanisms and flow channels that allow gradual pressure equalization during insertion. The expansion control mechanism prevents sudden bore expansion that would generate pressure spikes, while flow channels allow wellbore fluid to escape gradually, maintaining pressure control throughout the insertion process.
Solution Approach 2:
The system changes physical parameters by allowing controlled expansion of the insertion device as it enters the casing bore. The expansion control mechanism regulates the degree of expansion, and flow channels manage fluid pressure parameters, transforming the insertion process from a high-pressure event to a controlled, gradual process that prevents formation damage.
2Adaptability or versatility
If float valves are inserted into the casing bore, then matching threads are avoided, but the casing may collapse from external pressure due to absence of internal fluid
Solution Approach 1:
The system introduces an intermediary fluid communication path through flow channels that connect the interior of the insertion device to the exterior casing bore. This intermediary pathway allows wellbore fluid to enter the casing interior during insertion, maintaining pressure balance and preventing casing collapse without requiring permanent fluid containment structures.
Solution Approach 2:
The system performs preliminary fluid communication establishment by providing flow channels that open during insertion to allow wellbore fluid to enter the casing. This preliminary action of establishing fluid communication prevents the pressure differential that would cause casing collapse before the cementing operation begins.
3Reliability
If float valves use spring-loaded normally closed design, then reliable sealing is achieved, but sufficient flow area without pressure drop is difficult to maintain
Solution Approach 1:
The system employs dynamic valve elements including flapper valves that pivot open under fluid pressure and diaphragm valves that flex to control flow. These dynamic mechanisms allow the valve to maintain a sealed closed position during normal operation while opening to provide full flow area when cementing is required, eliminating the pressure drop associated with spring-loaded designs.
Solution Approach 2:
The system extracts the spring mechanism from the valve design, replacing it with fluid-pressure-actuated opening mechanisms. This removal of the spring element eliminates the continuous opposing force that causes pressure drop, allowing the valve to open fully under cement pressure and provide unobstructed flow area when needed.
4Strength
If conventional float equipment is used with matching threads, then strong connections are achieved, but installation becomes arduous and time-consuming
Solution Approach 1:
The system segments the float valve assembly into a modular insertion device that can be inserted into the casing bore as a separate unit. This segmentation eliminates the need to thread the float valve onto the casing, allowing for quick insertion while maintaining connection strength through the expansion control mechanism and flow channel sealing system.
Solution Approach 2:
The system inverts the conventional approach by inserting the float valve into the casing bore rather than threading it onto the casing exterior. This inversion of the installation methodology eliminates threading operations entirely, replacing them with a simple insertion and expansion process that is both faster and maintains adequate connection strength.
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 system enables efficient fluid flow without pressure drop during installation, reduces formation damage, and ensures reliable sealing against backflow, facilitating safe and effective cementing operations by accommodating different casing configurations and materials.
Implementation Method 1
an elastomeric material to seal against the casing bore
Implementation Method 2
The slips can be set to grip the casing bore
Data Source
Figure 1
Figure 2A~2B
Figure 3A~5A
AI summary
The present disclosure provides a modular insert float system (2) that can be inserted into a casing (8) and attached to the casing internal surface by internal slips and sealing components (100). The system is modular in that three main components: an upper valve assembly (300), a lower valve assembly (200), and a pair of casing anchor and seal assemblies (100) along with top and bottom shoes (10, 12) form a kit that can be used for virtually any casing of a given size regardless of the threads, casing material grades, length of joint, or other variations.