Multi-Cycle Valve for Wellbore Perforating and Cleanout
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Solution Overview
Problem
Current methods for abrasive perforating and cleanout in wellbores require multiple assemblies, reverse circulation, or removal of the bottom hole assembly (BHA) to switch between perforating and cleanout modes, leading to inefficiencies and risks such as getting stuck in the wellbore, especially in horizontal wells.
Innovation Solution
A multi-cycle open/close valve (MCOCV) system that allows fluid to be pumped at varying flow rates to switch between abrasive perforating and cleanout modes within a single BHA, eliminating the need for reverse circulation and multiple assemblies by configuring the valve to open or close based on specific flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a reverse ball check valve is used in the BHA, then abrasive perforating can be performed by directing fluid through jetting nozzles, but cleanout requires reverse circulation which is time-consuming and increases risk of getting stuck
Solution Approach 1:
The patent employs a dynamic valve mechanism that automatically switches between closed and open states based on flow direction and pressure differential. During abrasive perforating, the valve closes to direct fluid through jetting nozzles; during cleanout, the valve opens to allow bidirectional flow, eliminating the need for manual intervention or separate BHA configurations
Solution Approach 2:
The BHA assembly integrates a multi-functional valve system that enables both abrasive perforating and cleanout operations using the same equipment. The valve mechanism allows the single BHA to perform multiple functions by switching flow paths, eliminating the need for separate BHAs for different operations
2Ease of operation
If a double flapper check valve is used to regulate flow direction, then conventional downward flow is controlled, but cleanout requires a completely separate BHA or surface modification
Solution Approach 1:
The patent uses a dynamic valve mechanism that automatically responds to flow direction and pressure differential, switching between closed and open states without manual intervention. This eliminates the need for complex BHA configurations or surface modifications required by static check valves
Solution Approach 2:
The BHA assembly integrates a multi-functional valve system that enables both abrasive perforating and cleanout operations using the same equipment. The valve mechanism allows the single BHA to perform multiple functions by switching flow paths, eliminating the need for separate BHAs
3Productivity
If reverse circulation is used for cleanout, then fill can be removed from the wellbore, but the BHA may get stuck in horizontal wells due to wormhole formation
Solution Approach 1:
The patent employs a dynamic valve mechanism that automatically switches between closed and open states based on flow direction and pressure differential. During cleanout, the valve opens to allow bidirectional flow while maintaining controlled annular circulation patterns that prevent wormhole formation and BHA sticking
Solution Approach 2:
The valve mechanism responds to pressure differential feedback from the wellbore conditions, automatically adjusting its state to optimize flow paths. This feedback control ensures efficient cleanout while preventing conditions that lead to BHA sticking in horizontal wells
4Adaptability or versatility
If multiple BHAs are used for perforating and cleanout, then operational flexibility is achieved, but significant time wastage and additional cycling fatigue occur
Solution Approach 1:
The BHA assembly integrates a multi-functional valve system that enables both abrasive perforating and cleanout operations using the same equipment. The valve mechanism allows the single BHA to perform multiple functions by switching flow paths, eliminating the need for separate BHAs and associated switching operations
Solution Approach 2:
The patent merges the functions of multiple BHAs into a single integrated assembly with an automatic valve mechanism. This combination allows both perforating and cleanout operations to be performed with one BHA, eliminating the time wastage and cycling fatigue associated with switching between separate assemblies
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 efficient and safe operation with a single BHA for both abrasive perforating and cleanout in both vertical and horizontal wells, reducing operational time and risk of getting stuck, while allowing for higher pump rates and better sand removal.
Implementation Method 1
a multi-cycle open/close valve (MCOCV) responsive to a plurality of flow rates... configured to: operate in a first operating mode to abrasive perforate the wellbore at one or more first flow rates; and operate in a second operating mode to cleanout the wellbore at one or more second flow rates
Implementation Method 2
pumping fluid, normally containing an abrasive medium, through specialized jetting nozzles at high pressure. The fluid, when ejected from the jetting nozzles, erodes through the casing, cement and into the formation
Implementation Method 3
when pumping fluid down the CT, the reverse ball check valve 70 is forced closed, preventing the fluid from exiting the nozzle 100 below (at the bottom of the BHA) and directing the fluid through the jetting nozzle(s) 50 in the portion of the BHA above
Implementation Method 4
During reverse cleanout the reverse ball check valve 70 allows fluid and fill from the wellbore to enter the nozzle 100 at the bottom of the BHA, enabling the fluid and fill to flow up to surface via the CT
Data Source
AI summary
An apparatus and a method of performing a plurality of operations in a wellbore with one direction of flow. A multicycle open/close valve (MCOCV) responsive to a plurality of flow rates is placed in a bottom hole assembly (BHA) and is used to perform abrasive perforating of a wellbore or cleanout of the wellbore using one direction of flow. At one or more first flow rates, the MCOCV is configured to operate in a first operating mode to abrasive perforate the wellbore. At one or more second flow rates, the MCOCV is configured to operate in a second operating mode to cleanout the wellbore. In an embodiment, the MCOCV includes a J-slot sequencing mechanism responsive to a sequence of flow rates to cycle the MCOCV through a plurality of operating modes.