Ramped Deflector Assembly for Multilateral Wellbore Tool Diversion
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Solution Overview
Problem
Traditional multilateral well construction methods are costly and not economically viable for unconventional frac operations, particularly due to the need for additional tools and processes that increase expenses beyond what is feasible for Drill and FRAC programs compared to single wells.
Innovation Solution
A deflector assembly with a tubular member having an uphole lateral wellbore portion and a downhole main wellbore portion, featuring an exit window and a ramped deflector that allows tools of different diameters to pass through or be diverted, enabling efficient formation of multilateral wells by integrating with existing casing strings and reducing the need for additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional solid whipstock assemblies are used to deflect window mills and form casing exits, then lateral wellbores can be created, but the device complexity and cost increase significantly making it economically unviable for unconventional frac operations
Solution Approach 1:
The patent removes the complex solid whipstock assembly from the system and replaces it with a simplified deflector element integrated into the casing string. The deflector is a simple angled component that guides the window mill during the initial run, eliminating the need for heavy whipstocks and subsequent re-entry operations. This extraction of the essential deflection function while removing unnecessary complexity directly resolves the contradiction.
Solution Approach 2:
The deflector is merged with the casing string itself, forming an integrated assembly rather than a separate tool. The deflector element is positioned within the casing and works in conjunction with the window mill during a single continuous operation. This merging eliminates the need for separate whipstock deployment and subsequent re-entry tools, reducing overall device complexity while maintaining the capability to form multilateral wells.
2Adaptability or versatility
If traditional multilateral well construction methods are used, then lateral wellbores can be formed, but the loss of time and additional operational steps reduce productivity
Solution Approach 1:
The deflector is pre-installed within the casing string before the window mill is deployed. This preliminary positioning ensures that the deflection path is already prepared, allowing the window mill to be guided immediately upon engagement without requiring separate whipstock deployment steps. This preliminary action eliminates time-consuming operational steps and improves productivity.
Solution Approach 2:
The system enables a continuous operational sequence where the deflector-guided window mill forms the exit window in a single continuous motion without interruption. The integrated design allows the window mill to pass through the deflector and complete the window formation in one continuous operation, eliminating the stop-start nature of traditional methods that require whipstock deployment, window formation, and subsequent re-entry operations.
3Adaptability or versatility
If multiple separate tools and re-entry methods are used, then lateral wellbores can be created, but the quantity of equipment and additional costs make the solution economically unviable
Solution Approach 1:
The deflector assembly is designed to perform multiple functions: it guides the window mill during initial deployment, defines the exit window geometry, and enables lateral wellbore formation. This multi-functional design eliminates the need for separate whipstock assemblies, window mills, and re-entry tools, reducing the quantity of equipment required while maintaining the capability to form multilateral wells.
Solution Approach 2:
The system segments the multilateral well formation process into a single integrated operation rather than requiring multiple separate tools. The deflector is divided into functional zones (leading edge, angled surface, trailing portion) that work together in sequence during one continuous operation, eliminating the need for multiple discrete tools and reducing equipment quantity.
Data Source
AI summary
Provided, in one aspect, is a deflector assembly. The deflector assembly may include a tubular member, the tubular member having an uphole lateral wellbore tubular portion and a downhole main wellbore tubular portion. The deflector assembly may further include an exit window located in a sidewall of the uphole lateral wellbore tubular portion, and a ramped deflector positioned within the uphole lateral wellbore tubular portion, the ramped deflector located proximate and ramping toward the exit window. The ramped deflector may include a through bore having a diameter (DTB) coupling the uphole lateral wellbore tubular portion and the downhole main wellbore tubular portion, the through bore forming a ramped deflector lip for allowing a first downhole tool having a diameter (D1) less than the diameter (DTB) to pass through the ramped deflector to the downhole main wellbore tubular portion, and for diverting a second downhole tool having a diameter (D2) greater than the diameter (DTB) toward the exit window.