Reverse Circulation Debris Tool Pressure Control Valve
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Solution Overview
Problem
Reverse circulation wellbore cleanup devices lack effective well control during deployment and retrieval, as they are prone to pressure surges from formations, which existing designs cannot adequately manage, leading to potential loss of the bottom hole assembly and the need for costly fishing operations.
Innovation Solution
A pressure control valve is integrated into the tool that can be triggered by sensors to close and isolate the well passage, preventing pressure surges from reaching the surface during tool deployment or retrieval, using various sensing mechanisms to determine the appropriate closure time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the debris chamber length is increased to over 1000 meters to improve debris collection capacity, then the tool can capture more debris, but the tool develops wall openings that cannot be captured in a lubricator due to limited lubricator length, requiring isolation of the formation for running in or removal
Solution Approach 1:
The tool is divided into segments with multiple wall openings along its length, each capable of being independently isolated. This segmentation allows the tool to maintain its long debris chamber structure while enabling selective isolation of specific sections during running in or removal operations, resolving the conflict between increased capacity and operational ease.
2Object-affected harmful factors
If rams are used to close off the annulus to control pressure surges, then the annulus is isolated, but pressure surges from the formation can still communicate to the surface through the open lower end of the tool
Solution Approach 1:
A closure device is positioned at the lower end of the tool that can be activated preliminarily before pressure surges occur or in conjunction with annulus closure. This preliminary action of closing the tool's lower end works together with annulus isolation to provide complete well control, preventing pressure surge communication to the surface and improving overall well control reliability.
3Object-affected harmful factors
If shear rams are used to control severe pressure events, then pressure control is achieved, but the bottom hole assembly is lost and requires fishing operations for retrieval
Solution Approach 1:
The closure device at the lower end of the tool is designed as a sacrificial component that can be set to close permanently or temporarily. In severe pressure events, this closure device can be activated to seal the tool's lower end, providing pressure control without requiring shear rams that would sacrifice the bottom hole assembly. This eliminates the need for costly fishing operations while maintaining effective pressure control.
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 valve effectively manages well pressure excursions, preventing loss of the bottom hole assembly and eliminating the need for shear rams, thereby ensuring safe and efficient tool operation and retrieval, even for long debris chambers.
Implementation Method 1
a sensor that detects a predetermined condition to shut the isolation valve within the tool housing
Implementation Method 2
an eductor powered by tubing flow from the surface to draw debris laden flow into the bottom of the tool. The flow enters through an inlet tube surrounded by a debris reservoir. The heavier debris settles into the reservoir while smaller debris continues up the tool drawn by the eductor fluid inlet at which there is a reduced pressure due to the connected motive fluid.
Implementation Method 3
A reverse circulation debris cleanup tool has a pressure control valve that closes up a passage through the body based on a sensed well condition to help pressure control the well when rams close around the tool to isolate the surrounding annulus.
Data Source
AI summary
A reverse circulation debris cleanup tool has a pressure control valve that closes up a passage through the body based on a sensed well condition to help pressure control the well when rams close around the tool to isolate the surrounding annulus. The sensor can hold the valve open for a predetermined time to allow debris removal operations and then close. The debris chamber below an eductor in a VACS tool can be thousands of feet long and the valve can provide protection during running in or removal of the tool from well pressure events so as to avoid using shear rams and losing the bottom hole assembly in the borehole and a fishing operation to get it out.