Rupture Disc Assembly With Sled Actuation for Low-Debris Release
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Solution Overview
Problem
Existing methods for removing buoyant chambers in wellbores require additional operational steps, such as drilling out plugs, increasing completion time and cost, and there is a need for rupture systems that can withstand high pressures and limit debris volume and particle size in well applications.
Innovation Solution
A rupture disc assembly with an actuating mechanism that transitions from a sealing mode to a release mode and disc failure mode, using an outer and inner sled to manage pressure and facilitate the rupture of the disc, allowing for a buoyant chamber to be released efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drilling out plugs is used to remove buoyant chambers, then the buoyant chamber can be removed, but completion time and cost increase
Solution Approach 1:
The invention extracts the harmful element (plug) by designing a rupture disc assembly that can be activated to break the plug sealing the buoyant chamber, eliminating the need for drilling operations. The rupture disc assembly includes a disc, actuating mechanism, and housing that work together to breach the plug and release the buoyant chamber contents.
Solution Approach 2:
The rupture disc assembly is pre-installed within the buoyant chamber before deployment. The actuating mechanism is positioned and configured in advance to enable controlled rupture of the disc and subsequent release of the plug, allowing for rapid removal without requiring additional drilling equipment or operations.
2Reliability
If conventional rupture systems are used, then they can release pressure, but they generate excessive debris volume and particle size
Solution Approach 1:
The rupture disc is designed with a specific geometry featuring a shallow taper inward toward the bottom surface, which segments the rupture process into controlled stages. This geometric segmentation directs the failure mode to produce smaller debris particles and reduces overall debris volume compared to conventional flat-disc rupture systems.
Solution Approach 2:
The rupture disc incorporates a shallow taper on its side surface that creates localized stress concentration at specific regions. This local geometric modification controls where and how the disc ruptures, directing the failure to occur in a manner that minimizes debris generation while maintaining effective pressure release functionality.
3Stress or pressure
If high pressure is withstood during casing installation, then casing can be installed to desired depth, but operational complexity increases
Solution Approach 1:
The actuating mechanism is designed to transition the rupture disc assembly dynamically between a sealing mode (where the disc maintains the buoyant chamber seal during high-pressure casing installation) and a release mode (where the disc ruptures to release the chamber). This dynamic capability allows the system to adapt to changing pressure conditions without requiring multiple static components.
Solution Approach 2:
The rupture disc assembly serves multiple functions: it maintains pressure containment during casing installation, enables controlled release when needed, and facilitates buoyant chamber removal. The integrated design of the disc, actuating mechanism, and housing allows a single component to perform what would traditionally require multiple separate operations or devices.
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 rupture disc assembly effectively manages high pressures during casing installation, reducing operational steps and debris, and enhances the reliability and adaptability of rupture systems in wellbore applications.
Implementation Method 1
When the pressure facing surface of the rupture disc is subjected to a disc failure trigger pressure, the actuating mechanism may be activated to change the rupture disc assembly from the sealing mode to the release mode
Implementation Method 2
The rupture disc assembly effectively manages high pressures during casing installation
Data Source
AI summary
Disclosed is a rupture disc assembly for use in making a temporary seal in a vessel such as a casing string. The rupture disc assembly may generally include (A) a rupture disc having a side surface having a shallow taper inward towards a bottom surface of the rupture disc (B) an actuating mechanism including (i) an outer sled having an inner supporting surface forming a taper complimentary to the shallow taper of the side surface, (ii) an inner sled disposed within the outer sled and having a support shoulder to support the bottom surface of the rupture disc and (iii) a securing mechanism and (C) a housing to house the rupture disc and actuating mechanism.