Cementing Stage Tool with Rupture-Disk Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cementing stage tools struggle to selectively control fluid communication between a tubular string bore and an annulus during cementing operations, necessitating improvements for efficient cement placement and minimization of post-operation cleanup.
Innovation Solution
A cementing stage tool with an opening sleeve and rupture disks that respond to pressure differentials to control fluid flow, allowing selective communication between the tubular string bore and annulus, and features like shear members and closing sleeves to manage plug displacement and fluid flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing cementing stage tools are used to control fluid communication, then cement placement can be performed, but selective control between tubular string bore and annulus is difficult to achieve, leading to cement contamination in the bore
Solution Approach 1:
The tool divides fluid control into separate pathways using distinct valves: a first valve controls communication between the bore and annulus, while a second valve controls circulation within the bore. This segmentation allows independent control of each flow path, preventing cement contamination in the bore while enabling annulus cementation.
Solution Approach 2:
The tool introduces intermediate components including a bypass passage with a bypass valve that mediates between the bore and annulus, and a circulation valve that mediates bore circulation. These intermediaries provide precise control over fluid pathways, enabling selective cement placement without contaminating the bore.
2Productivity
If existing tools are used for cementing operations, then cement can be placed in the annulus, but post-operation cleanup is increased due to lack of precise flow control
Solution Approach 1:
The tool employs dynamic valve control mechanisms that can be actuated during operation to change flow pathways. The circulation valve and bypass valve can be opened or closed based on operational needs, allowing the system to adapt between cementation mode and circulation mode, thereby improving efficiency and reducing cleanup.
Solution Approach 2:
The tool enables recovery of excess cement and fluids through controlled circulation back up the bore. The circulation valve allows fluids to be redirected upward, and the bypass valve provides additional pathways for fluid recovery, minimizing waste and reducing post-operation cleanup requirements.
3Ease of operation
If existing cementing stage tools are used, then cementing operations can proceed, but operation indication is inefficient due to inability to monitor flow rate changes
Solution Approach 1:
The tool provides feedback on operational status through flow rate monitoring at the surface. By controlling circulation through the circulation valve and observing flow rate changes, operators can determine when the plug has been successfully displaced and when cementation is complete, enabling efficient real-time monitoring without losing critical operational information.
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 controlled cement placement by ensuring fluid communication is established without cement entering the tubular string bore, reducing post-operation cleanup and allowing for efficient operation indication through flow rate changes.
Implementation Method 1
a rupture disk configured to prevent fluid flow between the flow passage and the housing port and to permit fluid flow between the flow passage and the housing port in response to a predetermined pressure differential applied from the flow passage to the housing port
Data Source
AI summary
A method of cementing a tubular string in a wellbore can include applying a predetermined pressure differential from a flow passage extending axially through the tubular string to an annulus surrounding the tubular string, thereby opening a rupture disk of a cementing stage tool connected in the tubular string, and then flowing a fluid through the flow passage and into the annulus via the rupture disk, thereby displacing an opening plug into engagement with an opening sleeve of the cementing stage tool. A cementing stage tool can include a longitudinal flow passage, an outer housing assembly, an opening sleeve that prevents fluid flow between the flow passage and a housing port in a run-in configuration, and a rupture disk that permits fluid flow between the flow passage and the housing port in response to a predetermined pressure differential applied from the flow passage to the housing port.