Segmented Flow Diverter for Bidirectional Wellbore Cleanup
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Solution Overview
Problem
Wellbore cleanup tools with flow diverters that maintain wellbore wall contact in both directions, such as cup seals, restrict movement speed when running into the wellbore and can pressurize the formation, leading to reduced productivity and increased operational costs.
Innovation Solution
A wellbore cleanup tool with a segmented flow diverter that articulates to reduce resistance when moving in one direction, allowing for rapid movement by bypassing fluid around the outside, and retracts to divert debris-laden fluid into the annular space when moving in the opposite direction, using a combination of fixed and movable components guided on a support sleeve or inclined track.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cup seals maintain wellbore wall contact in both directions, then debris diversion into the annular space is achieved, but tool movement speed is restricted and formation pressurization occurs
Solution Approach 1:
The flow diverter is designed as a movable component that can change its position or configuration based on the direction of tool movement. When the tool moves in the debris collection direction, the diverter extends to contact the wellbore wall and divert fluid into the annular space. When the tool moves in the opposite direction, the diverter retracts or articulates to allow rapid fluid bypass, eliminating resistance to tool movement and preventing formation pressurization.
Solution Approach 2:
The flow diverter is divided into segmented components that can move independently relative to each other. This segmentation allows the diverter to articulate and reconfigure based on flow direction, with some segments extending to engage the wellbore wall while others retract to create flow paths, optimizing performance for bidirectional tool movement.
2Reliability
If flow diverter blocks fluid flow to divert into annular space, then debris capture is improved, but formation pressurization and operational costs increase
Solution Approach 1:
The flow diverter dynamically adjusts its flow blocking characteristics based on tool movement direction. During debris collection, the diverter maintains contact with the wellbore wall to effectively divert fluid into the annular space. During tool insertion or reverse movement, the diverter articulates to reduce flow resistance, allowing fluid to bypass easily and preventing formation pressurization.
3Speed
If cup seals are deflected from wellbore wall during tool insertion, then tool speed is improved, but debris diversion capability is lost
Solution Approach 1:
The flow diverter is designed to respond dynamically to tool movement direction. When the tool is inserted, the diverter articulates or retracts to clear the wellbore wall contact, allowing rapid fluid bypass and high insertion speeds. When the tool moves in the debris collection direction, the diverter extends or is positioned to engage the wellbore wall, restoring effective debris diversion capability.
Data Source
AI summary
A wellbore cleanup tool collects debris when moved in one direction downhole. A flow diverter is extended for such flow diversion when debris is collected. When running the tool in the opposite direction in the wellbore, the flow diverter is in whole or in part articulated to retract so as to reduce resistance to fluid that passes around the outside of the tool. A segmented diverter can have fixed and movable components that are guided. The movable components can become longitudinally offset from the fixed components for movement in the direction where maximum flow bypass around the outside of the tool is desired. In an alternative embodiment, the diverter segments can all be movable on an inclined track to retract against a bias force for fluid bias with movement of the tool in the opposite direction allowing the bias to push the segments on the inclined track for diversion of debris laden fluid into a capture volume in the tool.