Downhole Self-Isolating Drilling System for Blowout Prevention

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Solution Overview

Problem

During wellbore drilling, hydrocarbons can flow to the surface before the well is set for production, causing well blowouts, and the aggregation of formation cuttings can reduce drill bit life, penetration rate, and lead to stuck pipes or lost circulation.

Innovation Solution

A downhole self-isolating wellbore drilling system comprising a cutting grinder tool to pulverize formation cuttings and an isolation tool that controls the flow of the mixture with drilling mud, using an elastomer that expands in response to hydrocarbons to block flow and a density-sensitive floating member to manage fluid density changes, thereby preventing uncontrolled hydrocarbon influx and reducing the risk of tool sticking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If drilling continues without isolation mechanism, then drilling productivity is maintained, but risk of well blowout increases due to uncontrolled hydrocarbon influx

Engineering Contradiction:

Improvewell blowout preventionVSAvoiddrilling system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The isolation tool is pre-installed in the drill string before drilling operations begin. The elastomeric material is pre-positioned to automatically expand and block the flow path when hydrocarbons are detected, eliminating the need for real-time intervention and reducing system complexity while maintaining high reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The isolation tool employs self-activating mechanisms where the elastomeric material automatically expands upon contact with hydrocarbons, and the floating member automatically blocks the flow path when hydrocarbon density is detected. This eliminates the need for external control systems, reducing device complexity while ensuring reliable blowout prevention.

Inventive Principle:

Principle #25Self-service

2Reliability

If formation cuttings are not pulverized, then device complexity is reduced, but aggregation of cuttings causes stuck pipe and lost circulation

Engineering Contradiction:

Improvestuck pipe preventionVSAvoidcuttings management complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cutting grinder tool is integrated directly into the drill string assembly, combining the functions of drilling, cuttings pulverization, and flow management in a single integrated system. This reduces overall device complexity while ensuring cuttings are continuously pulverized to prevent aggregation, stuck pipe, and lost circulation.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If hydrocarbons flow to surface unchecked, then drilling speed is maintained, but well blowout occurs reducing productivity

Engineering Contradiction:

Improvedrilling speedVSAvoidwell control safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The isolation tool incorporates automatic detection mechanisms that sense the presence of hydrocarbons in the drilling fluid. The elastomeric material responds to hydrocarbon contact by expanding to block flow, and the floating member rises or falls based on fluid density changes caused by hydrocarbon presence. This automatic feedback system maintains well control safety without interfering with normal drilling operations, allowing continuous productivity when conditions are safe.

Inventive Principle:

Principle #23Feedback

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 system proactively limits the risk of uncontrolled hydrocarbon influx, improves wellbore cleaning, and decreases the risk of tool sticking, enhancing safety and efficiency in wellbore drilling operations.

Implementation Method 1

The isolation tool can include an elastomer that expands in response to being contacted with hydrocarbons

Methodology Applied

Scientific EffectAbsorption (physical): Absorption (physical)

Implementation Method 2

The isolation tool can include a floating member having a density that is greater than a density of the mixture that includes hydrocarbons and lesser than a density of the mixture that excludes hydrocarbons

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS10161192B2Downhole self-isolating wellbore drilling systems

Publication Date: 2018.12.25 SAUDI ARABIAN OIL CO

AI summary

One example of a downhole self-isolating wellbore drilling system to pulverize formation cuttings includes a cutting grinder tool and an isolation tool. The cutting grinder tool can be attached to a drill string uphole relative to a drill bit attached to a downhole end of the drill string. The cutting grinder tool can receive and pulverize formation cuttings resulting from drilling a formation using the drill bit. The isolation tool can be attached to the drill string uphole relative to the cutting grinder tool. The isolation tool can control flow of the pulverized formation cuttings mixed with a drilling mud uphole through the drill string.