Valve Assembly Controls Expandable Sleeve Expansion Timing
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Solution Overview
Problem
Existing well completion methods often compromise safety by risking premature expansion of annular barriers during cementing operations, leading to potential blockages and incomplete cement jobs.
Innovation Solution
A completion method and system utilizing a second well tubular metal structure with an expandable annular barrier and a valve assembly that maintains a closed position until a specific pressure is reached, ensuring the annular barrier expands only after the cementing process is complete, using a breakable element to change the valve assembly's condition and expand the metal sleeve to abut the borehole wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the annular barrier is designed to expand during cementing operations, then zone isolation effectiveness is improved, but premature expansion may occur blocking the annulus and preventing complete cement placement
Solution Approach 1:
The valve assembly is pre-configured in a closed position during cementing operations to prevent premature expansion of the annular barrier. The breakable element is designed to fail at a specific pressure threshold, automatically transitioning the valve to an open position only after cementing is complete, thus ensuring the barrier expands at the correct time without blocking the annulus during cement placement.
2Reliability
If pressure is applied to expand the annular barrier, then sealing against the borehole wall is improved, but unintentional expansion may occur during cleaning and cementing operations
Solution Approach 1:
The valve assembly acts as an intermediary between the pressurization system and the annular barrier. It controls the flow of pressurized fluid to the barrier, ensuring that pressure is only transmitted to expand the barrier when the valve is in the open position. During cleaning and cementing, the closed valve position prevents pressure transmission, avoiding unintentional expansion while still allowing these operations to proceed.
3Reliability
If the valve assembly remains closed during cementing, then premature expansion is prevented, but fluid communication is blocked until the breakable element fails
Solution Approach 1:
The valve assembly utilizes pressure as a controlling parameter, with the breakable element designed to fail at a specific pressure threshold. During cementing, the valve remains closed under normal operating pressures. When pressure exceeds the breakable element's failure threshold after cementing is complete, the element fails and automatically opens the valve, allowing fluid communication and barrier expansion without requiring complex control systems.
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
This approach prevents unintentional expansion of annular barriers during cleaning and cementing, ensuring the cement job is completed without premature blockages, allowing for secure and effective zone isolation in the well.
Implementation Method 1
pressurising the inside of the second well tubular metal structure to a third pressure above the first pressure and the second pressure breaking a breakable element in the valve assembly
Implementation Method 2
expandable by means of pressurised fluid from within the second well tubular metal structure through a valve assembly into an annular space between the tubular part and the expandable metal sleeve
Data Source
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AI summary
The present invention relates to a completion method for completing a well having a top comprising, drilling a borehole below a first well tubular metal structure in the well, circulating mud at least partly while drilling the borehole, providing a second well tubular metal structure having at least one unexpanded annular barrier having a tubular part surrounded by an expandable metal sleeve, expandable by means of pressurised fluid from within the second well tubular metal structure through a valve assembly into an annular space between the tubular part and the expandable metal sleeve. The second well tubular metal structure having a first end closest to the top and a second end, the valve assembly having a first condition in which fluid communication between an inside of the second well tubular metal structure and the space is disconnected, and having a second condition allowing fluid communication between the inside of the second well tubular metal structure and the annular space, running of the second well tubular metal structure into the well to a position at least partly below the first well tubular metal structure, circulating cleaning fluid at a first pressure out through the second end to remove at least part of the mud, displacing cement at a second pressure down through the second well tubular metal structure and out through the second end into an annulus between the second well tubular metal structure and a wall of the borehole, pressurising the inside of the second well tubular metal structure to a third pressure above the first pressure and the second pressure breaking a breakable element in the valve assembly, which changes condition from the first condition to the second condition, further pressurising the inside of the second well tubular metal structure, expanding the expandable metal sleeve to abut the wall of the borehole. The invention also relates to a completion system for completing a well having a top.