Variable Flow Diverter Tool for Downhole Wear Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Milling tools and mud motors in downhole operations experience wear due to continuous exposure to pressurized fluid when not actively milling, reducing their lifespan and efficiency.
Innovation Solution
A variable flow diverter tool with an elongate outer sleeve and inner element, featuring a spring mechanism that aligns or blocks pressurized fluid ports to divert fluid away from the mud motor and milling tool as needed, allowing for controlled fluid flow based on tool position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressurized fluid continuously flows through the mud motor and milling tool, then the tools remain ready for operation, but wear increases and lifespan decreases
Solution Approach 1:
The patent extracts the harmful continuous fluid flow from the milling tool and mud motor by providing an alternative flow path through the diverter mechanism. The fluid is taken out of the tool assembly and redirected through the annular space between the outer sleeve and inner element, eliminating unnecessary wear while maintaining operational readiness.
Solution Approach 2:
The diverter mechanism acts as an intermediary between the fluid source and the milling tool/mud motor. By introducing this intermediate control element, the system can selectively redirect fluid flow away from the tools during non-milling operations, reducing wear while preserving the capability to restore full flow when needed.
2Reliability
If the diverter mechanism is added to control fluid flow, then tool wear is reduced, but device complexity increases
Solution Approach 1:
The diverter mechanism employs dynamic elements including a movable inner element that can shift between positions, a spring that provides automatic return force, and a cam-operated locking system. This dynamic design allows the mechanism to automatically transition between diverted and non-diverted flow states based on operational needs, providing complex functionality through relatively simple mechanical components.
3Object-affected harmful factors
If the inner element is held in the diverted position, then wear is reduced, but fluid flow to the mud motor is blocked
Solution Approach 1:
The diverter mechanism operates periodically, switching between two distinct states: diverted flow (reducing wear) and non-diverted flow (enabling milling operation). The cam-operated locking mechanism and spring system enable this periodic transition, allowing the fluid flow to be cyclically redirected to the mud motor when needed and away from it during non-milling operations.
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 tool extends the lifespan of milling tools and mud motors by reducing wear through controlled fluid diversion, optimizing fluid flow during milling and non-milling phases, and enabling efficient operation in cased wellbores.
Implementation Method 1
a spring installed within the upper chamber and situated between the base of the upper body and the base of the upper chamber
Data Source
AI summary
A downhole tool configured to vary the amount of pressurized fluid delivered to other tools incorporated into a bottom hole assembly, such as a mud motor. The tool comprises an inner element installed within an outer sleeve. The inner element is configured to move between three different positions relative to the outer sleeve. In a first position, pressurized fluid is diverted away from downstream tools within the bottom hole assembly. In a second and third position, pressurized fluid is directed towards downstream tools. Movement of the tool between the different positions is caused by varying external forces applied to the tool.