Vibration-Induced Wellbore Casing Installation
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Solution Overview
Problem
The installation of wellbore casing is hindered by high friction between the casing string and the wellbore, and ensuring even cement distribution and hardening is challenging, often requiring costly re-drilling or re-reaming when traditional methods fail.
Innovation Solution
A vibration assembly powered by fluid flow through a turbine, which imparts vibrations to the casing string to reduce friction and aids in cement distribution, equipped with sensors and a bypass mechanism to monitor and communicate installation parameters wirelessly, and constructed from drillable materials for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional methods are used to install casing, then the installation process is simple, but high friction between the casing string and wellbore prevents successful installation
Solution Approach 1:
The patent applies mechanical vibration through a vibration assembly that includes an unbalanced shaft rotating at high speed to generate vibrations. These vibrations reduce the coefficient of friction between the casing string and wellbore, enabling the casing to be pushed through the wellbore wall without excessive force or re-drilling operations.
2Ease of operation
If traditional casing installation is used, then the process is straightforward, but even cement distribution and hardening cannot be ensured
Solution Approach 1:
The vibration assembly generates mechanical vibrations that facilitate even distribution of cement in the annulus between the casing string and wellbore. The vibrations prevent cement clumping and ensure uniform hardening, eliminating the need for costly re-reaming operations if cement distribution is insufficient.
3Ease of operation
If vibration assembly is added to reduce friction, then casing installation becomes possible, but device complexity increases
Solution Approach 1:
The vibration assembly is designed to be self-powered by utilizing the fluid flow (drilling mud or cement) already circulating through the wellbore. The fluid flow drives the turbine, which rotates the unbalanced shaft to generate vibrations, eliminating the need for external power sources or complex control systems.
Solution Approach 2:
The vibration assembly is constructed from drillable materials that can be easily removed after use. This disposable approach reduces the complexity and cost of recovery operations, as the assembly can be drilled out without requiring complex retrieval mechanisms or extensive wellbore work.
4Productivity
If sensors and bypass mechanism are added to monitor installation parameters, then communication efficiency improves, but device complexity increases
Solution Approach 1:
The monitoring system utilizes the existing fluid flow and turbine rotation to power sensors and communicate installation parameters. The system leverages the natural energy available in the wellbore environment, reducing the need for additional power sources or complex communication infrastructure.
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 vibration assembly effectively reduces friction during casing installation, facilitates even cement distribution, and enables efficient communication of installation parameters, reducing operational delays and costs by allowing for wireless monitoring and easy removal post-installation.
Implementation Method 1
A vibration assembly powered by fluid flow through a turbine, which imparts vibrations to the casing string to reduce friction
Implementation Method 2
A vibration assembly powered by fluid flow through a turbine
Data Source
AI summary
An unbalanced sub-assembly includes a turbine and a shaft coupled to the turbine at a first end of the shaft. The unbalanced sub-assembly is capable of rotating and imparting a vibration to the casing in response to a fluid being passed through the casing. A rupture disc is positioned on one end of the unbalanced sub assembly. The rupture disc is configured to rupture above a specified differential pressure threshold caused by fluid flowing through the vibration assembly. The rupture disc is capable of allowing the fluid to bypass the unbalanced sub assembly when the rupture disc is in a ruptured state. The rupture disc directs fluid through the unbalanced sub assembly when the rupture disc is in an un-ruptured state.