Downhole Vibratory Bypass Tool with Pressure-Actuated Screen
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Solution Overview
Problem
Vibratory tools in bottom hole assemblies are susceptible to reduced lifespan and pressure drop when abrasive fluids are used, necessitating a solution to bypass these fluids until the vibratory tool is needed.
Innovation Solution
A downhole tool with a bypass passageway and screens that divert abrasive fluids away from the vibratory tool until a predetermined pressure is reached, allowing the vibratory tool to operate effectively by blocking the bypass passageway and directing fluid through the operational flow path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If abrasive fluid flows through the vibratory tool, then the vibratory tool can be operated, but the lifespan of the vibratory tool is significantly reduced
Solution Approach 1:
The flow path is segmented into two separate paths: an operational flow path for activating the vibratory tool and a bypass passageway for protecting it. The bypass passageway is divided into an upper portion and a lower portion by a screen, creating distinct flow channels that separate abrasive fluid from the vibratory tool during non-operational periods.
Solution Approach 2:
The screen acts as an intermediary element that diverts abrasive fluid away from the vibratory tool. By positioning the screen to block the operational flow path, it mediates between the incoming abrasive fluid and the vibratory tool, redirecting the fluid through the bypass passageway and preventing direct contact that would cause wear and reduce lifespan.
2Stress or pressure
If the vibratory tool is always activated, then fluid pressure is utilized, but abrasive fluid reduces the pressure drop across the tool
Solution Approach 1:
The system dynamically switches between two operational states: bypass mode where the screen blocks the operational flow path and directs fluid through the bypass passageway, and active mode where pressure buildup causes the screen to shift and allow fluid through the operational flow path. This dynamic adjustment optimizes pressure utilization while protecting the tool.
Solution Approach 2:
The system uses hydraulic pressure dynamics to control the flow path selection. When pressure in the operational flow path exceeds a threshold, the screen is forced to shift position, automatically switching the flow path without mechanical actuators. This pneumatic/hydraulic control mechanism maintains pressure drop across the tool when needed while preventing abrasive damage.
3Duration of action of moving object
If a bypass passageway is added to protect the vibratory tool, then the tool lifespan is extended, but the device complexity increases
Solution Approach 1:
The screen is designed to automatically shift position based on pressure differential alone, without requiring external control mechanisms, actuators, or complex valve systems. The bypass mechanism is self-regulating: when pressure builds in the operational flow path, the screen naturally shifts to allow flow, and when pressure equalizes, it returns to the blocking position. This self-service approach extends tool lifespan while minimizing added complexity.
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 solution extends the lifespan of vibratory tools and maintains pressure, enabling controlled activation of vibratory operations when needed, thereby optimizing oil and gas operations in wellbores.
Implementation Method 1
When a pressure differential between the inlet and outlet of the bypass tool is less than a threshold value, a screen blocks an operational flow path of the vibratory tool
Implementation Method 2
When the pressure differential between the inlet and outlet of the bypass tool exceeds the threshold value, the screen shifts from a first position that blocks the operational flow path to a second position that opens the operational flow path
Data Source
AI summary
A downhole tool is disclosed herein that has an inlet for receiving fluid into a housing of the downhole tool. The downhole tool further includes a vibratory apparatus at least partially disposed within the housing of the downhole tool, the vibratory apparatus having an operational flow path disposed therein to operate the vibratory apparatus when fluid flowing through the operational flow path is above a predetermined pressure. Furthermore, the downhole tool has a bypass passageway disposed in the housing for providing an additional flow path for fluid through the downhole tool to prevent fluid from reaching the predetermined pressure in the operational flow path of the vibratory apparatus, the bypass passageway selectively blockable such that fluid in the operational flow path is increased above the predetermined pressure to activate the vibratory apparatus when the bypass passageway is blocked. A method of using the downhole tool is also disclosed.