Weir Assembly for Solids Separation in Horizontal Wellbores
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional systems for well completion operations struggle with solids accumulation in casing due to insufficient fluid viscosity, leading to limited capacity for contaminant slurry containment and susceptibility to bridging, plugging, and pack-off, especially in horizontal wellbores.
Innovation Solution
A weir assembly is inserted into the wellbore casing to create a tortuous fluid flow path using oriented weirs, which separates solids from fluids through gravity and velocity, allowing for self-cleaning and increased slurry containment capacity during cementing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional filter systems are used to remove solids from wellbore fluid, then solids removal is attempted, but the systems cannot be cleaned or unplugged once solids accumulate
Solution Approach 1:
The filter system is divided into multiple filter elements that can be individually removed and replaced. Each filter element is a separate component that can be accessed and serviced independently, allowing maintenance without replacing the entire filter system.
Solution Approach 2:
Filter elements are nested within a filter housing structure that allows for easy insertion and removal. The filter elements can be accessed through the housing without disassembling the entire filter system, enabling quick maintenance operations.
2Productivity
If wellbore fluid viscosity is insufficient to transport solids, then solids settle within the casing, but increasing viscosity is not always feasible
Solution Approach 1:
Instead of relying solely on fluid viscosity to transport solids horizontally, the system uses vertical dimension with upwardly inclined filter elements to lift solids out of the fluid stream. This dimensional approach to solids separation bypasses the limitation of insufficient fluid viscosity.
Solution Approach 2:
The filter elements act as an intermediary structure that provides mechanical support for solids removal. Rather than relying on fluid properties alone, the filter elements serve as a physical mediator that actively removes solids from the flowing fluid.
3Quantity of substance
If solids accumulate at the lower side of horizontal casing, then containment capacity is limited, but redesigning casing orientation is not practical
Solution Approach 1:
The internal casing space is segmented by multiple filter elements arranged at different positions and angles. This segmentation creates multiple zones for fluid flow and solids separation, effectively utilizing the available casing volume for slurry containment.
Solution Approach 2:
Filter elements are arranged at upwardly inclined angles relative to the horizontal casing axis, utilizing the vertical dimension within the horizontal casing. This angular arrangement creates effective solids separation and increases containment capacity without requiring casing reorientation.
4Reliability
If conventional systems are used in horizontal wellbores, then bridging, plugging, or pack-off occurs, but modifying the entire wellbore configuration is complex
Solution Approach 1:
The wellbore system is segmented by inserting modular filter assemblies at specific locations within the horizontal casing. These discrete filter segments provide localized solids management without requiring modification of the entire wellbore configuration.
Solution Approach 2:
Filter elements serve as intermediary structures within the horizontal wellbore that actively manage solids accumulation. These intermediaries prevent bridging and plugging by continuously separating solids from fluid, protecting the overall wellbore system without requiring its redesign.
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 weir assembly effectively prevents bridging, plugging, and pack-off by depositing solids away from flow openings, enhancing the capacity to contain contaminated slurry and facilitating easy removal of solids through fluid circulation, thus improving the efficiency of well completion operations.
Implementation Method 1
the shape, orientation, and placement of the weirs utilize gravity and velocity to enhance separation of the solids from the fluids
Implementation Method 2
the shape, orientation, and placement of the weirs utilize gravity and velocity to enhance separation of the solids from the fluids
Data Source
AI summary
A weir assembly system comprises an insert dimensioned to be inserted into a section of a wellbore and a plurality of weirs spaced within the insert so as to increase the separation of solids from fluid within the section of the wellbore when the fluid is flowing through the wellbore. The plurality of weirs may be oriented to create a tortuous fluid flow path, such that a flow opening of a first weir causes solids to deposit at a second weir without obstructing a flow opening of the second weir. Additional apparatus, methods, and systems are disclosed.