Well Control Tool Segmented Sleeve for High-Pressure Wear
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Solution Overview
Problem
Conventional well control systems in oil and gas exploration face challenges such as unreliable operation, damage susceptibility, and difficulty in determining the downhole position of sliding sleeves, leading to inefficiencies and equipment failure, especially in high-pressure environments and multi-production zone wells.
Innovation Solution
A well control tool comprising a tubular seal stem and orientation sleeve with latching fingers and ports, allowing controlled fluid circulation and secure positioning above an ESP, with features like shearable latching fingers and optimized port design for improved flow and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sliding sleeves are used to control fluid flow between tubing string and annulus, then well control is achieved, but the sleeves frequently fail to fully open or close, become stuck or locked, and are susceptible to tearing in half due to wear from high pressure fluids and debris
Solution Approach 1:
The sliding sleeve is divided into multiple segments that can move independently relative to each other. This segmentation allows the sleeve to flex and accommodate pressure differentials without failing, while the segments can still work together to fully open or close the flow path. The segmented design prevents the sleeve from becoming stuck or locked by allowing local adjustment to pressure changes.
Solution Approach 2:
The sliding sleeve incorporates dynamic elements including springs and movable segments that allow the structure to adapt to changing downhole conditions. The springs provide restoring force to ensure the sleeve returns to its proper position after being subjected to pressure differentials, preventing it from becoming stuck in intermediate positions.
2Device complexity
If conventional sliding sleeves are used with minimal material remaining at communication ports, then the design is compact, but the minimal material is susceptible to wear from high pressure fluids and debris leading to sleeve failure
Solution Approach 1:
The communication ports are constructed using composite materials that combine high strength and wear resistance properties. This allows sufficient material to be present at the ports to withstand wear from high pressure fluids and debris, while the overall sleeve design remains compact and efficient.
3Reliability
If the entire well is filled with kill fluid to control high pressure wells, then well control is achieved, but the kill fluid must be completely removed from the tubing string once production resumes
Solution Approach 1:
The system extracts or removes the need to completely fill and completely drain the wellbore for well control operations. By using the packer and sliding sleeve mechanism, kill fluid can be contained in specific zones without requiring complete wellbore filling, and removal is facilitated through controlled flow paths that enable faster recovery of production.
4Reliability
If sliding sleeves are installed near the downhole-end of the tubing string, then well control is achieved, but there is no way to determine whether the sleeve is in the fully-open/closed position or in a partially-open/closed position
Solution Approach 1:
The system incorporates visual indicators that change appearance or position based on the sliding sleeve state. These indicators allow operators to determine whether the sleeve is fully open, fully closed, or in an intermediate position, providing critical information for well control operations without requiring complex electronic sensors.
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 enables reliable and efficient control of fluid flow in both production and injection wells, reduces equipment wear, and allows for precise management of multiple production zones with enhanced flow characteristics and reduced downtime due to improved fluid flow and debris management.
Implementation Method 1
The well is killed by pumping in kill fluids, e.g., brine water or mud, such that the hydrostatic weight of the kill fluid creates sufficient pressure to exceed the pressure exerted by the trapped oil and gas.
Implementation Method 2
Where an ESP was connected to the end of the tubing string, often the ESP itself was used to circulate the heavy kill fluid.
Data Source
AI summary
An improved downhole well control tool (“WCT”) allows for the control of in-situ fluid flow from a production well having one or more production zones. The WCT is installed in a tubing string in a zone to be controlled. An extensible flow is provided having a threaded connection on its lower end for coupling a pressure gauge or other instrumentation. The extensible flow nipple at its upper end is coupled to a lock body, thereby forming a fully-assembled extensible seal. The seal stem and the gauge may then be lowered using wireline tool into engagement with a tubular sub-assembly having a port. Advantageously, the exterior lateral channels of the extensible flow nipple seal the ports in the tubular sub-assembly. Then, for example, a pressure test may be performed.