Structural Improvement of Differential Motion Assembly in In Situ Pressure-Preserved Coring System Using CFD Simulation

In situ pressure-preserved coring (IPP-Coring) is one of the most efficient methods for identifying the scale of the oil and gas content. However, the differential motion assembly of the IPP-Coring system often undergoes ball and ball seat seal failure and sticking due to surface erosion, and a greater pressure drop may unexpectedly trigger the assembly. This paper addresses these issues by improving the hydraulic structure of an assembly based on a deep understanding of the flow characteristics in the assembly, thus increasing the success rate of the IPP-Coring. Computational fluid dynamics (CFD) was employed to investigate flows in a differential motion assembly. The effects of the diameter and outlet structure of the ball seat on the fluid status, velocity, and pressure distribution were thoroughly analyzed. When the ball seat diameter increased from 30 to 40 mm, the maximum velocity and pressure drop decreased to 0.55 and 0.2 times their original values, respectively. There was a severe vortex area in the differential motion assembly due to the presence of the ball seat, but changing the outlet structure in the ball seat to an arc structure decreased the length of the vortex area and the fluid velocity near the wall to 0.7 and 0.4 times, respectively, compared with those with the original right-angled structure. In addition, the pressure drop decreased to 0.33 times the original value. Thus, the hydraulic structure of the assembly was improved, and a 40 mm diameter ball seat and an arc-shaped ball seat outlet were selected. Particle trajectory and erosion calculation results showed that the improved structure has a lower particle velocity and less impact on the wall, and the average erosion rate is only 0.42 times the value of the original structure. Due to the better erosion resistance and smaller pressure drop, the improved structure shows promise for field performance.