Acoustic Communication System for Sequential Liner Hanger Setting
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Solution Overview
Problem
Current methods for setting liner hangers and top packers in well completion processes are time-consuming and unreliable, often relying on ball-based systems that can be physically challenging and prone to complications, necessitating a faster and more reliable method for sequential tool operation.
Innovation Solution
A communication system utilizing flow-based signals picked up by an acoustic receiver in a master controller to wirelessly command slave controllers for tool actuation, with integrated sensors for data collection and autonomous decision-making, enabling confirmation of tool activation and allowing for data download after the operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ball-based systems are used to set liner hangers and top packers, then the tools can be actuated, but the process becomes time-consuming and prone to complications
Solution Approach 1:
The patent replaces the mechanical ball-based actuation system with an acoustic signal-based control system. Flow-based acoustic signals are transmitted through the wellbore fluid to trigger tool operations, eliminating the need for physical ball landing and pressure building. This substitution dramatically reduces operation time and eliminates complications associated with ball-based systems while maintaining reliable tool actuation.
Solution Approach 2:
The patent introduces acoustic signals as an intermediary medium to transmit control commands from the surface to downhole tools. Instead of direct mechanical contact via balls, acoustic waves serve as the mediator to trigger tool operations sequentially, enabling faster and more reliable actuation without the physical complications of ball-based systems.
2Ease of operation
If ball-based systems are used for tool actuation, then tools can be set, but physical complications arise from landing balls on seats
Solution Approach 1:
The patent eliminates the mechanical ball landing process by substituting it with acoustic signal-based actuation. Flow-based acoustic signals trigger tool operations without requiring physical balls to be landed on seats, thereby removing all associated physical complications while simplifying the operation process.
Solution Approach 2:
The patent extracts and removes the ball-based actuation mechanism from the system entirely. By eliminating the balls, seats, and associated mechanical components, the system avoids all physical complications related to ball landing while maintaining effective tool actuation through acoustic signaling.
3Productivity
If acoustic signaling is used for tool actuation, then operation speed increases, but system complexity increases with master and slave controllers
Solution Approach 1:
The patent segments the control system into a master controller at the surface and slave controllers at downhole tools. The master controller generates and transmits acoustic signals, while slave controllers receive signals and execute specific tool operations. This segmentation enables fast sequential operation of multiple tools while distributing system complexity across modular components rather than requiring a single complex control unit.
Solution Approach 2:
The patent creates a universal acoustic signaling system that can actuate multiple different downhole tools through a common communication protocol. The master controller and slave controllers use standardized acoustic signal transmission and reception, allowing the same basic architecture to control various tools (liner hangers, top packers, etc.) without requiring tool-specific complex control systems.
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
Facilitates faster and more reliable sequential operation of subterranean tools, ensuring accurate confirmation of tool activation and efficient data collection for autonomous decision-making and post-operation analysis.
Implementation Method 1
flow based signals that are picked up with an acoustic receiver at a master controller
Data Source
AI summary
A communication system for sequential operation of subterranean tools involves flow based signals that are picked up with an acoustic receiver at a master controller, which then signals one or more slave controllers that operate tools and communicate back to the master controller that the subject tool has been operated. Sensors associated with the control system gather data downloaded when the master controller is pulled out of the hole. The system can be used to set a liner hanger and release a running tool and communicate that the liner hanger and running tool has activated. This can be confirmed with setting down weight and noting the running string going from tension to compression with a load cell or by translating the running string within the hole. The liner top packer can be set with a flow based signal to the master controller which is then removed with the running string.