Autonomous Downhole Cutting Tool for Stuck Pipe

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for freeing stuck drill strings in wellbores require prior knowledge of the stuck location and rely on surface support, leading to inefficiencies and increased operational costs due to the need for wire-line units and prolonged mobilization times.

Innovation Solution

The development of downhole autonomous cutting tools that can detect and cut stuck pipes without surface support, equipped with a sensor module, hydraulic motor, locking unit, and actuation unit, allowing for autonomous operation and elimination of the need for prior location knowledge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If mechanical and hydraulic tools are used to free the drill string, then the stuck pipe can be cut and freed, but prior knowledge of the stuck location is required and surface support is needed

Engineering Contradiction:

Improveoperation simplicityVSAvoidlack of prior location knowledge

Core Design Contradiction:

Ease of operationVSLoss of information

Solution Approach 1:

The cutting tool is designed to autonomously locate the stuck pipe section and perform cutting operations without requiring surface support or prior knowledge of the stuck location. The tool self-navigates downhole, detects the stuck section through sensor feedback, and executes the cutting operation independently, thereby eliminating the need for wire-line units and surface intervention.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The cutting tool is deployed downhole in advance to position itself at the stuck location before the actual cutting operation is required. The tool travels through the drill string ahead of time, prepares the cutting elements, and positions the locking mechanism near the stuck section, so that when activation is signaled, the cutting can begin immediately without waiting for location identification or surface preparation.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If wire-line units are used to deploy cutting tools, then cutting operations can be performed, but operational time increases from days to weeks

Engineering Contradiction:

Improvecutting operation efficiencyVSAvoidmobilization and operational time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The cutting tool is extracted from the constraint of requiring wire-line deployment and surface support. By designing the tool to be freely deployable through the drill string without wire-line attachment, the system eliminates the time-consuming mobilization and deployment procedures associated with wire-line units, reducing operational time from weeks to days.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical wire-line deployment system with a fluid-driven or gravity-assisted deployment mechanism. The cutting tool is propelled downhole through the drill string using drilling fluid pressure or gravitational force, eliminating the need for complex wire-line handling equipment and significantly reducing mobilization and deployment time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If wire-line units are deployed for cutting operations, then cutting can be performed, but operational costs increase

Engineering Contradiction:

Improvecutting operation capabilityVSAvoidoperational cost

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The cutting tool is designed as a disposable or single-use downhole device that is deployed, activates once to cut the stuck pipe, and then remains in the wellbore. This eliminates the need for expensive wire-line units and their associated mobilization costs. The low cost of the disposable tool compared to the expensive wire-line equipment results in significant operational cost savings.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Ease of operation

If the cutting tool is supported from the surface on a wire-line, then control and actuation are possible, but device complexity and operational requirements increase

Engineering Contradiction:

Improvetool control capabilityVSAvoidsystem complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The cutting tool transitions from a static, surface-controlled system to a dynamic, autonomous system. The tool incorporates sensors, actuators, and control logic that enable it to adapt to downhole conditions, automatically locate the stuck section, and execute cutting operations without continuous surface intervention. This dynamic capability reduces system complexity by eliminating wire-line infrastructure while maintaining full operational control.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11492862B2Cutting pipes in wellbores using downhole autonomous cutting tools

Publication Date: 2022.11.08 SAUDI ARABIAN OIL CO

AI summary

A downhole autonomous cutting tool and methods are described. The downhole autonomous cutting tool including: a body comprising a hydraulic motor, the body having a generally cylindrical configuration such that the body limits a downhole flow of fluids past the autonomous cutting tool between the autonomous cutting tool and the pipe when the tool is deployed in the pipe; a locking unit attached to the body, the locking unit actuable to engage inner surfaces of the pipe in the wellbore; a sensor module operable to detect interactions between the pipe and walls of the wellbore; an actuation unit attached to the body and rotatable by the hydraulic motor, the actuation unit operable to move a plurality of cutting elements between a running position and a cutting position; and a control unit in electronic communication with the sensor module, the locking unit, and the actuation unit.