Composite Downhole Tool Mandrel for Wellbore Isolation
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Solution Overview
Problem
Conventional downhole tools used for wellbore isolation face challenges such as degradation under extreme downhole conditions, poor sealing, and difficulty in removal due to debris accumulation, leading to operational delays and increased drilling time.
Innovation Solution
A downhole tool made of filament wound composite material with a mandrel, metal slips, and a composite member featuring deformable and resilient portions, designed to form a reliable seal and facilitate easy drilling through with serrated teeth and pin inserts for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal plugs are used for wellbore isolation, then structural strength and durability are improved, but drilling time and operational costs increase due to difficulty in removal
Solution Approach 1:
The plug body is constructed from composite materials that provide both the necessary structural strength to withstand wellbore pressures and the drillability to be easily removed. This composite construction allows the plug to meet both contradictory requirements simultaneously.
2Reliability
If conventional metal plugs with compressible seal elements are used, then sealing capability is improved, but reliability deteriorates under extreme downhole conditions due to material degradation
Solution Approach 1:
The seal element is designed to change its physical parameters in response to downhole conditions. The compressible material is selected to maintain sealing effectiveness across a range of temperatures and pressures, adapting its properties to ensure reliable sealing under extreme conditions without degrading.
3Force
If conventional metal slips are used for tool retention, then grip strength is improved, but ease of operation worsens due to debris accumulation and difficulty in removal
Solution Approach 1:
The slips are designed with different material properties at different locations - the outer surface that contacts the wellbore wall is made of a softer, debris-resistant material that maintains grip strength while preventing debris accumulation, while the inner portion remains structurally sound for retention. This local differentiation resolves the contradiction between grip strength and ease of removal.
Data Source
AI summary
A downhole tool for use in a wellbore that includes a mandrel made of a composite material, the mandrel having a distal end and a proximate end. The downhole tool has a metal slip having a slip body comprising at least one longitudinal hole, and a face surface configured with a set of mating grooves. The downhole tool has a lower sleeve disposed about the mandrel at the distal end, the lower sleeve having a set of pin inserts configured to engage the set of mating grooves.