Composite Downhole Tool with Channelled Setting Sleeve
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Solution Overview
Problem
Conventional downhole tools face challenges in forming reliable seals in extreme wellbore conditions, are difficult to drill through due to metallic components, and encounter issues with debris accumulation and pre-setting, leading to operational delays and increased costs.
Innovation Solution
A downhole system featuring a composite frac plug with a mandrel, bearing plate, slips, and a sealing element, designed for horizontal orientations, utilizing a composite material that is easier to drill through and includes a setting sleeve with channels to reduce hydraulic drag and facilitate faster pullout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metallic downhole tools are used, then strength and durability are improved, but drilling time and difficulty increase
Solution Approach 1:
The patent applies composite materials by constructing the downhole tool body from concrete or cement-based composite materials instead of traditional metals. This composite material provides sufficient strength for downhole operations while being easily drillable, resolving the contradiction between tool strength and drilling time by offering a material that satisfies both requirements through its unique properties of being both strong enough for the application and easily removable via drilling.
2Reliability
If compressible seal members are used, then sealing capability is improved, but reliability under extreme conditions deteriorates
Solution Approach 1:
The patent applies parameter changes by modifying the seal member material properties to withstand extreme wellbore conditions. Instead of using conventional compressible seal members that degrade under high temperature and pressure, the invention uses seal members made from materials with altered parameters (temperature resistance, pressure resistance) that maintain their sealing capability under extreme conditions, thus improving reliability while resisting harmful environmental factors.
3Reliability
If conventional downhole tools are used, then sealing capability is improved, but ease of removal deteriorates
Solution Approach 1:
The patent applies composite materials to resolve the contradiction between sealing capability and ease of removal. The concrete or cement-based composite tool body maintains sufficient strength for sealing operations but is inherently easy to drill through for removal. This material choice simultaneously achieves reliable sealing during operation and facilitates quick removal afterward, eliminating the trade-off present in conventional metallic tools.
4Strength
If solid setting sleeves are used, then structural strength is improved, but hydraulic drag increases
Solution Approach 1:
The patent applies porous materials by incorporating channels or voids within the setting sleeve structure. This porous design reduces the solid material volume, thereby decreasing hydraulic drag and energy loss during fluid flow through the wellbore. The channels allow fluid passage while the remaining solid structure maintains sufficient strength for the setting operation, resolving the contradiction between structural strength and hydraulic drag.
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 system provides a reliable and resilient seal, reduces drilling time and costs, and effectively withstands extreme wellbore conditions while being easier to remove and less prone to pre-setting, enhancing operational efficiency.
Implementation Method 1
a setting sleeve with channels to reduce hydraulic drag and facilitate faster pullout
Implementation Method 2
The tool 102 generally includes a body 103 with a compressible seal member 122 to seal the tool 102 against an inner surface 107 of a surrounding tubular
Implementation Method 3
a compressible seal member 122 to seal the tool 102 against an inner surface 107
Implementation Method 4
the slips 109, 111 are driven against corresponding conical surfaces 104. This movement axially compresses and/or radially expands the compressible member 122, and the slips 109, 111, which results in these components being urged outward from the tool 102 to contact the inner wall 107
Data Source
AI summary
A downhole system useable for downhole operations that includes a work string comprising a downhole end; a setting sleeve coupled with the downhole end; and a downhole tool engaged with the setting sleeve during run-in. The setting sleeve has an outer sleeve surface having an at least one channel disposed therein. The downhole tool includes a mandrel made of a composite material.