Integrated Downhole Completion Assembly for Pressure-Set Deployment

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Solution Overview

Problem

Conventional downhole tools require numerous parts, are prone to failure, and are cumbersome, leading to increased maintenance and deployment time, especially in extreme wellbore conditions, and often necessitate the use of adapter kits to combine different components, which complicates operations.

Innovation Solution

A completion assembly comprising a first sub and a second sub, where the second sub is engaged with the first sub in a run-in configuration to maintain pressure integrity, and a non-mechanical force, such as fluid pressure, is used to move the assembly from the run-in to a disconnected configuration, eliminating the need for conventional setting tools and adapter kits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional setting tools and adapter kits are used to combine different components, then the downhole tool can be deployed, but the device complexity increases and deployment time increases

Engineering Contradiction:

Improvecompatibility between setting tool and downhole toolVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the setting tool and downhole tool into a single integrated completion assembly. The first sub includes a setting tool with a pressure chamber, while the second sub includes the downhole tool, and they are coupled together to function as one unit. This eliminates the need for separate adapter kits and reduces the total number of parts while maintaining compatibility and deployability.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If conventional setting tools with multiple parts are used, then the downhole tool can be set, but the reliability decreases due to more parts prone to failure

Engineering Contradiction:

Improvefailure resistanceVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By integrating the setting tool and downhole tool into a single completion assembly with fewer internal interfaces and connections, the patent reduces the number of parts that could potentially fail. The coupled design minimizes the number of separate components and assembly steps, thereby improving overall reliability in the downhole environment.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If conventional setting tools requiring adapter kits are used, then different components can be combined, but the ease of operation decreases

Engineering Contradiction:

Improvecomponent compatibilityVSAvoiddeployment ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent pre-couples the setting tool and downhole tool into an integrated completion assembly before deployment. This eliminates the need for field assembly using adapter kits and simplifies the deployment process to a single string operation, significantly improving ease of operation while maintaining the ability to combine different tool components in the design.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If conventional setting tools with numerous parts are used, then the downhole tool can be deployed, but the productivity decreases due to increased deployment time

Engineering Contradiction:

Improvedeployment speedVSAvoidnumber of parts

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

By integrating multiple functions into a single coupled completion assembly, the patent reduces the number of separate deployment operations required. The first sub and second sub are pre-assembled and deployed together as one unit, eliminating time-consuming field assembly steps and improving deployment productivity.

Inventive Principle:

Principle #5Merging (Combining)

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 solution provides a reliable and resilient seal with fewer parts, reduced deployment time, and easier operation, while maintaining pressure integrity, even in extreme conditions, by using a pre-assembled assembly that conveys hydraulic force directly to the downhole tool.

Implementation Method 1

The first sub may be configured to convey a non-mechanical force, such as hydraulic force, to the second sub

Methodology Applied

Scientific EffectHydraulic force: Hydraulic Press

Implementation Method 2

the second sub configured to maintain pressure integrity of a primary pressure chamber disposed at least partially within the first sub, the second sub, or both

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS20260002421A1Downhole completion assembly and related systems and methods of use

Publication Date: 2026.01.01 THE WELLBOSS CO LLC

AI summary

A completion assembly suitable for use in a wellbore, the completion assembly having a first sub engaged with a second sub in an assembled or run-in configuration. In the assembled or run-in configuration, the completion assembly is configured to maintain pressure integrity of a primary pressure chamber disposed at least partially within at least one of: the first sub, the second sub, or both.