Downhole Control Line Guidance System for Expandable Tubulars
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Solution Overview
Problem
In the resource exploration and recovery industry, running control lines downhole can interfere with downhole tool operations and either reduce the flow area of tubular strings when internal or require special structures to avoid interference when external, posing challenges in routing and tool functionality.
Innovation Solution
A downhole tool with an expandable member and activation mechanism that allows a control line guidance system to shift the control line radially outwardly from the outer surface of a tubular member, ensuring non-interference with tool operations while maintaining flow area integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the control line is run internally of the outer diameter (OD), then the routing is simple, but the overall flow area of the tubular string is reduced
Solution Approach 1:
The control line is routed from the external surface of the tubular string through a control line guidance system that extends radially outward, moving the control line into a third dimension (radial extension) rather than confining it to the internal or external surface planes. This dimensional transition allows the control line to be positioned outside the OD without permanently reducing the internal flow area.
Solution Approach 2:
A control line guidance system acts as an intermediary structure between the control line and the tubular string. This guidance system includes a radially extending portion that interfaces with the control line and a recess in the outer surface that receives the guidance system, enabling the control line to be routed externally without directly interfering with the internal flow path.
2Area of stationary object
If the control line is run externally of the outer diameter (OD), then the flow area is maintained, but special structures are required to prevent interference with tool operation
Solution Approach 1:
The control line guidance system is divided into distinct functional segments: a radially extending portion that interfaces with the control line, a recess in the outer surface that receives the guidance system, and an activation mechanism portion that interfaces with the expandable member. This segmentation allows each component to perform its specific function while working together to route the control line without interference.
Solution Approach 2:
The control line guidance system is designed to be dynamically adjustable through the activation mechanism. When the expandable member expands radially outward, the activation mechanism causes the control line guidance system to shift, allowing the control line to move with the expansion while maintaining its external routing and avoiding interference with the tool operation.
3Ease of operation
If the control line is routed over the expandable member, then the routing path is defined, but the control line may interfere with tool operation during expansion
Solution Approach 1:
The control line is positioned and routed over the expandable member before the expansion operation begins. The control line guidance system is pre-configured with the radially extending portion and recess structure that anticipates the expansion motion, allowing the control line to be guided safely during the subsequent expansion without causing interference.
Solution Approach 2:
The activation mechanism provides feedback from the expandable member's expansion motion to the control line guidance system. As the expandable member expands radially outward, the activation mechanism detects this motion and automatically shifts the control line guidance system to maintain proper spacing and routing, preventing interference with tool operation.
Data Source
AI summary
A downhole tool including a tubular member having an outer surface and an inner surface defining a flow bore. An expandable member is arranged on the outer surface. The expandable member is selectively radially outwardly expandable. An activation mechanism is operatively connected to the expandable member. The activation mechanism is operable to radially outwardly expand the expandable member. A control line extends along the outer surface and over the expandable member. A control line guidance system is operable to shift the control line radially outwardly from the outer surface.