Downhole Disconnect Device with Motion Sensor and Timer
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Solution Overview
Problem
Existing disconnect methods for wellbore intervention tools are inefficient, prone to accidental disconnection, and require costly downtime and mechanical intervention, especially when tools become stuck in deviated or horizontal wells, and often fail to provide a suitable engagement surface for recovery tools.
Innovation Solution
A downhole disconnect device that automatically disconnects stuck intervention tools from wirelines without surface electric connection or operator interaction, using a motion sensor, timer, and actuator to ensure controlled disconnection and provide a standard fishing neck for recovery, eliminating human error and accidental disconnections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shear pin is designed to disconnect at low tensile load to accommodate weak wireline, then disconnection is achieved, but accidental disconnection occurs and wireline replacement is required
Solution Approach 1:
The disconnect device uses a dynamic locking mechanism with movable locking elements that can transition between locked and unlocked states. The locking elements are held in place by a retention mechanism that can be actively released, allowing the system to adapt its connection strength based on operational needs rather than relying on a fixed shear load threshold.
Solution Approach 2:
The patent replaces the passive mechanical shear pin system with an active control system using solenoids or hydraulic actuators to release the locking elements. This substitution allows for controlled disconnection without relying on mechanical failure thresholds, eliminating accidental disconnections caused by load variations.
2Reliability
If a cutter is sent down to sever the wireline to release it from BHA, then disconnection is achieved, but the method is inefficient and may fail to locate or sever the wireline in deviated wells
Solution Approach 1:
The disconnect device is pre-installed on the intervention tool before deployment. The locking and release mechanisms are already in place and configured, eliminating the need to send additional tools downhole to perform the disconnection action. The system is ready to disconnect immediately when the release signal is received.
Solution Approach 2:
The disconnect device performs the disconnection function autonomously using its own integrated locking and release mechanisms. The system uses the existing wireline tension and the actuator force to accomplish the disconnection without requiring external cutting tools or additional mechanical intervention from the surface.
3Reliability
If known disconnect methods are used, then disconnection can be achieved, but mechanical intervention by operator is required and human error occurs
Solution Approach 1:
The patent replaces manual operator intervention with an automated control system that uses solenoids, hydraulic actuators, or electronic controllers to release the locking elements. The system can be triggered by pre-programmed timers, sensor inputs, or surface commands, eliminating the need for mechanical manipulation by operators and reducing human error.
Solution Approach 2:
The disconnect device autonomously monitors operational parameters and can automatically initiate the disconnection sequence when predetermined conditions are met, such as a timer expiration or detection of a stuck tool condition. This self-service capability eliminates the need for continuous operator monitoring and manual activation.
4Reliability
If the tool becomes stuck and known disconnect methods are used, then disconnection is achieved, but no suitable engagement surface is provided for fishing tool recovery
Solution Approach 1:
The disconnect device incorporates a standardized fishing neck or engagement surface as part of its structure, which serves dual purposes: it provides the connection interface for the wireline/BHA and simultaneously serves as a universal engagement point for fishing tools. This multi-functional design ensures that regardless of how the tool becomes stuck, the same structural feature can be used for both operation and recovery.
Data Source
Figure 1
Figure 2a~2d
Figure 2e
AI summary
A downhole disconnect device for disconnecting an intervention tool string from a wireline, includes: a tubular body having a first part directly or indirectly coupleable to the wireline and a second part connectable directly or indirectly to an intervention tool string; an actuator for disconnecting the second part of the tubular body from the first part of the tubular body; at least one sensor to detect when the tool string is stuck in use and to produce an output signal accordingly; a controller configured to receive the output signal and selectively operate the actuator accordingly; and a power source. The tubular body is adapted to house the actuator, sensor, controller and power source and the device further comprises a timer configured to delay operation of the actuator by a predetermined time on receipt of the output signal from the sensor. There is also a method of operating the downhole disconnect device.