Downhole Expansion Tool with Segmented Piston Modules

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Solution Overview

Problem

Existing downhole tools require high forces to expand casings or liners in well bores, which can damage the system and are inefficient, necessitating a reduction in the forces needed for expansion.

Innovation Solution

The use of separate expansion modules positioned axially along the casing/liner, with pistons controlling fluid communication between annulus spaces to distribute the expansion force, allowing for sequential and controlled expansion by moving the modules relative to each other, reducing the need for high differential pressures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If high forces are applied to expand the casing/liner, then the expansion is achieved, but the system is exposed to high level forces that can harm it

Engineering Contradiction:

Improveexpansion forceVSAvoidsystem damage

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The expansion tool is divided into multiple expansion modules (at least two) that are distributed along the casing/liner. Each module applies expansion force independently, distributing the total expansion force across multiple locations. This segmentation reduces the force required at each location and prevents any single point from承受ing excessive force that could damage the system.

Inventive Principle:

Principle #1Segmentation

2Force

If high differential pressure is used to drive the expansion, then the expansion force is sufficient, but the system stress increases

Engineering Contradiction:

Improveexpansion forceVSAvoidsystem stress

Core Design Contradiction:

ForceVSStress or pressure

Solution Approach 1:

The hydraulic system is segmented into multiple annulus spaces (at least two) separated by pistons. Each annulus space can be pressurized independently or sequentially, allowing the expansion force to be distributed across multiple expansion modules. This reduces the differential pressure required in any single space, thereby reducing system stress while still achieving sufficient expansion force through the cumulative effect of multiple modules.

Inventive Principle:

Principle #1Segmentation

3Force

If sequential expansion is implemented using multiple modules, then the force requirement per module is reduced, but the device complexity increases

Engineering Contradiction:

Improveforce per moduleVSAvoidtool unit structure

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The piston serves multiple functions: it acts as a sealing element dividing annulus spaces, a hydraulic control element for fluid communication, and a mechanical connector for the expansion module. This multi-functionality reduces the need for separate components for each function, thereby limiting the increase in device complexity despite the use of multiple expansion modules.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The return fluid conduit is arranged inside the first fluid conduit, with the annular space between them serving as the well annulus. This nested arrangement optimizes space utilization within the tool unit, allowing multiple components to coexist in a compact configuration, thereby reducing overall device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

This approach reduces the required force for expansion, minimizing system stress and enabling efficient, sequential expansion of the casing/liner, while maintaining control over the expansion process through fluid communication and modular design.

Implementation Method 1

The tool unit in accordance with the invention is operated by the differential fluid pressure brought about over the piston(s) of the tool unit

Methodology Applied

Scientific EffectDifferential fluid pressure: Pressure Gradient

Implementation Method 2

By the introduction of pressurized fluid into one of the well annulus spaces the following differential fluid pressure occurring over the piston may be used for displacing the whole tool unit in the well bore

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Implementation Method 3

The piston may be provided solely as a sealing element

Methodology Applied

Scientific EffectSealing:

Implementation Method 4

the forces necessary to carry out casing/liner expansion may be reduced... the expansion to be carried out is distributed among the expansion modules, and thus the force necessary to cause the deformation of each expansion module is reduced

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS8925629B2Down hole well tool with expansion tool

Publication Date: 2015.01.06 REELWELL AS

AI summary

A down hole well tool (3) for installing a casing/liner (1) in a well bore (2), wherein the down hole well tool comprises a tool unit comprising at least one first fluid conduit (6) and a return fluid conduit (5) in use forming an annulus between the tool unit and the casing/liner. The tool unit further comprises at least one piston (7a, 7b) in the annulus dividing the annulus into annulus spaces (8a, 8b, 8c). At least two expansion modules (9a, 9b) for the expansion of the casing are positioned displaced in the axial direction of the casing. The expansion modules are arranged to be moved relative to each other in the axial direction of the casing.