Downhole Controlled Failure Structure for Easier Tool Retrieval

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Solution Overview

Problem

Downhole tools often break in difficult-to-reach locations, leading to costly and time-consuming replacement operations due to the challenges of accessing and removing broken components from deep wells.

Innovation Solution

The implementation of a controlled failure structure in downhole components, utilizing additive manufacturing to create a selected three-dimensional geometry with distinct material properties, allowing for predictable failure patterns that facilitate easier removal and subsequent utility, such as a fishing neck profile, through the use of toroidally shaped discontinuities and material property changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If traditional downhole tools are used without controlled failure structures, then the tools can perform their function, but when they break they create difficult-to-remove debris that requires costly and time-consuming retrieval operations

Engineering Contradiction:

Improveease of tool replacementVSAvoidtime for retrieval operations

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-designing a controlled failure structure (weak plane) in the downhole tool before it is deployed. This weak plane is intentionally created with reduced material properties so that when the tool fails, it will break along this predetermined path into manageable segments. This preliminary structural design ensures that upon failure, the tool breaks in a controlled manner that facilitates easier retrieval, thereby resolving the contradiction between tool functionality and ease of replacement.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies segmentation by designing the tool to break into multiple controlled segments along the predetermined weak plane. Instead of creating a single large difficult-to-remove debris piece, the controlled failure structure causes the tool to segment into smaller, more manageable portions that can be more easily retrieved from the wellbore. This segmentation principle directly addresses the retrieval difficulty problem while maintaining tool functionality during operation.

Inventive Principle:

Principle #1Segmentation

2Ease of repair

If traditional downhole tools are used without controlled failure structures, then the tools can perform their function, but when they break they require expensive retrieval operations

Engineering Contradiction:

Improveease of tool replacementVSAvoidoperational costs

Core Design Contradiction:

Ease of repairVSLoss of energy

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies the blessing in disguise principle by converting the harmful effect of tool breakage (creating difficult-to-remove debris) into a beneficial outcome (controlled segmentation for easier retrieval). The controlled failure structure transforms the random, uncontrolled breakage that causes retrieval problems into a predictable, manageable failure mode. This converts the harm of tool failure into a benefit by ensuring that even when the tool breaks, it does so in a way that minimizes retrieval costs and operational disruptions.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If additive manufacturing is used to create controlled failure structures with distinct material properties, then controlled failure profiles are achieved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvecontrolled failure profile precisionVSAvoidadditive manufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies local quality by creating a controlled failure structure with distinct material properties in a specific localized region of the downhole tool. The additive manufacturing process enables precise deposition of material with different properties (such as different alloy composition, porosity, or density) only at the weak plane location, while the rest of the tool maintains its full structural integrity. This localized modification approach achieves the desired controlled failure profile without requiring complex manufacturing for the entire tool, thereby resolving the contradiction between manufacturing precision and process complexity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies parameter changes by modifying specific material parameters (such as composition, density, porosity, or mechanical strength) in the controlled failure structure region during additive manufacturing. By changing these material parameters locally at the weak plane, the patent creates a predetermined failure path with distinct material properties that differ from the surrounding tool material. This parameter modification approach enables precise control over failure behavior while using the same basic additive manufacturing process for the rest of the tool, thus achieving manufacturing precision without excessive overall process complexity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11566474B2Additive manufacturing controlled failure structure and method of making same

Publication Date: 2023.01.31 BAKER HUGHES CO

AI summary

A downhole component including a first portion; a second portion; a controlled failure structure between the first portion and second portion. A method for improving efficiency in downhole components.