Downhole Line Separation Tool Casing Protection
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Solution Overview
Problem
In oil and gas wells, control lines often break and fall into the lower casing during the replacement of upper casings, leading to installation issues and potential leaks, as existing tools lack effective solutions for separating or removing stuck lines without damaging the casing.
Innovation Solution
A downhole line separation tool with a tool housing, an electrical motor, an annular separation element, and a projecting part that extends beyond the separation element to abut the casing edge, allowing for cutting and separation of control lines without harming the casing, along with a pump, accumulation section, and anchoring tools to manage fluid and prevent rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a control line cutter is mounted on the outer face of the upper casing, then control lines can be cut during casing replacement, but the control line cutter may fail or the casing may not have such a cutter, causing control lines to fall into the lower casing
Solution Approach 1:
The cutting function is extracted from the upper casing and implemented as a separate downhole tool that can be deployed independently. This separates the cutting operation from the casing replacement process, allowing the tool to be used even when no cutter is mounted on the casing.
Solution Approach 2:
A separate downhole separation tool acts as an intermediary device between the control line and the casing. This tool provides the cutting capability that would otherwise require to be integrated into the casing assembly, reducing overall system complexity while maintaining reliability.
2Ease of operation
If the upper casing is pulled out with control lines, then control lines can be removed, but the control lines often break and enter the inside of the lower casing
Solution Approach 1:
The control line is cut at a controlled location above the lower casing before the casing is pulled out. This preliminary cutting action prevents the line from breaking uncontrollably during the pulling operation and entering the lower casing.
Solution Approach 2:
The mechanical pulling operation that risks line breakage is replaced with a controlled cutting operation using a rotatable annular separation element with cutting bits, providing more reliable line removal.
3Adaptability or versatility
If control lines are squeezed between upper and lower casing, then lines remain in place, but this causes installation issues and potential leaks
Solution Approach 1:
The control line is cut and removed from the annular space between casings before the upper casing is installed. This preliminary removal action prevents installation defects and potential leaks that would occur if lines were squeezed between casings.
Solution Approach 2:
The control line is extracted from the problematic position between the casings using the downhole separation tool, eliminating the source of installation issues and leaks while maintaining casing installation flexibility.
4Ease of operation
If an annular separation element rotates for cutting control lines, then lines can be separated, but the casing may be damaged by machining
Solution Approach 1:
A stationary projecting part acts as an intermediary stop that limits the rotation of the annular separation element. This ensures the cutting element separates the control line without rotating far enough to machine or damage the casing.
Solution Approach 2:
The projecting part provides a preliminary stopping action that prevents the harmful effect of excessive rotation. By abutting the casing edge first, it counteracts any potential damage before it can occur.
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 tool effectively separates control lines from the casing without damaging it, allowing for proper installation of new upper casings and preventing leaks, while the pump and accumulation section facilitate retrieval of separated line pieces.
Implementation Method 1
an electrical motor arranged within the first housing part and powered through a wireline connected to the first tool end... a rotatable shaft arranged within the second housing part and rotated by the electrical motor for rotating the annular separation element
Implementation Method 2
The annular separation element may comprise several bits arranged at the element end and along a circumference of the annular separation element... forming an edge for abutment to and cutting into a line in a casing
Data Source
AI summary
The present invention relates to a downhole line separation tool for submerging into a casing in a wellbore, the downhole line separation tool having a first tool end, a second tool end and a tool axis, comprising a tool housing having a first housing part and a second housing part, an electrical motor arranged within the first housing part and powered through a wireline connected to the first tool end, an annular separation element having an element end facing away from the first tool end and being rotatably connected within the second housing part, and a rotatable shaft arranged within the second housing part and rotated by the electrical motor for rotating the annular separation element, wherein the second housing part comprises a sleeve part having a sleeve end, at least part of the annular separation element projecting from the sleeve end further away from the first tool end than the sleeve, the second housing part comprising at least one projecting part extending further away from the first tool end than the annular separation element along the tool axis. Moreover, the present invention also relates to a downhole system comprising an upper casing connected to a lower casing and arranged in the wellbore.