Downhole Patch Setting Tool with Bladder Assemblies
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Solution Overview
Problem
Current downhole patch setting tools are inadequate for sealing perforated zones exceeding 10 meters in well tubular structures, requiring multiple patch installations and resulting in inefficient sealing due to the need for multiple runs in the well.
Innovation Solution
A downhole patch setting tool with a top and a tool body having a bore, bladder assemblies at both ends, and an expandable metal patch that can be expanded over a distance of more than 10 meters using a pressure-controlled valve to allow pressurized fluid into an annular space, enabling simultaneous expansion of the patch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple patches are set in succession to seal long perforated zones, then the sealing coverage is improved, but the operation time and complexity increase significantly
Solution Approach 1:
The patent combines multiple patch-setting functions into a single tool by integrating multiple bladder assemblies (first, second, and third bladder assemblies) along the tool body. Each bladder assembly can be independently activated to expand patches at different locations, allowing multiple sealing operations to be performed in one continuous run through the well, thereby maintaining comprehensive sealing coverage while dramatically reducing operation time
Solution Approach 2:
The tool body is segmented into multiple sections with separate bladder assemblies positioned at different locations along its length. Each bladder assembly corresponds to a specific zone that can be sealed independently. This segmentation allows the single tool to handle multiple discrete sealing requirements along a long perforated zone without requiring multiple tool passes
2Reliability
If multiple runs in the well are required to set several patches, then the sealing coverage for long zones is improved, but the device complexity and operational difficulty increase
Solution Approach 1:
The patent merges multiple patch-setting operations into a single integrated tool by positioning multiple bladder assemblies along one tool body. The tool can be deployed in a single run through the well, with each bladder assembly capable of being activated independently to create patches at different locations, thereby achieving comprehensive sealing without requiring multiple tool deployments
Solution Approach 2:
The tool body serves multiple functions simultaneously: it houses multiple bladder assemblies for creating patches at different locations, provides a common fluid supply system through the bore, and enables independent activation of each bladder assembly. This multi-functionality allows a single tool to perform what previously required multiple specialized operations
3Manufacturing precision
If patches are expanded sequentially in multiple steps, then the sealing precision is improved, but the time required and risk of deformation hardening increase
Solution Approach 1:
The patent employs periodic or sequential activation of different bladder assemblies through controlled fluid injection. Each bladder assembly can be activated in a controlled sequence or simultaneously, allowing precise timing of expansion events. This periodic action enables the patch material to be expanded at optimal intervals, achieving precise sealing while minimizing total expansion time and preventing deformation hardening that would occur with prolonged or repeated expansion cycles
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
Enables efficient sealing of long perforated zones with a single pressurization step, reducing the time and effort required for patch installation and ensuring effective sealing without deformation hardening, allowing for longer patches that can properly seal off production zones.
Implementation Method 1
allow pressurised fluid into the bladder assemblies to expand the bladder assemblies
Implementation Method 2
expandable metal patch having an inner diameter in an unexpanded condition
Implementation Method 3
a valve arranged in the third opening for controlling passage of the pressurised fluid from the bore to the annular space
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
The present invention relates to a downhole patch setting tool (1) for expanding a patch over a distance of more than 10 metres in a well (50), the downhole patch setting tool having a top (51) and comprising a tool body (2) having a bore (3), an outer face (4), a first end (5) and a second end (6), the second end being arranged closer to the top than the first end, a first bladder assembly (11) arranged at the first end on the outer face and a second bladder assembly (12) arranged at the second end on the outer face, the bore at least extending from the first bladder assembly to the second bladder assembly, an expandable metal patch (14) circumferenting the tool body, the first bladder assembly and the second bladder assembly creating an annular space (15) therebetween, the expandable metal patch having an inner diameter in an unexpanded condition, the tool body having a first opening (16) opposite the first bladder assembly and a second opening (17) opposite the second bladder assembly, providing fluid communication between the bore and the first bladder assembly and the second bladder assembly in order to allow pressurised fluid into the bladder assemblies to expand the bladder assemblies, wherein the tool body has a third opening (18) arranged between the first bladder assembly and the second bladder assembly, and a valve (19) arranged in the third opening for controlling passage of the pressurised fluid from the bore to the annular space. The present invention also relates to a downhole completion system and to a patch setting method.