Downhole Pressure Intensifier for Tubular Morphing
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Solution Overview
Problem
Delivering sufficient pressurized fluid to deep downhole locations in oil or gas wells is challenging due to pressure reduction with depth and the complexity of existing hydraulic fluid delivery tools, which can lead to inefficiencies and increased risk of leakage.
Innovation Solution
A pressure intensifier comprising an elongate mandrel with integrated annular pistons and a cylindrical body that moves relative to the mandrel, allowing for increased fluid pressure to be achieved through a series of pistons and a locking mechanism to simplify construction and reduce leakage, enabling efficient delivery of morph fluid for tubular morphing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If fluid is pumped from surface to deep downhole locations, then fluid can be delivered to the location, but fluid pressure reduces with depth and cannot adequately ensure sufficient morphing pressure
Solution Approach 1:
A pressure intensifier mechanism is introduced as an intermediary device located downhole that receives fluid at lower pressure from the surface and intensifies it to the required high pressure for morphing. This mediator overcomes the pressure loss due to depth by converting low-pressure fluid into high-pressure fluid through mechanical intensification stages.
Solution Approach 2:
The system replaces the inadequate surface pumping mechanical system with a downhole pressure intensifier mechanism that uses mechanical leverage and fluid pressure multiplication to generate the required high pressures, substituting the surface-based mechanical approach with a downhole-based mechanical intensification approach.
2Reliability
If existing hydraulic fluid delivery tools are used, then fluid delivery is enabled, but device complexity increases and risk of leakage increases
Solution Approach 1:
Multiple functional components are merged into a single integrated pressure intensifier assembly, combining the piston mechanism, sealing system, and fluid delivery pathway into one unified device. This integration reduces the number of external connections and potential leakage points while maintaining all necessary functions.
Solution Approach 2:
The pressure intensifier is designed to be self-contained with internal sealing and pressure maintenance mechanisms that do not require external intervention or additional complex control systems. The device autonomously maintains pressure integrity through its internal design, reducing reliance on external support systems and minimizing leakage risks.
3Reliability
If multiple component parts are used in pressure intensifier, then functionality is achieved, but manufacturing complexity increases and failure risk increases
Solution Approach 1:
The pressure intensifier is designed with segmented modular components that can be manufactured separately using standardized processes and then assembled. This segmentation allows each component to be optimized for its specific manufacturing requirements while maintaining overall system reliability, and facilitates quality control during manufacturing.
Solution Approach 2:
The design optimizes geometric parameters and material properties of components to enable manufacturing with standard tolerances and conventional fabrication methods. By carefully selecting parameters such as wall thicknesses, radii, and connection geometries, the device achieves high reliability without requiring complex or specialized manufacturing processes.
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 solution allows for efficient and reliable delivery of high-pressure fluid to downhole locations, reducing the complexity of components and minimizing leakage, thereby enhancing operational efficiency and ensuring effective tubular morphing in a single stroke.
Implementation Method 1
a pressure differential between fluid in the inner bore and morph fluid in the chamber
Implementation Method 2
the mandrel and the cylindrical body move relative to one another
Data Source
AI summary
A pressure intensifier and method of increasing fluid pressure at a desired location in a well bore. A central mandrel having a bore therethrough is affixed in a string. Surrounding the mandrel is a cylindrical body having stacked pistons. At a predetermined fluid pressure through the bore, the pistons release and are moved downwards, to integrate pressure across the pistons and act on a chamber pre-filled with application fluid. The application fluid is forced through delivery conduits at a higher pressure than the predetermined fluid pressure and may be used to morph a tubular. In an embodiment, the predetermined fluid pressure is field adjustable.