Downhole Pressure Intensifier for High-Force Sliding Element Setting
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Solution Overview
Problem
Existing downhole tools face limitations in hydraulic setting force, as surface equipment is limited in the amount of force it can provide, leading to insufficient deployment of sliding elements such as sealing assemblies or anchoring assemblies, and increasing pressure can prematurely shear wellbore features.
Innovation Solution
A pressure intensifier system is combined with a traditional hydraulic setting mechanism, using a first piston with different surface areas connected to a second piston via incompressible fluid, allowing selective engagement to achieve higher localized pressures and forces for full deployment of sliding elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional hydraulic setting mechanism is used, then the system is simple, but the output force is insufficient to fully deploy sliding elements
Solution Approach 1:
A pressure intensifier is introduced as an intermediary device between the hydraulic setting mechanism and the sliding element. The pressure intensifier includes a first piston with different surface areas connected to a second piston via incompressible fluid, which amplifies the hydraulic pressure to generate sufficient output force for full deployment of the sliding element while maintaining system simplicity
Solution Approach 2:
The pressure intensifier changes the pressure parameter by using a first piston with different surface areas at its pressure receiving end and pressure output end. This surface area difference creates a pressure multiplication effect, transforming the hydraulic pressure into intensified pressure that delivers the required output force
2Force
If pressure is increased to provide sufficient setting force, then the sliding element can be fully deployed, but wellbore features may be prematurely sheared
Solution Approach 1:
The pressure intensifier applies high pressure locally only at the sliding element interface through its focused output area, rather than distributing high pressure throughout the entire wellbore system. This localized pressure application provides sufficient setting force for deployment while avoiding premature shearing of wellbore features
3Force
If triple piston design is used to achieve increased output force, then sufficient force is provided, but the tool length increases
Solution Approach 1:
The pressure intensifier merges the functions of multiple pistons into a single integrated device. By combining the pressure receiving end, fluid chamber, and pressure output end with different surface areas into one compact unit, the system achieves the same force multiplication effect as triple piston designs but with significantly reduced tool length
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 system enables the same increased output force with lower fluid pressure and shorter tool length compared to traditional triple piston designs, while avoiding premature shearing of wellbore features.
Implementation Method 1
a first piston (262) having a first pressure receiving end (264) with a larger piston surface area (AL1) and a first pressure output end (266) with a smaller piston surface area (AS); and a second piston (268) coupled to the first piston (262), the second piston (268) having a second pressure receiving end (270) with a larger piston surface area (AL2)
Data Source
AI summary
Provided is a downhole tool, a well system, and a method. The downhole tool, in one aspect, includes a mandrel, a sliding element positioned radially about the mandrel, and a pressure intensifier positioned radially about the mandrel and coupled to the sliding element. In one aspect, the pressure intensifier includes a first piston having a first pressure receiving end with a larger piston surface area (AL1) and a first pressure output end with a smaller piston surface area (AS). In one aspect, the pressure intensifier includes a second piston coupled to the first piston, the second piston having a second pressure receiving end with a larger piston surface area (AL2). In one aspect, a fluid chamber is defined between the first pressure output end and the second pressure receiving end. In one aspect, the pressure intensifier is configured to move the sliding element with an applied force.