Downhole Seal Release Tool Using Vibration and Tubing Cutting
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Solution Overview
Problem
Conventional methods for freeing stuck downhole tools, such as seal assemblies, in a wellbore are time-consuming and inefficient, often taking around eleven days of rig time and delaying well completion.
Innovation Solution
A downhole tool equipped with a piston sub-assembly to generate mechanical vibrations and a cutting sub-assembly to cut through adjacent tubing, powered by a motor assembly, which can be operated using electrical or hydraulic power through a wireline or tubular working string, allowing for simultaneous vibration and cutting operations to free the stuck tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (deploying down hole cutter, running overshot with fishing assembly) are used to free stuck seal assembly, then the stuck object can be freed, but the operational time increases to around eleven days of rig time
Solution Approach 1:
The patent combines multiple functions (vibration generation, cutting, and powering) into a single integrated downhole tool that can be deployed in one trip. The tool merges a piston sub-assembly for vibration, a cutting sub-assembly with cutting blades, and a motor assembly, allowing simultaneous or sequential operations to free and retrieve the stuck seal assembly without requiring multiple separate conventional operations.
Solution Approach 2:
The patent employs dynamic vibration generation through the piston sub-assembly that creates mechanical vibrations to jar the stuck seal assembly loose. The system dynamically adjusts operations through a control system that can activate vibration modes, cutting modes, or combinations thereof, enabling adaptive response to the stuck object's conditions during the single deployment.
2Reliability
If conventional multi-step procedure is used, then the stuck seal assembly can be freed, but the well cost increases and delivery time is delayed
Solution Approach 1:
The downhole tool performs preliminary cutting of the production tubing adjacent to the stuck seal assembly during the same deployment trip. By pre-cutting the tubing and generating vibrations to loosen the seal assembly, the system eliminates the need for subsequent separate milling or retrieval operations, thereby accelerating the overall well completion process.
Solution Approach 2:
The downhole tool is designed as a multi-functional system that can perform vibration generation, cutting, and potentially retrieval operations within a single deployment. The tool incorporates both a piston sub-assembly for vibration and a cutting sub-assembly with rotating cutting blades, allowing it to address multiple objectives (freeing the seal and cutting the tubing) that would traditionally require separate specialized tools and operations.
3Loss of time
If a single integrated downhole tool with motor assembly is used, then operational time is reduced to single trip, but the device complexity increases
Solution Approach 1:
The downhole tool is segmented into distinct functional sub-assemblies: a top sub-assembly for coupling to conveyance, a piston sub-assembly with multiple pistons for vibration generation, a cutting sub-assembly with rotating cutting blades, and a motor assembly. This modular segmentation allows each component to be optimized independently while working together in an integrated system, managing complexity through functional decomposition.
Solution Approach 2:
The motor assembly serves as an intermediary power source that converts electrical or hydraulic energy into mechanical motion for both the piston sub-assembly and cutting sub-assembly. This central intermediary component coordinates the operations of multiple sub-assemblies, enabling a single deployment to perform multiple functions that would otherwise require separate tools.
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 enables the freeing of stuck seal assemblies in a single trip, reducing operational time and cost by mechanically vibrating and cutting through tubing to release the seal, thus enhancing efficiency and reducing wellbore intervention duration.
Implementation Method 1
a piston sub-assembly coupled with the top sub-assembly and including a plurality of pistons configured to moveably contact a portion of a seal assembly installed in the wellbore to generate mechanical vibrations to jar the seal assembly from being stuck in the wellbore
Implementation Method 2
a cutting sub-assembly coupled with the top sub-assembly and the piston sub-assembly and including at least one cutting blade configured to moveably cut through a portion of a production tubing adjacent the seal assembly
Data Source
AI summary
A downhole tool includes a top sub-assembly configured to couple to a downhole conveyance that is operable to run the downhole tool into a wellbore formed from a terranean surface into a subterranean formation; a piston sub-assembly coupled with the top sub-assembly and including a plurality of pistons configured to moveably contact a portion of a seal assembly installed in the wellbore to generate mechanical vibrations to jar the seal assembly from being stuck in the wellbore; a cutting sub-assembly coupled with the top sub-assembly and the piston sub-assembly and including at least one cutting blade configured to moveably cut through a portion of a production tubing adjacent the seal assembly; and a motor assembly coupled with the piston sub-assembly and the cutting sub-assembly, the motor assembly including a motor configured to supply power to the piston sub-assembly and the cutting sub-assembly.