Remotely Operable Retrievable Downhole Tool Setting Module

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Solution Overview

Problem

Existing retrievable downhole tools face challenges in controlled setting and unsetting processes, often causing damage to wellbore casings due to the use of drag blocks and J-slot mechanisms, which are inefficient and costly, and lack precise control over setting operations.

Innovation Solution

A remotely operable retrievable downhole tool equipped with a setting module that includes a motor, sensor, electronic control device, piston, pump, gearbox, and mechanical slips, which uses fluid pressure fluctuations to actuate the slips and apply a setting force, allowing for controlled setting and unsetting without external equipment or drag blocks, thereby preventing accidental setting and reducing wellbore damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If drag blocks and J-slot mechanisms are used to set retrievable downhole tools, then the tools can be set in the wellbore, but the wellbore casing or wall is damaged and the setting process is difficult to control

Engineering Contradiction:

Improvesetting controlVSAvoidwellbore damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the traditional mechanical drag block and J-slot setting mechanism with a remotely operable setting module that uses fluid pressure actuation. The setting module includes a piston and pump system that can be controlled from the surface to apply controlled setting forces, eliminating the need for drag blocks that damage the wellbore casing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a setting module as an intermediary device between the wellbore tool and the surface control system. This setting module includes a piston and pump mechanism that mediates the setting force application, allowing controlled engagement and disengagement without direct mechanical contact that would damage the wellbore casing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If traditional mechanical slip systems are used for setting operations, then the tools can be set, but the system is complex and costly

Engineering Contradiction:

Improvesetting operationVSAvoidmechanical slip system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical slip systems with a remotely operable setting module that uses fluid pressure actuation. The setting module includes a piston and pump system that can be controlled from the surface, simplifying the overall system while maintaining reliable setting operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The setting module is designed to be self-contained with integrated motor, pump, and piston components that can operate autonomously once activated. The system uses fluid pressure fluctuations to automatically actuate the slips, reducing the need for complex external mechanical slip systems.

Inventive Principle:

Principle #25Self-service

3Force

If drag blocks are used to apply setting force, then the tool can be set, but the setting force application is ineffective and damaging

Engineering Contradiction:

Improvesetting forceVSAvoidcasing damage

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the drag block mechanism with a hydraulically actuated piston system. The piston can be precisely controlled to apply setting force through fluid pressure, allowing effective force application without the damaging mechanical contact of drag blocks against the wellbore casing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The piston acts as an intermediary that transmits setting force smoothly and controllably. Instead of direct mechanical contact between drag blocks and the casing, the piston mediates the force application through fluid pressure, preventing casing damage while maintaining effective setting force.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables repeatable and controlled setting and unsetting of downhole tools, reduces the risk of wellbore damage, and lowers costs associated with mechanical slip systems, while allowing for safe and efficient operation of bridge plugs and other wellbore operations.

Implementation Method 1

The motor can use the pump, the gearbox, and other suitable component of the setting module to actuate the mechanical slips by displacing fluid in the piston

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Implementation Method 2

A first amount of force can be generated by the piston to obtain a second, relatively small, force applied by the mechanical slips on the casing of the wellbore

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11634959B2Remotely operable retrievable downhole tool with setting module

Publication Date: 2023.04.25 HALLIBURTON ENERGY SERVICES INC

AI summary

A setting module for setting a packer assembly in a wellbore can include a motor, a sensor, and an electronic control device. The sensor can detect pressure of fluid from a surface of the wellbore in an inner diameter of the setting module and output detected pressure to an electronic control device. The electronic control device can detect a triggering pressure sequence of the fluid from the surface and can, in response to detecting the triggered pressure sequence, output a command to the motor to drive a pump to cause a slip to move for setting the packer assembly.