Downhole Tool Actuator System for Stuck Valve Intervention
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Solution Overview
Problem
Well intervention operations face challenges in actuating stuck downhole valves due to sand or contaminants, which can lead to further jamming or damage when increasing mechanical forces are applied, and current cleanup methods using coiled tubing are costly and time-consuming.
Innovation Solution
A downhole tool string with a combination of a non-vibrating and vibrating actuator system to engage and move stuck valves, allowing for precise force application and vibration to dislodge debris without damaging the valve or tool string.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If increasing mechanical forces are applied to unstick the valve, then the valve may be freed from sand or contaminants, but the valve may become further jammed or seized, and potentially damaged
Solution Approach 1:
The patent applies mechanical vibration through a downhole tool that generates vibratory motion to dislodge sand and contaminants from stuck valves. The vibration frequency and amplitude are controlled to be sufficient to free the valve from contamination but not so intense as to cause damage or further jamming. This resolves the contradiction by replacing static increasing force with dynamic vibratory force that loosens contaminants without harming the valve mechanism.
Solution Approach 2:
The patent changes the parameters of force application by transitioning from continuous increasing mechanical force to controlled vibratory force with specific frequency and amplitude parameters. The downhole tool adjusts vibration parameters in real-time based on feedback from force sensors, maintaining optimal force levels that free the valve without causing damage. This parameter control resolves the contradiction between applying sufficient force and preventing valve damage.
2Object-affected harmful factors
If coiled tubing with milling tool and debris collection tool is used for cleanup operation, then sand and contaminants can be removed from the wellbore, but the cost, equipment footprint, and operational time increase
Solution Approach 1:
The patent extracts the harmful sand and contaminants directly at the valve location using a compact downhole tool that combines vibration generation with localized debris disruption. Instead of extracting all debris from the entire wellbore using coiled tubing, the tool focuses on removing contaminants only where they are causing the valve to stick. This targeted extraction resolves the contradiction by eliminating harmful factors without requiring extensive cleanup operations.
Solution Approach 2:
The patent introduces a vibratory intermediary mechanism that mediates between the downhole tool and the stuck valve. The vibration acts as an intermediary force that loosens and dislodges sand and contaminants, allowing them to be cleared by normal wellbore flow or minimal cleaning operations. This intermediary vibration resolves the contradiction by addressing the harmful contaminants without requiring the full complexity of coiled tubing cleanup equipment.
3Ease of operation
If pressure pulses are applied to remotely open the valve, then the valve can be actuated without downhole intervention, but the opening mechanism may become stuck and require mechanical actuation
Solution Approach 1:
The patent applies preliminary vibratory action to the valve before attempting remote actuation with pressure pulses. By pre-vibrating the valve mechanism, sand and contaminants are loosened and removed in advance, ensuring that subsequent pressure pulse actuation or mechanical opening proceeds smoothly without the valve becoming stuck. This preliminary action resolves the contradiction by preparing the valve for reliable remote operation while preventing the sticking that would require mechanical intervention.
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 effective actuation of stuck valves with reduced risk of damage, using a combination of non-vibrating axial forces and vibrating forces to dislodge debris, thus minimizing operational costs and time while maintaining equipment integrity.
Implementation Method 1
a second actuator operable to apply a vibrating force to the engagement device while the engagement device is engaged with the downhole feature
Data Source
AI summary
A downhole tool string for conveying within a wellbore, including an engagement device for engaging a downhole feature located within the wellbore, a first actuator for applying a substantially non-vibrating force to the engagement device while the engagement device is engaged with the downhole feature, and a second actuator for applying a vibrating force to the engagement device while the engagement device is engaged with the downhole feature.