Downhole Tool Welded Sections Internal Passage
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Solution Overview
Problem
Existing methods for manufacturing downhole tools with internal passages and complex geometries face limitations such as structural integrity issues due to weld joints in thin-walled areas, limited length, and difficulties in routing wires, particularly in drilling assemblies for the oil and gas industry.
Innovation Solution
A downhole tool comprising multiple sections welded together with an elongate internal passage extending through the weldments, featuring radially displaced holes aligned and joined with a circumferentially extending weld bead, and a radially extending hole to connect the passages, allowing for longer sections with improved structural integrity and wire routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If passages are drilled from the ends of the drill string section to house electrical wires, then wire routing is enabled, but stress risers are created that may lead to structural failure
Solution Approach 1:
The patent transitions from drilling passages axially from the ends of the drill string section to drilling passages radially from the outer surface. This dimensional change in passage orientation eliminates stress risers at threaded connections while still enabling wire routing from sensors to the central bore, thereby resolving the contradiction between ease of wire routing and structural integrity.
2Productivity
If the drill string section is made longer to improve drilling efficiency, then productivity increases, but the complexity of manufacturing and assembling increases
Solution Approach 1:
The patent divides the drill string section into multiple segments or sections that can be manufactured separately and then assembled together. This segmentation allows each section to be manufactured independently with standard procedures, reducing the complexity of manufacturing long sections while enabling the assembly of extended drill strings for improved drilling efficiency.
3Ease of operation
If passages are drilled through threaded end regions, then wire housing is achieved, but threading re-work becomes difficult
Solution Approach 1:
The patent extracts the wire housing function from the threaded end regions by drilling passages radially from the outer surface away from the threaded connections. This extraction allows threaded sections to be manufactured and re-worked independently without compromising wire routing capabilities, thereby resolving the contradiction between wire housing and threading re-work ease.
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 longer downhole tool sections with enhanced structural integrity and improved wire routing, addressing the limitations of previous methods by maintaining passage integrity and accommodating multiple sensors and devices along the drill string.
Implementation Method 1
an intermediate tool section mounted to the downhole section with a lower weldment, and an uphole section positioned opposite the downhole section mounted to the intermediate tool section with an upper weldment
Data Source
AI summary
A downhole tool is described that includes at least three sections welded together. The downhole tool has a downhole section, an intermediate tool section mounted to the downhole section with a lower weldment, and an uphole section positioned opposite the downhole section mounted to the intermediate tool section with an upper weldment. The downhole tools as described herein include an elongate internal passage that extends from the downhole section to the uphole section through the lower weldment and the upper weldment. The elongate internal passage is sized to receive drilling fluid therethrough. Furthermore, one or more of the downhole section, the intermediate tool section, and the uphole section includes: a) at least one sensor module, b) a cavity, and c) a plurality of bores (holes). In certain embodiments, the downhole tool may be triple combo tool, an acoustic logging tool, or a directional tool, such as a steerable tool.