Downhole Wireline Machining Tool Abrasive Insert Segmentation

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Solution Overview

Problem

Existing downhole wireline tools face limitations in removing restrictions such as metal nipples and stuck valves in well tubular metal structures due to limited power availability, which restricts the methods available for increasing the inner diameter of well casings.

Innovation Solution

A downhole wireline machining tool string with a rotatable tool part and a stationary driving unit powered through a wireline, featuring abrasive inserts made of tungsten carbide, cubic boron nitride, or diamonds embedded in a binder material, which are distributed around the circumference and arranged in multiple rows to reduce torque and power requirements, allowing for incremental diameter increase with reduced power consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a wireline tool is used to remove restrictions in a well, then the operation can be performed with limited power availability, but the power available downhole is very limited which reduces the operation methods available

Engineering Contradiction:

Improveoperation methods availableVSAvoidpower available downhole

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

The patent replaces traditional high-power mechanical cutting systems with an abrasive machining system that uses inserts distributed around the circumference of the tool. This substitution allows effective restriction removal with significantly reduced power requirements, enabling operations in low-power wireline environments while maintaining versatility in handling various restriction types.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cutting tool is segmented into multiple abrasive inserts distributed around the circumference rather than using a single centralized cutting mechanism. This segmentation distributes the cutting load across multiple points, reducing the torque and power required at any single point while maintaining effective restriction removal capability.

Inventive Principle:

Principle #1Segmentation

2Productivity

If traditional cutting tools are used to increase inner diameter, then restrictions can be removed, but the torque and power consumption are excessive for wireline operations

Engineering Contradiction:

Improverestriction removal efficiencyVSAvoidpower consumption

Core Design Contradiction:

ProductivityVSPower

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The abrasive inserts engage the restriction partially around the circumference rather than requiring full engagement. This partial action approach allows progressive restriction removal with lower power consumption, as not all inserts need to cut simultaneously at full depth.

Inventive Principle:

Principle #16Partial or excessive action

3Power

If abrasive inserts are distributed around the circumference, then torque and power requirements are reduced, but the complexity of the machining tool increases

Engineering Contradiction:

Improvepower requirementsVSAvoidmachining tool structure

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The distributed abrasive inserts serve multiple functions: they cut the restriction, distribute cutting loads, and can be arranged in different patterns for various restriction types. This multi-functionality justifies the increased structural complexity by providing versatile operation capabilities with reduced power requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The insert distribution pattern, spacing, and arrangement can be adjusted as parameters to optimize performance for different restriction types and power availability conditions. This parametric flexibility allows the same basic tool structure to adapt to various operational requirements without fundamental redesign.

Inventive Principle:

Principle #35Parameter changes

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 effectively increases the inner diameter of well tubular metal structures by milling away restrictions with reduced torque and power consumption, enabling efficient removal of metal, ceramic, rubber, or cement obstructions while maintaining insert effectiveness through wear replacement and fluid flow for extended service life.

Implementation Method 1

a driving unit configured to rotate the rotatable tool part and powered through the wireline

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

the inserts projecting from the outer face of the body and being distributed around the circumference... effectively increases the inner diameter of well tubular metal structures by milling away restrictions

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentEP3757345B1Downhole wireline machining tool string

Publication Date: 2024.03.20 WELLTEC AS

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AI summary

The present invention relates to a downhole wireline machining tool string for increasing an inner diameter of a well tubular metal structure in a well or cutting out a piece, e.g. in a downhole valve, the downhole wireline machining tool string having a longitudinal axis and comprising a rotatable tool part comprising a machining tool having a first end part, a second end part, a diameter and a circumference, and a stationary tool part comprising a driving unit configured to rotate the rotatable tool part and powered through the wireline, wherein the machining tool comprises a body having an outer face and a fastening element for fastening a machined piece.