Drill Pipe Expansion Assembly Sealing System
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Solution Overview
Problem
Existing drill pipe expansion assemblies require frequent replacement of sealing cups during multiple runs, leading to time-consuming and costly operations due to cup damage.
Innovation Solution
A drill pipe expansion assembly with a movable expansion unit and positioning unit that maintains sealing elements in a fixed position using pressurized fluid, preventing damage and allowing for multiple expansions without cup replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing cups are used to seal off a zone for pressurisation during completion component expansion, then the expansion operation can be performed, but the sealing cups are damaged and must be replaced after only one run
Solution Approach 1:
The sealing system is divided into multiple sealing cups (first sealing cup and second sealing cup) positioned at different locations. Each sealing cup handles specific sealing tasks, distributing the mechanical stress and damage accumulation across multiple components rather than concentrating it on a single reusable cup.
Solution Approach 2:
The patent employs disposable sealing cups that are designed to be replaced after a single use, while the expensive positioning unit and expansion tool remain in place. This approach recovers and reuses the high-value equipment while sacrificing low-value consumable sealing elements, thereby reducing overall operational costs and time.
2Reliability
If sealing cups are replaced between two runs, then fresh sealing elements can be used for the next expansion, but the replacement process is time-consuming and expensive
Solution Approach 1:
The sealing cups are pre-positioned and pre-configured on the expansion tool before entering the wellbore. All necessary sealing elements are already in place and properly secured, eliminating the need for time-consuming replacement operations between runs and maintaining continuous operational efficiency.
Solution Approach 2:
The expansion tool is designed with universal, interchangeable sealing cups that can be used for different completion components and expansion scenarios. This multi-functionality allows the same tool assembly to handle various sealing requirements without requiring specialized replacement procedures.
3Adaptability or versatility
If the expansion unit is moved during expansion, then access to different completion components can be achieved, but the sealing elements may be damaged or displaced
Solution Approach 1:
The expansion tool incorporates a positioning unit with movable components that can dynamically adjust the position of the expansion unit along the wellbore. The system transitions from a static configuration to a dynamic one, allowing the tool to access multiple completion components while maintaining sealing integrity through controlled movement and repositioning mechanisms.
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
Enables multiple expansions of completion components in a single run without replacing sealing elements, reducing operational time and costs by maintaining sealing elements in a predetermined position.
Implementation Method 1
The positioning unit may be fluidly connected with the drill pipe, and pressurised fluid in the drill pipe may be supplied to the positioning unit in order to move the fixation element from the retracted position to the projected position.
Implementation Method 2
a tubular element having a certain length, where the length of the tubular element comprises a plurality of drill pipe sections, the tubular element comprising a first end and a second end and a wall having an outer face and an outlet for ejection of pressurised fluid
Data Source
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AI summary
The present invention relates to a drill pipe expansion assembly (1) for expansion of a completion component (3) located at a fixed position in a well (4) having a longitudinal axis (5), the drill pipe expansion assembly comprising an expansion unit (6) which is moveable in relation to the completion component comprising a tubular element (7) comprising a first end (8) and a second end (10) and a wall (11) having an outer face (12) and an outlet (14) for ejection of pressurised fluid, and a first sealing element (15,15a) and a second sealing element (15, 15b) arranged on the outer face on each side of the outlet, and a positioning unit (20) comprising a body (21) and a first fixation element (22) movable between a projected position and a retracted position in relation to the body, the positioning unit being connected with the tubular element in order to maintain the expansion unit in a fixed position in relation to the completion component (3) during expansion. The present invention further relates to a downhole system.