Dual-Circuit Pressure Intensifier for Sliding Element Deployment
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Solution Overview
Problem
Existing downhole tools face limitations in hydraulic setting force due to surface equipment constraints, leading to insufficient deployment of sliding elements, and traditional triple piston designs require excessive tool length and pressure to fully deploy these elements.
Innovation Solution
A pressure intensifier mechanism is combined with a traditional hydraulic setting mechanism, using a first piston with varying surface areas and a second piston connected via incompressible fluid, allowing selective engagement to achieve higher localized pressures with reduced overall tool length and pressure requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional triple piston design is used to increase hydraulic setting force, then the output force is improved, but the tool length and pressure requirements increase excessively
Solution Approach 1:
The hydraulic setting mechanism is divided into two independent circuits: a low-pressure circuit for initial deployment and a high-pressure circuit for final setting. This segmentation allows each circuit to be optimized independently, avoiding the need for a long triple-piston arrangement while achieving the required force levels through selective activation of the high-pressure intensifier circuit.
Solution Approach 2:
The patent introduces a pressure intensifier that multiplies hydraulic pressure by a factor of 3-4x in the second circuit. This dimensional change in pressure magnitude allows the system to achieve high setting forces without proportionally increasing tool length, as the force multiplication occurs through pressure intensification rather than mechanical leverage requiring long piston strokes.
2Ease of operation
If surface equipment is used to provide hydraulic setting force, then the system is simple to operate, but the setting force is insufficient to fully deploy sliding elements
Solution Approach 1:
A pressure intensifier acts as an intermediary device between the surface hydraulic system and the sliding elements. This intensifier multiplies the hydraulic pressure by 3-4x, providing the additional force needed to fully deploy the sliding elements while maintaining compatibility with standard surface equipment operating parameters.
Solution Approach 2:
The patent employs a dual-circuit hydraulic system where the second circuit incorporates a pressure intensifier that uses hydraulic principles to amplify pressure. This allows the system to generate high setting forces using standard surface hydraulic equipment, maintaining ease of operation while overcoming the force limitation.
3Force
If high pressure is applied to fully deploy sliding elements, then the deployment is complete, but the pressure requirements exceed surface equipment capabilities
Solution Approach 1:
The hydraulic system is segmented into two circuits with different pressure levels. The first circuit operates at low pressure for initial deployment, and the second circuit, activated only when needed, provides high pressure through the intensifier. This segmentation allows complete deployment force to be achieved while keeping the base operating pressure within surface equipment capabilities.
Solution Approach 2:
The system changes the pressure parameter dynamically by switching between two circuits. The pressure intensifier in the second circuit multiplies the input pressure by 3-4x, allowing the system to achieve high deployment forces temporarily without requiring surface equipment to continuously operate at excessive pressure levels.
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 efficient deployment of sliding elements with lower fluid pressure and shorter tool length compared to traditional designs, while maintaining the same output force, by selectively activating the pressure intensifier only when needed.
Implementation Method 1
a second piston (268) coupled to the first piston (262), the second piston (268) having a second pressure receiving end (270) with a larger piston surface area (AL2)... a fluid chamber (274) defined between the first pressure output end (266) of the first piston (262) and the second pressure receiving end (270) of the second piston (268)
Data Source
AI summary
Provided is a downhole tool, a well system, and a method. The downhole tool, in one aspect, includes a mandrel, a sliding element positioned radially about the mandrel, and a pressure intensifier positioned radially about the mandrel and coupled to the sliding element. In one aspect, the pressure intensifier includes a first piston having a first pressure receiving end with a larger piston surface area (AL1) and a first pressure output end with a smaller piston surface area (AS). In one aspect, the pressure intensifier includes a second piston coupled to the first piston, the second piston having a second pressure receiving end with a larger piston surface area (AL2). In one aspect, a fluid chamber is defined between the first pressure output end and the second pressure receiving end. In one aspect, the pressure intensifier is configured to move the sliding element with an applied force.