Dual-Flow Mandrel Retrofit for Protected Downhole Electronics
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Solution Overview
Problem
Existing well completion systems face challenges in efficiently deploying and maintaining downhole monitoring and control devices without exposing them to hostile wellbore environments, leading to potential degradation and increased capital expenses.
Innovation Solution
A dual flow mandrel system with a passive, non-electronic configuration that can be retrofitted with intelligent monitoring and control devices, allowing for rigless deployment and installation of electronics only when needed, thereby protecting equipment from harsh conditions and reducing capital expenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If downhole monitoring and control devices are deployed early in well completion, then production monitoring and control can be established sooner, but the devices are exposed to hostile wellbore environments causing degradation and increased capital expenses
Solution Approach 1:
The mandrel is deployed first as a passive structural component to establish the physical framework for future device installation. This preliminary action creates a protected environment and defined pathways before sensitive electronic devices are introduced, allowing time for device preparation and selection without exposing them to harsh wellbore conditions.
Solution Approach 2:
The completion system is divided into distinct phases: initial passive mandrel deployment, followed by later active device installation. This segmentation separates the rough wellbore environment from the sensitive electronic components, deploying structural elements first and sensitive monitoring/control devices second when conditions are more favorable.
2Productivity
If intelligent monitoring and control devices are installed immediately, then real-time production management can be achieved, but capital expenses increase due to early equipment deployment and maintenance
Solution Approach 1:
The passive mandrel structure is installed in advance to provide the necessary mechanical framework and flow control pathways. This preliminary infrastructure reduces later capital expenses by eliminating the need for more complex active devices during initial deployment, while still enabling future real-time monitoring when financially viable.
Solution Approach 2:
The system initially employs simpler, less expensive passive mandrel components that can be easily replaced or upgraded later. These initial passive components are cost-effective temporary solutions that enable future installation of more sophisticated intelligent devices without requiring immediate high capital investment.
3Reliability
If the wellbore environment is made habitable for electronics, then device performance improves, but the complexity of the completion system increases
Solution Approach 1:
The completion system separates the wellbore environment into distinct zones: the harsh external wellbore environment and the protected internal mandrel environment. This segmentation allows electronics to be installed within the protected mandrel interior where conditions are more favorable, without requiring modification of the entire wellbore environment, thus limiting complexity increase to only the protected zone.
Solution Approach 2:
The passive mandrel acts as an intermediary structure between the hostile wellbore environment and the sensitive electronic devices. It provides mechanical protection, defined flow pathways, and structural support, creating a buffered environment that protects electronics from direct exposure to harsh conditions without requiring extensive system modifications.
Data Source
AI summary
A combined rig and rigless deployed completion system includes a rig deployed dual flow mandrel arranged in a mandrel section of a pipeline. The dual flow mandrel includes a cylindrical mandrel body with a wall defining an interior volume, and a mandrel partition arranged in the interior volume. The mandrel body has a set of radial ports defined in the wall. The mandrel partition includes a barrel and at least two flanges. The barrel is concentrically arranged in the interior volume of the mandrel body and defines a central channel extending from the first end to the second end of the mandrel body. The flanges protrude radially from the barrel and extend longitudinally along an outer face of the barrel to contact the interior surface of the mandrel body. The barrel and the mandrel body define an annular space and the flanges partition the annular space into annular channels.