Expandable Block Set Segmentation for Downhole Wear
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Solution Overview
Problem
Conventional expandable downhole tools face operational inefficiencies due to wear and tear, leading to reduced effectiveness and increased maintenance costs, as individual segments wear out and break away, necessitating frequent tool replacement and operational delays.
Innovation Solution
The implementation of an expandable block set with multiple longitudinally arranged segments, where one segment wears out to expose a backup segment, allowing the tool to maintain engagement with the formation, extending its operational life and reducing maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional expandable downhole tools are used with single segments, then the structure is simple and easy to manufacture, but the operational life is reduced due to wear and tear requiring frequent replacement
Solution Approach 1:
The expandable block set is divided into multiple segments arranged longitudinally, where each segment can independently wear and break away. This segmentation allows the tool to maintain functionality as segments are consumed, directly resolving the contradiction by enabling extended operational life through modular wear-resistant segments while keeping each individual segment structurally simple
2Reliability
If frequent tool replacement is performed to address wear, then the tool reliability is maintained, but operational delays and maintenance costs increase
Solution Approach 1:
Backup segments are pre-installed in the expandable block set before deployment. When the primary segment wears out, the backup segment is already in position to immediately take over engagement with the formation. This preliminary preparation eliminates the need for tool replacement trips, maintaining reliability while preventing operational delays
3Duration of action of moving object
If multiple segments are added to extend operational life, then the duration of action is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The tool is designed with multiple identical or similar segments that can be manufactured using the same processes and materials. This standardization across segments maintains manufacturing ease while the multiplicity of segments extends operational life through progressive wear and backup functionality
Data Source
AI summary
An expandable tool includes an expandable block set having a plurality of segments longitudinally arranged. Each segment of the plurality of segments has a segment configuration. The segment configurations of the expandable block are customized for a particular application, based on the anticipated formation type. During operation, the downhole segment wears or breaks away, exposing the uphole segment, which takes over as the primary segment.