Downhole Tubular Expansion Tool Ratcheting Reaction Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional expansion tools for tubular liners in well casings face challenges in securing and expanding liners along their full length, leading to unexpanded portions that require additional trips and compromise sealing integrity due to axial shrinkage and movement issues.
Innovation Solution
The development of a self-adjusting expansion tool with a ratcheting reaction assembly and slips that securely grip the casing, allowing stepwise expansion of the outer clad and subsequent inner clad within the expanded outer clad, preventing unwanted movement and ensuring full-length expansion without the need for intermediate retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional expansion tools are used to expand tubular liners, then the expansion process can be completed, but unexpanded portions remain that require additional trips and compromise sealing integrity
Solution Approach 1:
The expansion tool employs a dynamic reaction assembly that can adjust its position along the liner as expansion progresses. The reaction assembly includes movable components that track with the expander, allowing the tool to maintain proper reaction forces throughout the entire expansion process without requiring intermediate retrieval or repositioning operations.
Solution Approach 2:
The expansion tool is divided into functional segments including a reaction assembly with multiple reaction members distributed along its length. These segmented reaction members can independently engage with different portions of the liner, providing distributed reaction forces that enable complete expansion of the entire liner length in a single operation.
2Ease of operation
If slips are set within the bore of the expandable liner to secure the tool, then the tool can be positioned, but the liner cannot be secured for full-length expansion and unexpanded portions remain
Solution Approach 1:
Instead of setting slips within the liner bore to secure the tool, the invention inverts the approach by having the reaction assembly engage the liner from the outside or through alternative mechanical means that do not require internal slip setting. This allows the liner to be fully secured for expansion along its entire length without the limitations imposed by slip placement.
3Productivity
If the expandable liner is expanded beginning at an end spaced apart from the slips, then expansion can proceed, but the liner cannot be secured in position and movement occurs causing unexpanded portions
Solution Approach 1:
The reaction assembly serves as an intermediary mechanism between the expander and the liner, providing continuous reaction forces that stabilize the liner during expansion. The reaction members distribute and control the forces applied to the liner, preventing unwanted movement and ensuring stable expansion along the full length of the liner.
4Ease of manufacture
If conventional expansion tools are used, then expansion can be performed, but additional trips are required to retrieve unexpanded portions
Solution Approach 1:
The expansion tool is designed to perform the expansion function continuously along the entire length of the liner in a single operation. The reaction assembly maintains continuous engagement and control throughout the expansion process, eliminating the need to stop, retrieve, or reposition components, thereby completing the useful action without interruption or additional trips.
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 the installation of dual clad liners with optimal structural and sealing integrity by preventing axial movement and shrinkage-related issues, allowing for complete expansion in a single operation and maintaining sealing integrity throughout the process.
Implementation Method 1
The elastic limit of the liner material is exceeded to produce plastic deformation of the liner and to cause the liner to retain an expanded diameter engaged with the bore of the casing
Implementation Method 2
The elastic limit of the liner material is exceeded to produce plastic deformation of the liner and to cause the liner to retain an expanded diameter engaged with the bore of the casing. It will be understood that the liner may be expanded slightly beyond the intended diameter in order to elastically resist a residual collapsing force applied by the casing after the expander passes
Data Source
AI summary
An expansion tool includes a housing and a hydraulic power section for stroking a first expander on a pulling mandrel through a bore of an expandable outer clad, the expansion tool including a ratcheting reaction assembly, having a ratchet rack and a ratcheting component thereon, that engages a proximal end of the outer clad to prevent axial movement of the outer clad as the first expander is drawn through a portion of the bore of the outer clad to expand the outer clad. The ratcheting reaction assembly remains engaged with the proximal end of the outer clad as the housing is repositioned uphole to permit staged expansion of the outer clad using the first expander.