Helical Indicating Tool for Multi-Zone Rotational Alignment
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Solution Overview
Problem
Current downhole completion systems are limited in their ability to rotationally align tools across multiple zones, particularly for frac tools, and struggle with controlling erosive flow paths and optimal alignment, which hinders the durability and effectiveness of frac tools and multizone completions.
Innovation Solution
The system employs an indicating tool with a mandrel and indicator housing, where the mandrel is longitudinally movable and the housing is rotationally locked, featuring a helical member that engages with the outer tubular's helical profile face, allowing for rotational alignment and locking of the inner string within the outer tubular, enabling precise positioning and rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single point rotational alignment connection is used at the top of lower completion, then the monitoring equipment can be linked to surface equipment, but the system cannot achieve rotational alignment across multiple zones and has limited control over erosive flow paths
Solution Approach 1:
The indicating tool divides the alignment function into discrete segments by providing multiple indicating tools, each with unique helical member configurations (different pitches, diameters, or hand orientations). Each tool segment can be independently engaged with corresponding helical profile features in the outer tubular at different depth zones, enabling zone-specific rotational alignment without requiring a complex centralized system.
Solution Approach 2:
The helical member on the indicating tool serves as an intermediary element between the inner string and the outer tubular's helical profile face. This intermediary mechanism transfers rotational alignment from the outer tubular to the inner string through camming action, enabling precise rotational positioning without direct complex coupling mechanisms.
2Reliability
If linear alignment only is used for service string to outer string, then the installation process is simplified, but the durability of frac tools is reduced due to uncontrolled erosive flow paths and suboptimal alignment
Solution Approach 1:
The helical member and helical profile face replace linear alignment features with curved, three-dimensional camming surfaces. As the inner string is lowered into the outer tubular, the helical surfaces cam together to automatically rotate the inner string into the correct rotational alignment position. This curved geometry provides both optimal alignment for durability and controlled flow paths while maintaining relatively simple installation through the natural camming action during lowering.
3Productivity
If rotational alignment is not achieved for frac tools across multiple zones, then the installation process is simpler, but the effectiveness and durability of frac tools are significantly hindered
Solution Approach 1:
The indicating tool achieves rotational alignment through self-service camming action during the lowering process. The helical member automatically engages with the helical profile face in the outer tubular, and the camming geometry self-generates the rotational torque needed to align the inner string. This eliminates the need for external alignment equipment or complex active control systems, providing effective multi-zone alignment with moderate system complexity.
4Measurement precision
If the member is always engaged with the outer tubular, then rotational alignment is maintained, but the indicating tool cannot be moved longitudinally past alignment points
Solution Approach 1:
The indicating tool employs dynamic engagement where the helical member can transition between engaged and disengaged states. During lowering, the helical member engages with the helical profile face to provide precise rotational positioning at each zone. When passing through an alignment point, the tool can be rotated or manipulated to disengage the helical member from the profile face, allowing longitudinal movement past the alignment point while maintaining the capability to re-engage at subsequent zones for continued precise positioning.
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
This solution enables targeted connection points for monitoring equipment across multiple zones, ensures rotational alignment of frac sleeves, and maintains a stable flow path, enhancing the durability and effectiveness of frac tools and multizone completions.
Implementation Method 1
Engagement of the side of the member with the helical profile face of the inner profile of the outer tubular imparts rotation to the indicating tool during longitudinal movement of the tool within the outer tubular
Data Source
AI summary
An indicating tool includes a mandrel including a support, an indicator housing surrounding the mandrel, and a member movable radially with respect to the housing. The mandrel is movable longitudinally with respect to the indicator housing, and the indicator housing is at least substantially rotationally locked with respect to the mandrel. The member is engageable with an inner profile of an outer tubular in which the indicating tool is employed, and the member has a substantially helical side. The member is movable radially inward towards the mandrel when the support is longitudinally displaced from the member, and the member is blocked from movement radially inwards when the support is longitudinally aligned with the member.