Hydraulic Piston Microchip Release System for Drilling Data Collection

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Solution Overview

Problem

Drilling microchips used to collect downhole data often run out of battery and clog internal components of the drill string, leading to inaccurate estimations of temperature, pressure, and wellbore trajectory during drilling operations due to their limited battery life and propensity to clog.

Innovation Solution

A microchip system that includes a sliding sleeve, ball landing seat, microchip ring, hydraulic piston, and ball catcher, allowing microchips to be released downhole without clogging the drill string and enabling in-situ charging, thereby ensuring continuous data collection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If drilling microchips are pumped downhole using drilling mud, then downhole data can be collected in real time, but the microchips run out of battery by the time they reach the observation section

Engineering Contradiction:

Improvebattery lifeVSAvoidwell depth

Core Design Contradiction:

Duration of action of moving objectVSLength of stationary object

Solution Approach 1:

The microchips are pre-charged in a charging chamber before deployment. The charging mechanism is activated in advance to ensure sufficient battery life for the entire journey through the wellbore, solving the problem of battery depletion before data collection can occur.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A piston mechanism uses hydraulic pressure from drilling mud to propel charged microchips from the charging chamber into the annulus. This hydraulic propulsion system enables the release and transport of microchips without requiring them to carry sufficient battery for the entire transit time.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If drilling microchips are pumped through the drill string, then downhole data can be collected, but the microchips clog internal components including drill bit nozzles and rotor/stator interface

Engineering Contradiction:

Improvedata collection capabilityVSAvoidclogging of internal components

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The microchips are extracted from the internal drill string flow path and released directly into the annulus between the drill string and wellbore. This eliminates their passage through internal components, preventing clogging of drill bit nozzles, rotor/stator interfaces, and other internal drilling equipment while maintaining data collection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The sliding sleeve acts as an intermediary mechanism that receives charged microchips and releases them into the annulus. This intermediary structure provides a controlled release point that bypasses the internal drill string components, preventing clogging while enabling microchip deployment.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If microchips are released into the wellbore, then real-time data collection is enabled, but the release mechanism must be triggered reliably at the correct location

Engineering Contradiction:

Improvedata collectionVSAvoidrelease mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The release mechanism uses a simple ball-triggered piston system instead of complex electronic or mechanical controls. A ball dropped through a port activates the piston, which then propels microchips into the annulus. This mechanical substitution provides reliable operation with minimal complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses the existing drilling mud flow and pressure to operate the release mechanism. The hydraulic pressure from the drilling circulation system automatically actuates the piston when triggered, eliminating the need for external power sources or complex control systems.

Inventive Principle:

Principle #25Self-service

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 accurate real-time data collection of temperature, pressure, and wellbore trajectory by ensuring microchips are charged and deployed effectively, reducing errors associated with battery depletion and clogging, thereby enhancing drilling operations.

Implementation Method 1

The hydraulic piston releases the plurality of microchips through the exit groove and into the well

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Implementation Method 2

triggered by reception of a ball, blocking a flow path, in the ball landing seat

Methodology Applied

Scientific EffectFlow blocking: Pressure Increase

Data Source

PatentUS11828163B2Piston-based drilling microchips release system

Publication Date: 2023.11.28 SAUDI ARABIAN OIL CO

AI summary

A system includes a sliding sleeve, a ball landing seat, a plurality of microchips, a hydraulic piston, and a ball catcher. The sliding sleeve has a solid wall body and is installed within a tubular body. The tubular body has an exit groove. The ball landing seat is formed by the sliding sleeve. The plurality of microchips are housed in a microchip ring installed within the sliding sleeve. The hydraulic piston is installed within the microchip ring and is triggered by reception of a ball, blocking a flow path, in the ball landing seat. The hydraulic piston releases the plurality of microchips through the exit groove and into the well to gather data. The ball catcher is configured to receive and hold the ball after the plurality of microchips are released into the well.