Impact Casing Reshaping Tool With Flow-Activated Deformation Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Casing deformation during oil drilling poses hazards to downhole operations, obstructs drilling tools, compromises wellbore seal integrity, and affects oil extraction processes, reducing the lifespan of the well.
Innovation Solution
An intelligent impact casing reshaping tool with a detection unit, control unit, and repair module that collects pipe wall information, activates an impact module to repair deformations by adjusting drilling fluid flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional casing repair methods are used, then the structure is simple, but the repair effectiveness is poor and cannot address complex casing deformations
Solution Approach 1:
The tool is divided into multiple functional modules: detection module with sensors, power module with turbine and transmission system, repair module with impactors and push blocks, and control module. Each module performs a specific function, allowing the complex repair task to be broken down into detectable, powerable, and executable components that work together systematically
Solution Approach 2:
The detection module continuously monitors casing deformation status and transmits data to the control module. The control module processes this information and adjusts the repair module's operations accordingly, creating a closed-loop feedback system that enables precise, adaptive repair operations based on real-time casing conditions
2Productivity
If manual intervention is required for casing repair operations, then the control is flexible, but the operation efficiency is low and response time is delayed
Solution Approach 1:
The tool autonomously performs detection, power generation, and repair operations without continuous manual intervention. The detection module automatically identifies deformation, the power module self-regulates based on detected conditions, and the repair module executes corrections automatically, enabling the system to service itself through integrated sensors and actuators
Solution Approach 2:
Manual mechanical operations are replaced with an automated system combining electronic sensors, hydraulic power transmission, and computer-controlled actuators. The control module processes detection data and automatically actuates the repair mechanism, substituting human-operated mechanical systems with an integrated electromechanical automation system
3Power
If drilling fluid flow rate is increased to activate the impact module, then the repair power is sufficient, but the energy consumption increases
Solution Approach 1:
The system dynamically adjusts drilling fluid flow rate based on real-time detection of casing deformation severity. The control module modulates the flow to match the actual repair power requirements, increasing flow only when deformation detection triggers repair mode and reducing flow when repair is complete or deformation is minimal, optimizing energy utilization across varying operational conditions
Solution Approach 2:
The system changes the physical parameter of drilling fluid flow rate to control power delivery. By varying flow rate from low (during detection and idle) to high (during active repair), the system adapts power output to match repair needs, converting a static energy consumption pattern into a dynamic parameter that responds to operational requirements
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 effective repair of casing deformations by monitoring and controlling the tool from the surface, preventing leaks and ensuring smooth drilling operations.
Implementation Method 1
a turbine (7), a power shaft (8)... The drilling fluid drives the rotation of the turbine, which is connected at a lower end of the guide wheel shaft
Implementation Method 2
When the drilling fluid flow rate increases, the turbine speed rises, the turntable speed increases, and the centrifugal block, under the influence of centrifugal force, stretches the centrifugal spring
Implementation Method 3
an impact spring (31), a repair push block (38)... The impact spring is between the impact hammer and the bearing seat
Data Source
AI summary
An intelligent impact casing shaping tool in the field of deformation casing shaping and repair is disclosed. It includes a power module, a detection module, and a repair module. The power module generates power through rotation of a turbine, while the detection module sends pipe wall information to a ground receiving device in real-time. When pipe wall defects are detected, repair operations can be done by increasing the flow rate of the drilling fluid. As the flow rate increases, a clutch unit in the repair module engages with a power disk by centrifugal force of a centrifugal block, transmitting power to a cam seat. When the cam seat rotates, the cam engages with a roller, lifting an impact hammer. As the roller descends, an impact spring releases energy, and a repair push block strikes the deformed area, repairing the deformed casing.