Modular Lock Mechanism for Replaceable Downhole Tool Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing downhole tools with integrated designs face issues such as component loss, high replacement costs, long lead times, and a significant carbon footprint due to frequent replacements and transportation requirements.
Innovation Solution
A modular system comprising a tool body with an interfacing profile and a changeable tool assembly with an outer and inner matching profile, allowing for secure association and disassociation without components that can fall downhole, and enabling the use of replaceable blades manufactured using additive hard facing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a unibody or integrated design is used for downhole tools, then structural strength and reliability are improved, but component loss and failure hazards increase during retrieval operations
Solution Approach 1:
The tool assembly is divided into separable components including replaceable blades, a tool body, and a hub assembly that can be independently replaced. This segmentation allows the tool to maintain reliability during operation while enabling easy replacement of worn components without losing any parts downhole, directly resolving the contradiction between structural integrity and component loss prevention.
2Reliability
If the entire tool body is replaced after every operation, then tool reliability is maintained, but transportation costs and manufacturing lead times increase
Solution Approach 1:
The tool is segmented into a permanent tool body and replaceable components (blades, hub assembly). Only the worn components need replacement rather than the entire tool body, significantly reducing replacement time and transportation costs while maintaining reliability through the durable, reusable tool body.
Solution Approach 2:
Worn replaceable components are discarded and replaced while the tool body is recovered and reused. This approach maintains tool reliability through continuous component replacement while avoiding the need to transport and manufacture entire tool bodies for each operation, reducing lead times and costs.
3Reliability
If the entire tool body is replaced after every operation, then tool reliability is maintained, but manufacturing and transportation costs increase
Solution Approach 1:
The tool assembly is segmented into a reusable tool body and disposable replaceable components. This reduces manufacturing costs by eliminating the need to produce entire tool bodies for each operation, while maintaining reliability through the durable design of the tool body and quality replaceable components.
Solution Approach 2:
The system recovers and reuses the tool body while discarding only the worn replaceable components. This significantly reduces manufacturing and transportation costs compared to replacing entire tool bodies, while maintaining tool reliability through the durable, reusable design of the tool body.
4Productivity
If a modular replaceable component system is implemented, then manufacturing costs and lead times are reduced, but the complexity of the tool assembly increases
Solution Approach 1:
The tool assembly is divided into modular segments with standardized interfaces. This segmentation enables rapid replacement of components while managing complexity through standardization, allowing the tool to be disassembled and reassembled efficiently without creating excessive complexity in the overall system.
Data Source
AI summary
A tool assembly, a method and a system to be used in a downhole environment for downhole operations such as runs and retrieval of features are disclosed. A tool assembly include an outer tool profile, an inner matching profile, and a first interfacing surface. The inner matching profile is to be associated with an interfacing profile of a tool body and is to allow axial sliding for a first lock of the tool assembly to the tool body. A second lock is provided at a first shoulder-surface interface between the first interfacing surface and the tool body. The tool assembly is to be changeably associated with the tool body for use in the downhole operations.