Multi-diameter thrust cups for varying wellbore diameters
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Solution Overview
Problem
Conventional methods for conveying downhole tools through non-vertical wells using fluid drag are limited when the inner diameter of the drill pipe is significantly larger than the outer diameter of the tool, resulting in insufficient propulsion due to excessive annular cross-section and varying drill pipe diameters, which complicates the conveyance process.
Innovation Solution
A multi-diameter thrust device featuring thrust cups with axial end hubs and bowsprings that collapse radially to adjust to varying conduit diameters, allowing fluid to flow and generate thrust, while minimizing leakage and interference, and incorporating asymmetrical curved fingers for enhanced flexibility and ID navigation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If fluid drag is used to propel the downhole tool through drill pipe, then the downhole tool can be conveyed through non-vertical wells, but the fluid drag is insufficient when the annular cross section is large
Solution Approach 1:
The patent employs a flexible thrust cup made of elastomeric material that can deform and conform to the internal diameter of the drill pipe. This flexible membrane structure creates an effective seal against the pipe wall, reducing the functional annular cross-section and increasing fluid drag efficiency despite the actual large annular space between the tool and pipe.
2Adaptability or versatility
If the drill pipe has varying inner diameters, then different pipe sections can be used, but the fluid drag becomes insufficient due to the large annular cross section
Solution Approach 1:
The thrust cup is designed with dynamic flexibility, allowing it to adapt its shape and size to match varying drill pipe internal diameters. The elastomeric material enables the cup to expand or contract radially, maintaining an effective seal and optimizing fluid drag across different pipe sections with varying IDs.
Solution Approach 2:
The patent changes the physical parameters of the thrust cup (material composition, thickness, initial diameter) to enable it to adapt to different drill pipe ID ranges. The elastomeric material properties allow the cup to undergo reversible deformation, changing its effective diameter to match the conduit it encounters.
3Device complexity
If a single diameter thrust cup is used, then the structure is simple, but it cannot adapt to varying conduit diameters
Solution Approach 1:
The thrust cup is constructed as a flexible elastomeric membrane structure that can deform to accommodate different conduit diameters. This single-piece flexible design avoids the complexity of multiple rigid thrust cups with different diameters, while achieving the adaptability needed for varying drill pipe IDs through material flexibility and geometric design.
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
The multi-diameter thrust device effectively propels downhole tools through conduits with varying diameters by optimizing fluid flow and thrust generation, reducing leakage and interference, and ensuring reliable conveyance even in complex wellbore geometries.
Implementation Method 1
a plurality of bowsprings configured to collapse radially. Each bowspring of the plurality of bowsprings includes a first axial end portion coupled to the first axial end hub and a second axial end portion coupled to the second axial end hub
Implementation Method 2
pumping fluid into the drill pipe to push the downhole tool along the non-vertical section of the well, taking advantage of fluid drag to propel the downhole tool forward
Implementation Method 3
a first axial end hub disposed at a first axial end of the thrust cup, wherein the first axial end hub is configured to slide axially relative to the mandrel
Data Source
AI summary
Embodiments described herein provide a multi-diameter thrust device that includes one or more thrust cups. Each thrust cup of the one or more thrust cups includes a first axial end hub disposed at a first axial end of the thrust cup; a second axial end hub disposed at a second axial end of the thrust cup; and a plurality of bowsprings. Each bowspring of the plurality of bowsprings includes a first axial end portion coupled to the first axial end hub and a second axial end portion coupled to the second axial end hub. The plurality of bowsprings are disposed circumferentially about a central axis of the multi-diameter thrust device.