Multi-Stage Reciprocating Pump for Downhole Isolation
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Solution Overview
Problem
Downhole tools with reciprocating pumps face difficulties in efficiently utilizing power during both low-pressure and high-pressure periods of inflation operations, requiring a solution to optimize fluid flow and pressure settings for effective borehole isolation.
Innovation Solution
A multi-stage reciprocating pump downhole tool with a controller module, power module, compensator module, linear actuation module, fluid control module, and connection joint, featuring two pistons with different surface areas to manage fluid flow and pressure, automatically adjusts flowrate and pressure output based on setpoint pressures to efficiently inflate and reset the isolation tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-stage reciprocating pump is used, then the device complexity is low, but the pump cannot efficiently provide both high flow at low pressure and high pressure at lower flow rates during inflation operations
Solution Approach 1:
The reciprocating pump is divided into multiple stages with each stage having pistons of different sizes. The multi-stage configuration allows the pump to provide different flow rates and pressure levels at different times during the inflation operation, resolving the contradiction between pump efficiency and structural complexity.
Solution Approach 2:
Different pistons within the pump have different surface areas optimized for specific functions. Larger pistons are used for high flow rate delivery during early inflation stages, while smaller pistons handle high pressure requirements during later stages, creating local quality variations that solve the overall pump efficiency problem.
2Speed
If the pump provides high flow rate throughout the inflation process, then the inflation speed is high, but the isolation tool cannot achieve proper contact and sealing in the borehole
Solution Approach 1:
The pump system dynamically adjusts its output characteristics by switching between different piston stages during the inflation process. The controller monitors inflation progress and activates appropriate piston stages to provide high flow rate initially, then transitions to high pressure mode for proper isolation tool contact and sealing.
Solution Approach 2:
The reciprocating pump operates in periodic cycles with different piston stages activated at different periods. This periodic action allows the system to alternate between high flow rate phases for rapid inflation and high pressure phases for reliable isolation, solving the contradiction between speed and reliability.
3Reliability
If the pump provides high pressure throughout the inflation process, then the isolation tool achieves rapid contact, but the inflation process takes too long and power is wasted during low-pressure phases
Solution Approach 1:
The pump system dynamically switches between piston stages based on the inflation process requirements. During early stages when rapid inflation is needed, the system activates pistons optimized for high flow rate. When the isolation tool approaches the borehole wall and high pressure is required for contact, the system transitions to pistons optimized for high pressure, minimizing time loss.
Solution Approach 2:
The pump system changes its operating parameters by selecting different piston stages with different displacement volumes and pressure characteristics. This parameter change allows the pump to optimize its output for the current phase of inflation, providing high flow rate when needed and high pressure when needed, thereby reducing overall inflation time while ensuring reliable contact.
4Adaptability or versatility
If a multi-stage reciprocating pump is used, then the pump can provide variable flow and pressure output, but the device complexity and power consumption increase
Solution Approach 1:
The pump is segmented into multiple stages with pistons of different sizes, each optimized for specific flow and pressure requirements. This segmentation provides adaptability for variable inflation needs while keeping each individual stage relatively simple in structure.
Solution Approach 2:
The multi-stage reciprocating pump is designed to perform multiple functions: it can provide high flow rate for rapid inflation, high pressure for isolation tool contact, and variable output for different borehole conditions. This multi-functionality is achieved within a unified pump structure, balancing adaptability with structural complexity.
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-stage reciprocating pump tool optimizes fluid flow and pressure output, enabling efficient borehole isolation by providing high flow at low pressures and high pressure at lower flowrates, and automatically resetting to original flow capabilities upon pressure reduction, thus enhancing operational efficiency and rapid isolation.
Implementation Method 1
The hydraulic control module contains a hydraulic circuit to allow fluid through at a pressure provided by force applied to the combined surface areas of the large surface area piston and the small surface area piston
Implementation Method 2
The hydraulic control module contains a hydraulic circuit to allow fluid through at a pressure provided by force applied to the combined surface areas of the large surface area piston and the small surface area piston
Data Source
AI summary
Automated systems are disclosed that enable the rapid provision of fluids to downhole isolation tools. This is achieved by automatically optimizing the use of power available downhole by providing a high flowrate when pressure demand is low and a lower flowrate when pressure demand is high. Methods are disclosed which utilize the apparatus in a bottom hole assembly during downhole operations for isolating segments of a borehole.