Packer Release Tool With Backup Slip Cone Forcing
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Solution Overview
Problem
Existing packer and bridge plug release mechanisms face issues such as premature release of slips and seal elements before full equalization, leading to potential wellbore movement and stuck tools due to debris interference with travel stops, and insufficient release force or extension of the slip cone.
Innovation Solution
A reconfigurable grip tool that initially engages only the equalization mechanism, locks into a second position to access the release mechanism, and uses a ratchet lock to facilitate axial and radial movement for complete release, with an emergency option to re-engage the lower slip cone for forced release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single movement mechanism is used to accomplish both equalization and release, then the device complexity is reduced, but the reliability deteriorates because premature release can occur before full equalization
Solution Approach 1:
The release mechanism is divided into two distinct functional components: an equalization mechanism with a first set of slips and seal elements, and a release mechanism with a second set of slips and seal elements. This segmentation allows independent control of equalization and release operations, ensuring that equalization must be completed before release can occur, thereby improving reliability without requiring overly complex interlocking systems.
Solution Approach 2:
The equalization mechanism must be activated and completed before the release mechanism becomes accessible. The tool is initially blocked from engaging the release mechanism by dogs that act as travel stops during the equalization phase. Only after equalization is complete can the tool bypass these stops to access and activate the release mechanism, ensuring preliminary action is performed first.
2Ease of operation
If dogs acting as travel stops are used to block access to the release mechanism, then the sequential operation is controlled, but the ease of operation deteriorates due to debris interference with the dogs or recesses
Solution Approach 1:
The dogs that act as travel stops are extracted from the main body of the equalization mechanism and positioned on the outer periphery of the tool. This separation allows the dogs to be more easily bypassed by the release mechanism and reduces the likelihood of wellbore debris interfering with their operation, improving both accessibility and reliability.
Solution Approach 2:
A bypass mechanism serves as an intermediary element that allows the tool to selectively pass through or around the dogs acting as travel stops. This intermediary structure enables controlled access to the release mechanism while maintaining the sequential operation requirement, and its design minimizes debris accumulation points.
3Reliability
If the lower slip cone is not forced from under the slips, then the mechanism remains simple, but the reliability deteriorates when the slip cone fails to extend or gets pushed back causing the packer to get stuck
Solution Approach 1:
The lower slip cone is designed with dynamic movement capability, allowing it to be forced downward from under the slips during the release sequence. This dynamic action ensures complete separation of the seal elements from the borehole wall and prevents the packer from getting stuck, while the forcing mechanism is integrated into the existing release structure rather than adding separate complex systems.
Solution Approach 2:
The mechanism includes provisions to handle potential failure modes of the lower slip cone before they cause problems. The forcing mechanism is pre-positioned and activated as part of the normal release sequence, ensuring that if the slip cone fails to extend properly on its own, it can be forcibly removed from under the slips to prevent sticking, rather than requiring emergency intervention.
Data Source
AI summary
A tool equalizes a packer or bridge plug before it can release the slips and sealing element of the packer or bridge plug with a reconfigurable grip tool. In one configuration the grip tool is latched only into the equalizing mechanism for the packer or bridge plug. Having equalized the pressure and while still latched to the equalization mechanism the tool is reconfigured with a force and locked into a second configuration. From that position the grip tool can latch and move the release mechanism for total release and retrieval to the surface. Release force undermines a ratchet lock for the slips to allow extension as the sealing element extends axially and radially retracts. If the slips fail to release with undermining of the ratchet lock then a set down force can be applied to re-engage the lower slip cone to push it from the lower slips for a release.