Downhole Piston Frangible Element Bypass

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Solution Overview

Problem

In resource exploration and recovery, when a piston in a pressure chamber becomes stuck, existing methods require creating an opening through an area of weakness in load and pressure retaining tubulars or using complex alignment methods to establish an alternative flow path for control pressure.

Innovation Solution

A downhole component with a piston featuring a frangible element allows for the bypassing of the stuck piston by breaking the frangible element using a tool mechanism, creating a control fluid passage for flow without compromising the tubulars or requiring intricate alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a puncturing tool is used to create an opening through an area of weakness in the pressure chamber, then an alternative flow path is established, but the tubular structure is damaged and complex alignment is required

Engineering Contradiction:

Improveflow path establishmentVSAvoidtubular damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The piston is divided into two separate portions by the frangible element, allowing the distal portion to be detached and removed through the proximal end without damaging the tubular structure. This segmentation enables the stuck piston to be bypassed while preserving the pressure chamber integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frangible element is pre-positioned within the piston structure to create a predetermined break point. This preliminary arrangement ensures that when activation force is applied, the piston will break at the intended location, allowing clean removal of the distal portion without unpredictable fragmentation or tubular damage.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a puncturing tool is used to create an opening through the pressure chamber, then an alternative flow path is established, but complex alignment methods are required

Engineering Contradiction:

Improveflow path establishmentVSAvoidalignment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By segmenting the piston into removable portions, the system eliminates the need for complex alignment procedures required by puncturing tools. The distal portion can be extracted through the proximal end along the existing axial passage, which is inherently aligned with the pressure chamber, thereby simplifying the overall device complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of creating an opening from the distal end through the pressure chamber wall, the invention inverts the approach by removing the distal piston portion through the proximal end. This reversal of the removal direction eliminates the need for complex alignment with weak areas in the tubular structure.

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If the piston remains intact, then the pressure chamber maintains structural integrity, but the stuck piston blocks the control pressure flow path

Engineering Contradiction:

Improvepressure chamber integrityVSAvoidcontrol pressure flow

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The piston is segmented into a proximal portion that remains in the pressure chamber maintaining structural integrity, and a distal portion that can be removed to restore flow. This segmentation allows the system to maintain strength when intact while enabling reliable flow restoration when stuck.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frangible element is preliminarily positioned to enable controlled separation of the piston portions. This preliminary action ensures that when control pressure flow is blocked, the piston can be reliably broken and the distal portion removed to restore flow without compromising the proximal portion's structural role.

Inventive Principle:

Principle #10Preliminary action

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 the creation of an alternative flow path for control pressure without damaging the tubulars or using complex alignment methods, effectively bypassing a stuck piston and maintaining the integrity of the pressure chamber.

Implementation Method 1

breaking a frangible element on a piston operatively connected with the flow tube to expose a control fluid passage extending through the piston

Methodology Applied

Scientific EffectFracture: Fracture Mechanics

Data Source

PatentUS10822919B2Downhole component including a piston having a frangible element

Publication Date: 2020.11.03 BAKER HUGHES CO

AI summary

A downhole component has a body including a first end portion, a second end portion and an intermediate portion extending therebetween. The intermediate portion includes an outer surface and an inner surface. The inner surface defines a flow path. An axial passage extends radially outwardly of the flow path between the outer surface and the inner surface. A piston is arranged in the axial passage. The piston includes a first end, a second end, an intermediate section extending therebetween and a frangible element arranged adjacent at least one of the first end, the second end, and along the intermediate portion.