Reconfigurable Grip Tool for Sequential Packer Release
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Solution Overview
Problem
Existing packer and bridge plug release mechanisms face issues such as premature release leading to unsafe conditions, debris interference preventing mechanism engagement, and stuck components due to inadequate retraction of slips and sealing elements, particularly with designs that rely on dogs and recesses for travel stops.
Innovation Solution
A reconfigurable grip tool that initially engages only the equalization mechanism, locks into a new position to access the release mechanism, and uses ratchet profiles for tandem movement to ensure complete release, with an emergency option to re-engage the lower slip cone for forced release, minimizing debris exposure and ensuring operability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single movement mechanism is used to accomplish both equalization and release, then device complexity is reduced, but reliability deteriorates due to risk of premature release causing unsafe conditions
Solution Approach 1:
The release mechanism is segmented into two distinct functional components: an equalization mechanism with a first travel stop and a release mechanism with a second travel stop. The grip tool sequentially engages these distinct mechanisms in a predetermined sequence, ensuring that equalization is completed before release can occur. This segmentation prevents premature release while maintaining manageable device complexity through modular design.
2Reliability
If dogs acting as travel stops are used to prevent premature release, then release safety is improved, but ease of operation deteriorates due to debris deposition blocking mechanism engagement
Solution Approach 1:
The grip tool incorporates an extendable body with telescoping sections that can dynamically change length. The body extends from a first length to a second, greater length to sequentially engage different travel stops. This dynamic extension capability allows the tool to adapt its reach based on the operational sequence required, maintaining reliability while improving ease of operation through flexible geometry.
3Ease of operation
If the grip tool body is extended to reach the release mechanism, then ease of operation is improved, but device complexity increases due to reconfiguration mechanisms
Solution Approach 1:
The grip tool body employs a telescoping structure where inner sections are nested within outer sections. The body can extend from a first length to a second, greater length by deploying nested segments, allowing the tool to reach both the equalization mechanism and the release mechanism without requiring multiple separate tools or overly complex articulation mechanisms.
4Reliability
If the lower slip cone is forced downhole to push from under the slips, then reliability is improved for stuck packer release, but force requirements increase
Solution Approach 1:
The system utilizes the stored potential energy of the set packer element itself to assist in the release process. When the lock ring is released and the packer element is allowed to extend downward, the stored energy automatically drives the lower slip cone downhole to push from under the slips. This self-service approach reduces the additional force required from the grip tool while improving reliability for stuck packer scenarios.
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.