Selective Rotational Alignment Mechanism for Downhole Tools
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Solution Overview
Problem
Current downhole completion systems are limited in their ability to rotationally align frac tools across multiple zones, leading to difficulties in controlling erosive flow paths and ensuring optimal alignment of tool strings, particularly in multi-zone completions and deep water environments where tools require precise positioning and alignment to prevent unwanted movement.
Innovation Solution
A multi-function tool connected to an inner string that selectively aligns ports between the inner and outer strings at various locations, using a combination of unlocking profiles and V-shaped collet fingers to enable rotational alignment and axial support, allowing the tool to bypass certain profiles and operate efficiently across multiple zones without needing to cycle through each zone individually.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hard boundary indicator is used to identify tool position through interaction with a unique profile on the ID of the outer string, then tool position can be identified and controlled, but excessive string manipulation is required when passing through multiple zones
Solution Approach 1:
The patent extracts the indication function from a single hard boundary profile and distributes it across multiple zones through multiple profiles. The indicating tool is removed from manual manipulation mode and integrated into an automated system that cycles through profiles automatically, separating the indication function from manual string manipulation.
Solution Approach 2:
The indicating tool performs self-service by automatically cycling through multiple zone profiles without requiring manual intervention. The system uses the tool's own movement through the profiles to generate indications, eliminating the need for operators to manually manipulate the string at each zone.
2Manufacturing precision
If rotational alignment is achieved at each zone through manual indication and cycling, then precise alignment can be obtained, but excessive time is consumed when service multiple zones
Solution Approach 1:
The patent implements preliminary action by pre-positioning multiple profiles at different zones along the outer string ID. The indicating tool is pre-configured to cycle through these profiles automatically, so that when the tool string is deployed, the indication and alignment process begins immediately without manual intervention at each zone.
Solution Approach 2:
The system maintains continuity of useful action by enabling the indicating tool to cycle through multiple zone profiles in a continuous automated sequence. Rather than stopping and manually cycling at each zone, the tool continuously moves through all profiles, maintaining uninterrupted indication and alignment across all zones.
3Manufacturing precision
If the tool is unlocked to allow rotation for alignment at each zone, then rotational alignment can be achieved, but unwanted tool movement occurs during tripping
Solution Approach 1:
The patent applies dynamics by making the tool's locking state conditional rather than fixed. The tool transitions between locked and unlocked states dynamically based on its position relative to the profiles. When passing through zones without alignment needs, the tool remains locked for stability; when encountering a profile requiring alignment, the tool automatically unlocks to allow rotation, then re-locks afterward.
Solution Approach 2:
The system implements local quality by applying different operational characteristics to different zones. Each zone profile has the capability to trigger local unlocking and rotation only at that specific location, while other zones maintain the locked stable state. This allows rotational alignment precisely where needed without affecting tool stability in other zones.
Data Source
AI summary
A multi-function tool is connected to an inner string to selectively align a port or ports in the inner string with ports in the outer string at various locations. The tool is locked from functioning at some locations where a locating collet will not selectively engage with an unlocking profile. In this more the tool will pass through the location unhindered. If an unlock profile is engaged the tool is enabled to be unlocked so that manipulation allows a support mandrel to align with collets that have an external V-shaped profile. Setting down weight allows the supported V-shaped profile on the collets engage a similar profile on the outer tubular to rotate, if needed, and to find support on a V-shaped profile on the surrounding tubular for performance of the borehole operation. Thereafter the locating collet engages a locking profile to disable the tool again.