Sand-Based Shearable Activation Device for Downhole Tools
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Solution Overview
Problem
Existing activation devices for downhole tools in the wellbore industry face challenges in efficiently actuating tools due to limitations in pressure transmission and tool operation, particularly in scenarios where a pressure up event is required, and existing solutions do not effectively utilize the structural properties of materials like sand for shearable components.
Innovation Solution
A shearable activation device with an outer shell made of consolidated sand encapsulating unconsolidated sand, designed to land on a seat and actuate the downhole tool by shearing the outer shell in response to hydraulic pressure, allowing it to pass through the seat and activate the tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the activation device uses a traditional solid structure, then it maintains structural integrity during travel, but it cannot be sheared by the seat to pass through and activate the tool
Solution Approach 1:
The activation device is segmented into two distinct sand regions: consolidated sand providing structural integrity and unconsolidated sand enabling shearability. This segmentation allows the device to maintain strength during travel while being capable of shearing to pass through the seat and activate the tool.
Solution Approach 2:
The activation device uses a composite structure combining consolidated sand and unconsolidated sand within the same device. This composite approach allows different regions to fulfill different functions: one region provides strength while the other enables shearing, resolving the contradiction between maintaining integrity and allowing activation.
2Strength
If the outer shell is made strong and durable, then it maintains structural integrity during passage, but it increases the force required to shear it
Solution Approach 1:
The outer shell is segmented into consolidated sand regions for strength and unconsolidated sand regions for ease of shearing. This segmentation ensures that only the necessary portions require high strength, while other portions are designed to shear easily under the applied hydraulic pressure.
Solution Approach 2:
Different regions of the outer shell have different material properties: consolidated sand in regions requiring strength and unconsolidated sand in regions designed for shearing. This local quality differentiation allows the shell to be strong where needed while remaining shearable where required for activation.
3Loss of energy
If the activation device has a smooth surface, then it reduces drag during travel, but it decreases contact area with the seat for activation
Solution Approach 1:
The surface of the activation device features localized grooves and dimples rather than being uniformly smooth or rough. These localized surface features provide adequate contact area with the seat for effective activation while maintaining overall smoothness to minimize drag during travel through the wellbore.
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 device effectively transmits hydraulic pressure to actuate the downhole tool, ensuring reliable operation by maintaining structural integrity during passage and dispersion, optimizing contact and reducing drag through surface configurations like grooves and dimples, thereby enhancing the efficiency of tool activation and fluid flow.
Implementation Method 1
actuate the downhole tool by shearing the outer shell in response to hydraulic pressure
Implementation Method 2
the cutting edge shears the outer shell
Data Source
AI summary
An exemplary activation device for a downhole tool includes an outer shell configured to sealingly engage a seat and configured to be sheared by the seat whereby the activation device can pass through the seat.