Segmented Slips for Downhole Sealing Devices
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Solution Overview
Problem
The existing manufacturing process for downhole sealing devices is lengthy and expensive due to the need for milled slips from solid materials, which limits the efficiency and cost-effectiveness of well plugging or isolation operations.
Innovation Solution
The development of segmented slips comprising multiple discrete segments that are pieced together, with engagement members made from harder materials embedded within a body formed from a lower-cost material, allowing for radial expansion and secure engagement with the well tubular, and a manufacturing method involving molding or casting of these segments to reduce production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If slips are milled from solid materials, then the sealing device can be manufactured with sufficient strength and durability, but the manufacturing process becomes lengthy and expensive
Solution Approach 1:
The slip is divided into multiple discrete segments that are molded separately and then assembled together. Each segment can be manufactured independently using cost-effective molding processes, and the segments are joined through interlocking features such as projections and slots. This segmentation allows for faster, cheaper manufacturing while maintaining the overall structural integrity and strength required for downhole sealing operations.
2Strength
If slips are milled from solid materials, then the sealing device can be manufactured with sufficient durability, but the manufacturing cost increases
Solution Approach 1:
By segmenting the slip into discrete pieces that can be molded separately, the manufacturing cost is reduced compared to milling from solid material. The molded segments can be produced using more economical processes, and the assembly of segments through projections and slots provides a cost-effective way to achieve the required durability.
Solution Approach 2:
The slip incorporates engagement members made from harder materials embedded within a body formed from a lower-cost material. This composite construction allows the use of inexpensive base material while incorporating hardened elements where needed for durability and engagement, thereby reducing overall manufacturing cost while maintaining required strength properties.
3Strength
If engagement members are made from harder materials, then the sealing device can engage more effectively with the well tubular, but the manufacturing complexity increases
Solution Approach 1:
The slip combines harder engagement members with a lower-cost body material in a composite structure. The harder engagement members are embedded within the molded body, creating a composite material construction that provides effective engagement with the well tubular while managing manufacturing complexity through an integrated molding process.
Solution Approach 2:
Harder materials are used specifically for the engagement members rather than the entire slip body. This local application of hard material provides the necessary engagement capability where needed, while the rest of the slip body can be manufactured from more cost-effective materials, thereby managing overall manufacturing complexity.
4Productivity
If segmented slips are used, then the manufacturing time and cost are reduced, but the assembly complexity increases
Solution Approach 1:
The slip is segmented into discrete pieces that can be manufactured separately and assembled together. The segments are designed with complementary features such as projections and slots that simplify the assembly process, allowing for relatively straightforward construction despite the increased number of components.
Data Source
AI summary
A slip for a downhole sealing device includes a plurality of slip segments angularly disposed about a central axis, each slip segment including, a body, and a plurality of engagement members molded or cast at least partially within the body, wherein each of the slip segments are releasably coupled to one another.