Downhole Shifting Tool with Self-Centralizing Anchor
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Solution Overview
Problem
Existing service tools face challenges in accurately and reliably manipulating various types and sizes of completion products in downhole environments, particularly in applying consistent radial forces and navigating through varying diameters while maintaining high load capabilities and safety features.
Innovation Solution
A mechanical intervention shifting tool composed of a shifter, linear actuator, and anchor systems, which includes a latching mechanism for precise radial load control, linkage designs for expansion ratios, and a self-centralizing anchor mechanism for uniform load distribution, along with fail-safe and active closure capabilities, and the use of force and displacement sensors for real-time feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a service tool uses a rigid gripping mechanism to apply radial load to completion products, then the gripping force and reliability are improved, but the tool cannot navigate through varying diameters and small openings
Solution Approach 1:
The gripping mechanism uses a dynamic compliant structure with spring-loaded fingers that can adapt to varying diameters and profile geometries. The spring mechanism allows the fingers to flex and conform to different completion product shapes while maintaining consistent radial gripping force, resolving the contradiction between rigid gripping reliability and adaptability to varying dimensions.
Solution Approach 2:
The service tool employs a variable pressure system that can dynamically adjust the radial load parameters applied to the completion product. By changing the pressure parameters in real-time, the tool maintains optimal gripping force across different diameter variations and profile features, achieving both reliable gripping and adaptability.
2Measurement precision
If the service tool uses a latching mechanism with high radial load control for accurate positioning, then the positioning precision is improved, but the device complexity increases
Solution Approach 1:
The latching mechanism incorporates sensors that provide real-time feedback on the radial load and positioning status. This feedback system enables accurate positioning by continuously monitoring and adjusting the latching force, while the intelligent control algorithm simplifies the overall mechanism complexity by automating the adjustment process rather than requiring complex mechanical adjustment devices.
Solution Approach 2:
The latching mechanism is designed with self-adjusting features where the spring-loaded fingers automatically conform to the profile geometry and apply appropriate radial load without requiring complex external control systems. The mechanism serves itself by using the reaction force from the profile feature to maintain accurate positioning, reducing overall device complexity.
3Reliability
If the anchor system is designed to provide fail-safe passive closure for safety, then the safety reliability is improved, but the capability to apply constant radial load independently of axial loads is reduced
Solution Approach 1:
The anchor system is segmented into multiple independent spring-loaded gripping fingers that can operate autonomously. Each finger provides fail-safe passive closure through its own spring mechanism, ensuring safety reliability. Simultaneously, the distributed arrangement of multiple fingers maintains constant radial load distribution independent of axial load variations, as each finger independently responds to radial positioning requirements.
4Adaptability or versatility
If the service tool uses linkage designs with large expansion ratios to pass through small diameters, then the adaptability to varying diameters is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The linkage mechanism employs a nested compact design where the expansion linkages are stored in a collapsed state within the tool body during conveyance. When deployment is required, the linkages expand outward in a controlled sequence. This nesting approach achieves large expansion ratios for navigating varying diameters while keeping the manufacturing complexity manageable through modular assembly of standardized linkage components.
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 accurate and reliable manipulation of completion products across different sizes and environments, ensuring high load generation and safety, even in high-debris conditions, with minimal configuration changes and real-time system feedback.
Implementation Method 1
The latching mechanism is actuated by a hydraulic system. The hydraulic system includes a hydraulic power unit that includes a first hydraulic cylinder having a first piston within the first hydraulic cylinder and coupled to the latching mechanism, a second hydraulic cylinder having a second piston within the second hydraulic cylinder and coupled to the latching mechanism
Data Source
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AI summary
A service tool that may be inserted into a tubular, the service tool including a shifting system having a latching mechanism and an anchoring system having a body with a gripping assembly housed within and coupled to the body. The shifting system may lock into a shifting profile geometry by applying an axial input force with a linear actuator system of the latching mechanism. The anchoring system has the capability to apply constant radial force that is independent of the borehole size. The anchoring system also includes an actuator disposed within a central bore of the body and coupled to the gripping assembly. The gripping assembly may anchor at least a portion of the service tool to the tubular, and the gripping assembly includes a plurality of anchor arms disposed within the opening and that may move relative to the body.