Propeller-Driven Untethered Downhole Tools for Lateral Well Access
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Solution Overview
Problem
Conventional downhole tools require extensive surface equipment and tethered connections, which are costly and inefficient, and struggle to access lateral portions of wells due to friction and buoyancy limitations.
Innovation Solution
Development of untethered, neutrally buoyant, propeller-driven downhole tools that traverse wells using internal power sources, eliminating the need for surface equipment and maintaining pressure barriers, with counter-rotating propellers to stabilize motion and reduce torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tethered tools (wireline, coiled tubing) are used to access wells, then downhole operations can be performed, but extensive surface equipment and large crews are required, increasing cost and logistical complexity
Solution Approach 1:
The patent removes the tether connection between surface equipment and downhole tools, extracting the tool from the conventional wireline/coiled tubing system. This allows the tool to operate independently at depth without requiring extensive surface handling equipment, large crews, or complex deployment infrastructure.
Solution Approach 2:
The downhole tool is equipped with its own propulsion system (propeller driven), navigation capabilities, and power supply (rechargeable battery), enabling it to deploy itself, navigate to target locations, and perform operations autonomously without continuous surface control or assistance from extensive surface equipment.
2Speed
If tractor-based robotic systems with wheels or tracks are used, then downhole tools can traverse the wellbore, but significant friction against the wellbore wall requires large amounts of energy, limiting speed and range
Solution Approach 1:
The patent replaces the mechanical wheel/track traction system with a fluid-dynamic propulsion system. Instead of using wheels or tracks that contact and friction against the wellbore wall, the tool uses a propeller to push against the wellbore fluid (oil, gas, or water), converting mechanical energy more efficiently into thrust without the high friction losses of solid-contact systems.
Solution Approach 2:
The propulsion system utilizes the wellbore fluid itself as the medium for generating thrust. The propeller accelerates the surrounding fluid to produce reactive thrust (similar to a jet or propeller-driven vehicle), leveraging hydraulic principles to move the tool through the wellbore with significantly lower energy consumption compared to mechanical traction systems.
3Reliability
If conventional tethered tools are used in pressurized wells, then two pressure barriers must be maintained, but this requires closed valves and complex pressure management, complicating deployment and recovery
Solution Approach 1:
By removing the tether connection, the tool eliminates the need to maintain continuous pressure barriers through closed valves during deployment and recovery. The tool can be deployed by opening wellhead valves, allowing free flow, and recovered similarly without requiring complex pressure management protocols that would be necessary for tethered systems.
Solution Approach 2:
The tool is equipped with a sealed housing and internal pressure equalization capabilities that allow it to withstand downhole pressures independently. This preliminary preparation of the tool's pressure containment system enables deployment in pressurized wells without requiring complex surface pressure management or multiple barrier systems.
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 efficient well logging and intervention operations without human supervision, reducing costs and logistical complexity by eliminating the need for large crews and expensive handling systems, while allowing access to lateral wells.
Implementation Method 1
a propeller configured to rotate about a longitudinal axis of the housing such that rotation of the propeller generates thrust for moving the untethered downhole tool within the well
Implementation Method 2
The propellers of the described untethered downhole tools are coaxial and counter-rotate, which improves thrust efficiency and cancels torque while traversing a well
Implementation Method 3
The untethered downhole tools described can overcome frictional forces while traversing a well, such that the untethered downhole tools remain neutrally buoyant while traversing the well
Data Source
AI summary
An untethered downhole tool includes a housing and a propeller. The housing is configured to house a logging tool and a power supply. The housing defines a longitudinal axis. The propeller includes a propeller blade. The propeller is coupled to the power supply for receiving power from the power supply to rotate. The propeller is positioned at an end of the housing such that the axis of rotation of the propeller is substantially parallel and/or inline with the longitudinal axis of the housing for the untethered downhole tool to traverse a well.