Vertically Cutting Downhole Tubulars With Rotary Blade
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Solution Overview
Problem
Downhole tubulars often become stuck during removal, necessitating severing or milling, which is inefficient and potentially hazardous.
Innovation Solution
A wellbore tool with a vertically mounted rotary blade and motor, powered by an e-line, capable of making vertical cuts through tubulars using a lead screw mechanism for precise positioning and cutting, reducing the need for chemicals and explosives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods (chemicals or explosives) are used to remove stuck tubulars, then the tubulars can be severed, but the process is hazardous and inefficient
Solution Approach 1:
The patent replaces chemical and explosive methods with a mechanical rotary blade cutting system. The blade motor rotates the blade at controlled speeds to mechanically sever the stuck tubular, eliminating hazards associated with chemicals and explosives while maintaining cutting effectiveness
Solution Approach 2:
The patent introduces a guide mechanism as an intermediary between the blade motor and the cutting action. The guide ensures the blade moves vertically in a controlled manner through the tubular, providing precise positioning and stable cutting performance
2Reliability
If multiple runs are required to remove stuck tubulars, then thorough removal is achieved, but rig time increases
Solution Approach 1:
The patent enables continuous cutting action through the tubular in a single run. The blade rotates continuously and moves vertically through the entire tubular length without interruption, eliminating the need for multiple runs and reducing rig time while ensuring complete removal
Solution Approach 2:
The patent uses a dynamic positioning system with the lead screw mechanism that allows the blade to adjust its vertical position continuously during cutting. This dynamic adjustment enables the blade to progress through the tubular smoothly and efficiently in one continuous operation
3Manufacturing precision
If a vertically mounted rotary blade is used, then precise vertical cutting is achieved, but the mechanism complexity increases
Solution Approach 1:
The patent divides the cutting mechanism into separate functional components: the blade motor for rotation, the lead screw for vertical positioning, and the guide for directional control. This segmentation allows each component to be optimized independently while working together to achieve precise vertical cutting
Solution Approach 2:
The guide mechanism serves multiple functions: it guides the blade's vertical movement, maintains proper alignment, and works with the lead screw for positioning. This multi-functionality reduces the need for additional separate components, managing complexity while maintaining precision
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 safe and efficient removal of stuck tubulars in a single run, reducing rig time and eliminating the risks associated with traditional methods.
Implementation Method 1
A lead screw is coupled to the blade motor mount. The lead screw is rotatable to control a vertical position of the rotary blade
Implementation Method 2
The blade motor is configured to rotate the rotary blade with sufficient speed and torque to cut through a wellbore tubular
Data Source
AI summary
A cutting assembly is housed within a main body. The cutting assembly includes a rotary blade mounted vertically within the main body. A blade motor is coupled to the rotary blade. The blade motor is configured to rotate the rotary blade with sufficient speed and torque to cut through a wellbore tubular. The blade motor is supported by a blade motor mount. A lead screw is coupled to the blade motor mount. The lead screw is rotatable to control a vertical position of the rotary blade. A lead screw motor is rotably coupled to the lead screw. The lead screw motor is configured to rotate the lead screw to adjust the vertical position of the rotary blade. A guide is located within the main body. The guide includes a profile that controls a horizontal position of the blade based on the vertical position of the rotary blade.