Downhole Vibratory Communication Signal Sub
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Solution Overview
Problem
Existing methods for actuating or controlling downhole devices in hydrocarbon production, such as using electrical, hydraulic, or wireless signals, face challenges due to signal dissipation by fluid bubbles and obstructions in the wellbore, making reliable transmission to deeper locations impractical.
Innovation Solution
A signal sub with a spring-loaded activation profile is used to generate a vibratory signal that interacts with a complementary contact profile within the wellbore, sensed by a downhole sensor, which transmits a responsive signal to a programmable controller to actuate or control downhole tools, such as packers, perforating tools, or valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wireless signals (vibrations, pressure pulses, electromagnetic waves) are transmitted along the casing or through well fluid to control downhole devices, then control capability is achieved, but signal dissipation occurs due to fluid bubbles, discontinuities and obstructions
Solution Approach 1:
The patent introduces a signal sub as an intermediary device that carries a mechanical activation profile through the wellbore. This physical intermediary bypasses the fluid medium that causes signal dissipation, allowing reliable transmission of control signals to downhole devices without being affected by bubbles, discontinuities, or obstructions in the well fluid.
Solution Approach 2:
The patent replaces wireless signal transmission (acoustic, electromagnetic) with a mechanical system. The signal sub with its activation profile creates direct mechanical contact with the downhole device, substituting the unreliable wireless communication through fluid with a reliable mechanical interaction that is immune to fluid-based signal dissipation.
2Reliability
If electrical, hydraulic or wireless control lines are run to downhole devices, then reliable control is achieved, but practical implementation becomes difficult
Solution Approach 1:
The patent extracts the control signal transmission function from complex infrastructure (electrical lines, hydraulic systems, wireless communication infrastructure) and implements it through a simple, self-contained signal sub. This extracted approach eliminates the need for running control lines to downhole devices while maintaining control reliability.
Solution Approach 2:
The signal sub is transported to the downhole location by normal wellbore operations (flowing fluid, moving equipment) without requiring separate control infrastructure. The system uses the existing wellbore environment to deliver the control signal, making implementation practical and eliminating the need for additional control lines or complex installation procedures.
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
This method enables reliable actuation or control of downhole devices by effectively transmitting vibratory signals through the wellbore, overcoming signal dissipation issues and allowing precise operation of tools like packers and perforating devices.
Implementation Method 1
The signal sub generates a vibratory pattern actuating signal upon contact between the actuating profile and the contact profile
Implementation Method 2
The sensor is capable of detecting a vibratory signal resulting from dynamic interaction between the actuating profile of the signal sub and the contact surface within the wellbore
Data Source
AI summary
Systems and methods for controlling one or more downhole tools. A vibratory signal is produced by interaction between an actuation profile and a contact profile. In response to the vibratory signal, a controller actuates one or more downhole tools.