Wireline Expansion Tool for Low-Stress Patch Sealing

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Solution Overview

Problem

Existing wireline expansion tools risk cracking completion tubular components like patches due to liquid expansion and often cannot be fully retracted, limiting their reuse and effective sealing in well operations.

Innovation Solution

A wireline expansion tool with an electric motor, axial force generator, and radial expansion tool section, utilizing a support structure connected to a first element that moves radially outwards to expand completion tubular components, such as straddles or liners, powered through a wireline, allowing for full expansion without material cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If liquid is used to expand the bladder for patch sealing, then the patch can be expanded to seal leaks, but the patch may crack and the bladder cannot be fully retracted for reuse

Engineering Contradiction:

Improvesealing effectivenessVSAvoidpatch integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent replaces the liquid-based hydraulic expansion system with a mechanically-driven expansion system. An electric motor drives a screw mechanism that converts rotational motion into linear axial movement, which then transforms into radial expansion force through inclined planes. This mechanical substitution eliminates the need for liquid expansion media and allows precise control of expansion forces to prevent patch cracking while enabling complete bladder retraction for reuse.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the expansion mechanism from liquid pressure to controlled mechanical force application. By using a screw mechanism with adjustable pitch and an electric motor with variable speed control, the system can precisely regulate the expansion parameters (force magnitude, application rate, and duration) to achieve reliable sealing without exceeding the patch's structural strength limits.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If liquid expansion is used for the bladder, then expansion can be achieved, but the bladder cannot be fully retracted limiting reuse

Engineering Contradiction:

Improvesealing functionVSAvoidbladder reusability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The mechanical screw-driven expansion system replaces liquid hydraulic expansion, enabling the bladder to be fully compressed back into its housing after use. The screw mechanism provides controlled bidirectional movement (expansion and retraction) that completely collapses the bladder, allowing it to be reused multiple times without residual deformation or liquid contamination issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If axial force is applied to expand the completion tubular component radially, then complete expansion can be achieved, but the tool structure becomes more complex

Engineering Contradiction:

Improveexpansion completenessVSAvoidtool structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs dimensionality transformation by converting axial linear motion from the screw mechanism into radial expansion motion through inclined planes or cam surfaces. This allows the tool to achieve complete radial expansion of the completion tubular component using a linear actuator, simplifying the overall structure compared to direct radial actuation while ensuring full expansion coverage.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

The tool ensures complete expansion of tubular components by minimizing material stress, enabling reuse and effective sealing of leaks in well casings, reducing the risk of fracturing during the expansion process.

Implementation Method 1

an electric motor connectable with and powered through a wireline

Methodology Applied

Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Implementation Method 2

the support structure connected with the first element for moving the support structure at least partly radially outwards

Methodology Applied

Scientific EffectMechanical advantage through inclined planes: Inclined Plane

Data Source

PatentUS12435587B2Wireline expansion tool

Publication Date: 2025.10.07 WELLTEC AS

AI summary

The present invention relates to a wireline expansion tool for setting of a completion tubular component such as a straddle, a liner, a patch or a liner hanger, the wireline expansion tool having an axial extension and comprising an electric motor connectable with and powered through a wireline, an axial force generator driven directly or indirectly by the electric motor for providing a movement along the axial extension, a radial expansion tool section connected with the axial force generator, and a completion tubular component, arranged at least partly around at least part of the radial expansion tool section for expanding at least part of the completion tubular component, wherein the radial expansion tool section comprises a first element movable along the axial extension by the axial force generator and a support structure connected with the first element, the support structure supporting the completion tubular component during expansion, and the first element being connected with the support structure for moving the support structure at least partly radially outwards for simultaneous expanding the completion tubular component. The invention also relates to a downhole tool string comprising the wireline expansion tool and a driving unit, such as a downhole tractor, for propelling the wireline expansion tool forward in the well.