Annular Barrier Bite Connection for Downhole Zonal Isolation
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Solution Overview
Problem
Existing annular barriers for zonal isolation in wells face challenges with unreliable fastening methods, particularly in varying hole diameters, and are time-consuming and laborious to install, especially when using expandable metal sleeves that require high expansion without compromising sealing ability.
Innovation Solution
An annular barrier featuring a tubular metal part with an expandable metal sleeve connected via a bite connection, utilizing a cutting ring and connection ring with threads or indentations, allowing for easy and secure fastening without altering material properties, capable of withstanding high expansion and temperatures, and facilitating on-site installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or crimping is used to fasten the expandable metal sleeve to the well tubular metal structure, then the sleeve can be securely attached, but the installation becomes time-consuming and laborious
Solution Approach 1:
The patent replaces complex mechanical fastening systems (welding equipment, crimping tools) with a simple threaded connection system consisting of a cutting ring, connection ring, and threaded bore. This substitution dramatically reduces installation time and complexity while maintaining secure attachment of the expandable metal sleeve to the well tubular metal structure.
Solution Approach 2:
The fastening system is divided into separate modular components: a cutting ring for creating the threaded bore, a connection ring with external threads, and the expandable metal sleeve with an internal threaded bore. This segmentation allows each component to be optimized independently and simplifies the installation process compared to monolithic welding or crimping systems.
2Adaptability or versatility
If the expandable metal sleeve is expanded to a larger extent to accommodate varying hole diameters, then adaptability improves, but the sealing ability may be jeopardized
Solution Approach 1:
The patent employs a threaded connection system that allows for controlled expansion of the expandable metal sleeve. The threaded bore and connection ring provide a mechanical interface that maintains sealing pressure while accommodating diameter variations. This parameter control mechanism enables the sleeve to adapt to different hole diameters without compromising the sealing ability, as the threaded connection can be tightened to maintain appropriate contact pressure.
3Strength
If traditional welding or crimping methods are used, then the expandable metal sleeve can be fastened to the tubular metal part, but the process is extremely difficult to perform on site
Solution Approach 1:
The patent replaces complex mechanical fastening systems (welding equipment, crimping tools) with a simple threaded connection system consisting of a cutting ring, connection ring, and threaded bore. This substitution dramatically reduces installation time and complexity while maintaining secure attachment of the expandable metal sleeve to the well tubular metal structure.
Solution Approach 2:
The cutting ring is designed to create its own threaded bore in the tubular metal part during installation. The cutting edges of the cutting ring automatically form the threaded interface as it is screwed onto the tubular part, eliminating the need for pre-drilling or specialized machining equipment at the installation site. This self-service capability greatly simplifies on-site installation.
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 solution provides a reliable, efficient, and cost-effective method for mounting the expandable metal sleeve, ensuring a strong metal-to-metal seal and higher radial expansion resistance compared to traditional welding or crimping, while being less time-consuming and easier to reproduce.
Implementation Method 1
when the inclined face slides along a tapering face of the expandable metal sleeve for pressing the first cutting edge into the outer part face
Implementation Method 2
pressing the first cutting edge into the outer part face, fastening the expandable metal sleeve to the tubular metal part
Implementation Method 3
the first part of the mechanical connection of the expandable metal sleeve may be a thread, and the second part of the mechanical connection of the connection ring may be a thread engaging the thread of the expandable metal sleeve
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The present invention relates to an annular barrier for providing zonal isolation in an annulus downhole between a well tubular metal structure and another well tubular metal structure or a wall of a borehole, comprising a tubular metal part with an outer part face, configured to be mounted as part of the well tubular metal structure an expandable metal sleeve surrounding the tubular metal part forming an expandable space there between, the expandable metal sleeve is configured to be expanded in a well downhole from a first outer diameter to a second outer diameter to abut against the well tubular metal structure or the wall of the borehole, the expandable metal sleeve having a first end, a second end, an outer face, and a longitudinal extension wherein the first end of the expandable metal sleeve has a mechanical connection, and wherein the first end of the expandable metal sleeve is connected to the tubular metal part by means of a bite connection comprising a cutting ring comprising an outer ring face having an inclined face and an inner ring face, having a first cutting edge configured to cut into the outer part face, and a connection ring with a mechanical connection engaging the mechanical connection of the expandable metal sleeve when the inclined face slides along a tapering face of the expandable metal sleeve for pressing the first cutting edge into the outer part face fastening the expandable metal sleeve to the tubular metal part. The invention also relates to a downhole system comprising at least one annular barrier and a well tubular metal structure of which the tubular metal forms part.