Annular Barrier Valve for Sleeve Burst Isolation in Wells
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Solution Overview
Problem
Existing annular barriers for zonal isolation in wells face issues where the expandable metal sleeve may burst during expansion due to unexpected borehole diameters, leading to potential fluid communication between the borehole and casing, and existing valves may not close effectively in such scenarios, compromising zonal isolation.
Innovation Solution
An annular barrier system featuring an expandable metal sleeve with a valve system that includes an isolation piston maintained by a shear element, which moves to isolate the annular space from the expansion opening if the sleeve bursts, utilizing a flow restriction in the first fluid channel to create a pressure difference that breaks the shear element and closes the valve, ensuring zonal isolation even if the sleeve ruptures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the expandable metal sleeve is expanded until it abuts the wall of the borehole, then zonal isolation is achieved, but the risk of the sleeve bursting increases due to unknown borehole diameter variations
Solution Approach 1:
The valve system is pre-configured with a shear element that breaks at a predetermined pressure difference. This preliminary arrangement ensures that if the sleeve bursts during expansion, the pressure differential automatically triggers the isolation piston to move to the closed position, sealing the annular space before fluid can escape to the borehole.
Solution Approach 2:
The flow restriction in the first fluid channel creates a pressure buffer mechanism. By deliberately designing an asymmetric flow path with restricted flow on one side, the system prepares a pressure differential cushion that activates the shear element and isolation mechanism only when needed, i.e., when the sleeve bursts and pressure equalizes through the unrestricted second channel.
2Device complexity
If existing valves are used in the annular barrier, then the structure is simpler, but the valves may not close effectively if the expandable metal sleeve breaks during expansion
Solution Approach 1:
The valve system is designed to be self-actuating through the shear element mechanism. When the sleeve bursts, the pressure differential automatically breaks the shear element and moves the isolation piston to the closed position without requiring external control systems, sensors, or additional power sources, thereby maintaining simplicity while ensuring reliable closure.
Solution Approach 2:
The system utilizes changes in pressure parameters to trigger the valve closure. The predetermined pressure difference across the shear element serves as the activation parameter, transforming the mechanical stress state into a positional change of the isolation piston that seals the annular space.
3Productivity
If the expandable metal sleeve bursts, then direct fluid communication between the borehole and casing occurs, but the expansion procedure must be aborted
Solution Approach 1:
The valve system extracts and isolates the annular space from the expansion opening through the isolation piston mechanism. When activated by the bursting event, the piston moves to block the first aperture, effectively separating the annular space containing the expandable sleeve from the expansion opening, thereby preventing fluid escape while allowing the expansion procedure to continue.
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 system effectively isolates the annulus from the expansion opening if the expandable metal sleeve breaks during expansion, allowing the expansion procedure to continue without fluid loss, ensuring zonal isolation and preventing direct fluid communication between the borehole and casing.
Implementation Method 1
the isolation piston is maintained in the first position by a shear element configured to break at a predetermined pressure difference between the first bore part and the second bore part
Implementation Method 2
the first fluid channel provides a flow restriction which provides a pressure difference across the isolation piston
Implementation Method 3
the expandable metal sleeve is configured to be expanded in the 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
Data Source
AI summary
The present invention relates to an annular barrier for providing zonal isolation in an annulus in a well downhole between a well tubular metal structure and another well tubular metal structure or a wall of a borehole, comprising a tubular metal part configured to be mounted as part of the well tubular metal structure, an expandable metal sleeve connected with and surrounding the tubular metal part forming an annular space there between, the expandable metal sleeve is configured to be expanded in the 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, and an expansion opening in the tubular metal part wherein the annular barrier further comprises a valve system comprising an isolation valve having a first position and a second, comprising an isolation bore, an isolation piston arranged in the isolation bore dividing the bore into a first bore part and a second bore part in the first position, the isolation piston is maintained in the first position by a shear element configured to break at a predetermined pressure difference between the first bore part and the second bore part, a first aperture arranged in the first bore part and being in fluid communication with the annular space, a second aperture arranged in the first bore part and being in fluid communication with the expansion opening through a first fluid channel, a third aperture arranged in the second bore part and being in fluid communication with the expansion opening through a second fluid channel, wherein in the first position the first aperture is in fluid communication with the second aperture, and in the second position the isolation piston prevents fluid communication between the first aperture and the second aperture.