Annular Barrier Press Connection Mounting
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Solution Overview
Problem
Existing annular barriers face challenges in mounting and maintaining sealing ability, especially in wells with varying diameters, as traditional fastening methods like welding or crimping are time-consuming and often unsuccessful, compromising the connection of expandable metal sleeves to tubular metal structures.
Innovation Solution
An annular barrier design featuring a tubular metal part with circumferential grooves and projections, allowing for expansion and engagement with an expander tool to form mechanical connections without altering material properties, enabling easier and faster mounting through a press or bite connection, ensuring reliable sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or crimping is used to fasten the expandable metal sleeve to the tubular metal structure, then the connection strength is improved, but the mounting time increases and the process becomes more complex
Solution Approach 1:
The connection process is divided into two distinct phases: first, the expandable metal sleeve is mounted onto the tubular metal structure in a simple slip-fit manner (quick mounting); second, the expander tool is used to create the mechanical interlocking connection through radial expansion (strong bonding). This segmentation allows the mounting and bonding operations to be separated in time and method.
Solution Approach 2:
The expandable metal sleeve is pre-mounted onto the tubular metal structure using a simple slip-fit connection before deployment. This preliminary mounting action allows the sleeve to be in position and ready for service, while the actual strong bonding through expansion is performed later using the expander tool, optimizing both initial installation speed and final connection strength.
2Strength
If welding or crimping is used to fasten the expandable metal sleeve, then the connection strength is improved, but the ease of operation deteriorates
Solution Approach 1:
The mounting operation is segmented into a simple initial slip-fit mounting phase (easy operation) and a subsequent expansion phase (performed from well surface). The segmentation allows the difficult bonding operation to be separated from the easy mounting operation, optimizing overall ease of operation.
Solution Approach 2:
The expander tool acts as an intermediary device that enables the creation of strong mechanical interlocking connections without requiring complex welding or crimping operations. The expander tool is introduced through the tubular metal structure and performs the bonding function from the well surface, simplifying the mounting operation.
3Adaptability or versatility
If the expandable metal sleeve is expanded to a larger extent in wells with varying hole diameter, then the adaptability is improved, but the sealing ability deteriorates
Solution Approach 1:
The mechanical interlocking connection is established through preliminary expansion action using the expander tool before the sleeve is subjected to service pressures. This preliminary action ensures that the sleeve is securely bonded to the tubular metal structure, maintaining sealing ability even when expanded to larger extents for adaptability to varying hole diameters.
Solution Approach 2:
The expandable metal sleeve utilizes radial expansion in a curved/spheroidal manner to adapt to varying hole diameters. The sleeve expands uniformly in all radial directions, maintaining its sealing capability while adapting to different wellbore sizes. The circumferential grooves and projections work together during this radial expansion to maintain both adaptability and sealing.
4Strength
If traditional fastening methods are used, then the connection strength is improved, but the device complexity increases
Solution Approach 1:
The complex welding or crimping equipment is extracted from the mounting process. Instead, a simple slip-fit mounting method is used initially, and the expander tool is introduced through the tubular metal structure to perform the bonding function from the well surface, reducing the complexity of the mounting process while maintaining connection strength.
Solution Approach 2:
The expander tool serves as an intermediary that simplifies the bonding process. Rather than requiring complex welding or crimping equipment to be positioned and operated at the well site, the expander tool is introduced through the existing tubular structure and performs the bonding function remotely, reducing device complexity.
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 secure, efficient, and cost-effective method for mounting expandable metal sleeves, capable of withstanding high expansion without compromising sealing, reducing time and costs compared to traditional welding or crimping methods.
Implementation Method 1
the tubular metal part bulges radially outwards in relation to the axial extension, forming at least one circumferential projection engaging the groove
Data Source
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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, the annular barrier having an axial extension and comprising a tubular metal part with an inner part face and an outer part face and 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 therebetween; the expandable metal sleeve is configured to be expanded in a well downhole from a first outer diameter to a second outer diameter in order to abut against the well tubular metal structure or the wall of the borehole, the expandable metal sleeve having a first end part, a second end part and an outer face, and at least one of the end parts comprising at least one circumferential groove facing the outer part face, wherein the tubular metal part bulges radially outwards in relation to the axial extension, forming at least one circumferential projection engaging the groove, thus providing a connection of the expandable metal sleeve to the tubular metal part. The invention also relates to a downhole system and a mounting method for mounting an expandable metal sleeve of an annular barrier to the tubular metal part.