Annular Barrier Pressure Intensification for Perforated Well Tubulars
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Solution Overview
Problem
Existing annular barriers cannot be effectively expanded in well tubular metal structures with screens or perforations without additional pressure force, as they require pressurization from within.
Innovation Solution
An annular barrier system with a pressure-intensifying unit and an activation chamber that creates a pressure difference, allowing expansion even in structures with openings, by connecting to either a lower or higher pressure source than the annulus or bore pressure, using a piston unit and non-return valves to control fluid flow and expand the expandable metal sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the well tubular metal structure has screens or perforations, then fluid can flow through the structure, but the annular barrier cannot be expanded by pressurization from within
Solution Approach 1:
The pressure intensifying unit is divided into separate functional components: a piston unit with first and second pistons, a pressure chamber, and non-return valves. This segmentation allows each component to perform its specific function - the first piston responds to annulus pressure, the second piston responds to bore pressure, and together they create the pressure differential needed for expansion without requiring the well tubular structure to be pressure-tight.
Solution Approach 2:
The pressure intensifying unit acts as an intermediary mechanism between the annulus pressure and the expandable metal sleeve. Instead of directly pressurizing the sleeve through the well tubular structure (which has openings), the system uses the pressure intensifying unit to convert the available annulus and bore pressures into the high pressure needed for expansion, mediating the pressure transmission process.
2Ease of operation
If additional pressure force is applied to expand the annular barrier, then expansion is achieved, but the system becomes more complex and requires intervention tools
Solution Approach 1:
The system is designed to expand automatically using the existing pressure differential between the annulus and the bore. The piston unit self-activates when the pressure conditions are met - the first piston moves in response to annulus pressure, which drives the second piston to intensify the pressure and expand the sleeve. No external intervention tools or additional pressure forcing equipment are needed.
Solution Approach 2:
The system uses hydraulic principles to achieve pressure intensification. The piston unit functions as a hydraulic press, where the movement of the first piston in response to annulus pressure drives the second piston to generate higher pressure in the expandable space. This pneumatic-hydraulic mechanism enables automatic expansion without mechanical intervention tools.
3Reliability
If the annular barrier is expanded using conventional pressurization, then the barrier provides zone isolation, but the system cannot maintain pressure integrity in structures with screens or perforations
Solution Approach 1:
The system applies pressure locally at the expansion site rather than requiring global pressurization of the well tubular structure. The piston unit creates a localized high-pressure zone in the expandable space between the expandable metal sleeve and the well tubular structure, allowing expansion to occur at this specific location even though the overall structure has openings elsewhere.
Solution Approach 2:
The system transitions from one-dimensional pressure transmission (through the well tubular structure wall) to a two-dimensional approach by utilizing both the annulus pressure and bore pressure simultaneously. The piston unit combines these two pressure sources in a dimensional sense, creating a pressure differential that acts radially outward to expand the sleeve, bypassing the need for axial pressure transmission through the perforated structure.
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 enables automatic expansion of the annular barrier without additional pressure force, ensuring effective zone isolation in well tubular metal structures with screens or perforations, maintaining pressure integrity and preventing premature expansion.
Implementation Method 1
an activation chamber (80) having a chamber pressure (PC) and being fluidly connected to a second opening (36) of the pressure-intensifying unit (20) in order to create a pressure difference between the annulus pressure (PA)/bore pressure (PB) and the chamber pressure (PC) for activating the pressure-intensifying unit (20) to increase the pressure of the fluid
Implementation Method 2
The piston unit (22) moves between a first position and a second position, wherein the movement of the piston unit (22) between the first position and the second position causes an expansion opening (11) of the annular barrier (1) to expand into the annulus (2)
Data Source
AI summary
An expandable annular barrier has a tubular metal part for mounting as part of the well tubular metal structure, the tubular metal part having a bore with a bore pressure, and an expandable metal sleeve surrounding the tubular metal part. The annular barrier has a pressure-intensifying unit for increasing the pressure of the fluid from the annulus or the bore before the fluid enters an expandable space, and an activation chamber having a chamber pressure and being fluidly connected to an opening of the pressure-intensifying unit in order to create a pressure difference between the annulus pressure/the bore pressure and the chamber pressure for activating the pressure-intensifying unit to increase the pressure of the fluid. The chamber pressure can be higher or lower than the annulus pressure or the bore pressure.