Bookend Seal Cartridge Assembly for Gap-Free Packer Expansion
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Solution Overview
Problem
Existing expansion mechanisms for tubular components in hydrocarbon exploration and production suffer from extrusion gaps and uneven support surfaces, leading to potential failure of packers and seals, and limited surface area for maximum force and pressure rating.
Innovation Solution
A combined seal and anchor assembly with a central slips cartridge and dual seal cartridges that move radially and circumferentially to form a constant outer diameter, providing radial and axial seals in compression, and includes support cones and energizing springs for maintaining compression load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If segmented metallic rings are used for expansion mechanisms, then the structure can be compact and easier to deploy, but spaces are formed between segments during expansion creating extrusion gaps that lead to failure of packers or seals
Solution Approach 1:
The ring is divided into multiple segments that can expand and contract radially. Each segment is a separate component that moves independently, allowing the ring to expand from a compact collapsed state to a larger expanded state while maintaining structural integrity through the segmented design
Solution Approach 2:
A seal element is introduced as an intermediary component between the segmented ring and the external environment. This seal element fills the extrusion gaps that form between segments during expansion, preventing fluid or gas leakage and maintaining system reliability without restricting the radial movement of segments
2Reliability
If multi-layered rings with offset segments are used to block extrusion gaps, then seal integrity is improved, but the ring creates uneven or stepped faces that are spatially inefficient and difficult to collapse reliably
Solution Approach 1:
The seal element is positioned locally at the extrusion gaps between segments rather than creating a complex multi-layered offset structure throughout the entire ring. This localized sealing approach blocks extrusion gaps effectively while maintaining a smooth, uniform outer surface that enables reliable collapsing without spatial inefficiency or operational difficulty
3Shape
If circumferentially lapped segments are used to avoid extrusion gaps, then a smoother surface is achieved, but the ring configuration becomes spatially inefficient and may be difficult to move back to collapsed configuration
Solution Approach 1:
The ring maintains its segmented structure with discrete segments that can move radially independently. This segmentation allows the ring to achieve a smooth outer surface when expanded while maintaining spatial efficiency in the collapsed state, as segments can be closely packed when retracted
Solution Approach 2:
The ring structure is designed to be dynamic, transitioning between expanded and collapsed states through radial movement of segments. The segments can move outward to form a smooth expanded surface and then retract inward to achieve compact storage, with the ability to reliably return to the collapsed configuration through controlled radial motion
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 assembly ensures seamless expansion and contraction without gaps, enhancing the sealing and anchoring capabilities while maintaining a consistent surface area for increased force and pressure rating.
Implementation Method 1
configured to move radially outward and slide circumferentially relative to each other
Implementation Method 2
first and second seal energizing spring assemblies disposed on opposite axial ends of the combined seal and anchor assembly and configured to maintain a minimum compression load against the seals
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 3A~3B
AI summary
Systems and methods presented herein include expanding and collapsing apparatus that include a slips cartridge that is bookended by seal elements. The pressure (e.g., whether from uphole and/or from downhole of the downhole tool) pushes at axial points at which the seal elements abut the slips cartridge. In addition, all of the load is transferred to the wellbore casing, and not to an inner mandrel at all. Specifically, the inner mandrel only experiences the setting force in tension. In addition, the elastomer that is being used is not stretched during expansion, but simply moved as it is expanded.