Downhole Packer Assembly for Uniform Metal Patch End Expansion
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Solution Overview
Problem
Existing downhole packer assemblies using multiple expandable tubular elements fail to adequately expand the ends of a metal patch, leading to restricted flow due to insufficient expansion, as the central part is fully expanded while the ends are expanded to a lesser degree.
Innovation Solution
A downhole packer assembly with a body part and two expandable tubular elements, where the distance between them increases upon reaching a predefined pressure threshold, allowing the expandable tubular elements to act as a mandrel, ensuring full expansion of the metal patch ends by maintaining higher pressure within the tubular elements compared to the confined space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single expandable tubular element is used to expand a long metal patch, then the central part is fully expanded, but the ends of the patch are expanded to a lesser degree causing flow restriction
Solution Approach 1:
The single expandable tubular element is divided into multiple separate expandable tubular elements (first, second, and optionally third elements) positioned at different locations along the metal patch. Each element can be independently expanded to ensure uniform expansion across the entire patch length, including the ends, thereby eliminating flow restriction caused by insufficient expansion at any single location.
2Productivity
If multiple expandable tubular elements are used to expand a long metal patch, then more locations can be expanded simultaneously, but the expandable elements are arranged within the longitudinal boundary of the patch limiting end expansion
Solution Approach 1:
The expandable tubular elements are arranged in a longitudinal sequence along the metal patch, extending beyond its transverse boundaries. This dimensional arrangement allows each tubular element to expand not only at its position but also to affect adjacent areas including the patch ends, ensuring complete coverage and adequate expansion at all locations simultaneously.
3Reliability
If expandable tubular elements are arranged within the longitudinal boundary of the metal patch, then the central part is fully expanded, but the ends of the patch cannot be expanded sufficiently
Solution Approach 1:
Different expandable tubular elements are positioned at specific locations including near the ends of the metal patch, with each element having tailored expansion characteristics suited to its local position. This allows the central part to be fully expanded by central elements while end elements specifically address the expansion needs of the patch ends, ensuring uniform quality across the entire structure.
4Volume of moving object
If the distance between expandable tubular elements is small, then the assembly is compact, but the pressure distribution is insufficient to expand the patch ends uniformly
Solution Approach 1:
The distance between expandable tubular elements is designed to be adjustable or optimized based on operational requirements. During expansion, pressure differentials and telescopic mechanisms dynamically adjust the spacing and pressure distribution to ensure uniform expansion across the patch, maintaining compactness when not in use while achieving adequate expansion uniformity during operation.
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
Ensures complete expansion of the metal patch ends, preventing flow restrictions and enhancing the sealing effectiveness of the assembly by utilizing pressure differentials and telescopic elements to achieve uniform expansion.
Implementation Method 1
an expandable tubular element can be inflated in order to expand the metal patch towards the inner face of the well tubular metal structure
Implementation Method 2
the expandable tubular element is arranged within the longitudinal boundary of the metal patch, which means that the expandable tubular element is not capable of expanding the ends of the patch sufficiently
Implementation Method 3
A downhole packer assembly with a body part and two expandable tubular elements, where the distance between them increases upon reaching a predefined pressure threshold, allowing the expandable tubular elements to act as a mandrel
Implementation Method 4
ensuring full expansion of the metal patch ends by maintaining higher pressure within the tubular elements compared to the confined space
Data Source
AI summary
A downhole packer assembly for expanding a metal patch in a well's downhole tubular metal structure has a body part with a longitudinal extension and a central part, a first expandable tubular element surrounding the body part and connected to the body part on one side, a second expandable tubular element surrounding the body part connected to the body part on an opposite side, and a metal patch having a first end, a second end, an inner face, and an outer face configured to face and abut the tubular metal structure. The metal patch surrounds the first and second tubular elements. The first tubular element is arranged at a first distance from the second tubular element in the longitudinal extension in a first operational state and at a second distance from the second tubular element in a second operational state, with the second distance being larger than the first.