Electronically Controlled Expandable Wellbore Sealing Device
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Solution Overview
Problem
Existing sealing devices for wellbores lack efficient electronic control and retrieval mechanisms, limiting their ability to be precisely inflated and deflated for effective zonal isolation and fluid management in open-hole formations.
Innovation Solution
The development of an electronically controlled expandable sealing device that can be inflated and deflated using a pump system, integrated with a microcontroller and motor encoder, allowing for precise pressure control and independent operation of multiple devices along a string, enabling reliable zonal isolation and fluid management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic fluid is pumped into the rubber casing to expand the sealing element, then the sealing device can isolate the annulus, but the device cannot be easily retrieved or repositioned
Solution Approach 1:
The sealing element transitions from a static expanded state to a dynamic deflatable state. The system allows the sealing element to be inflated for reliable isolation and then deflated for easy retrieval or repositioning, making the device adaptable to different operational needs throughout its lifecycle
Solution Approach 2:
The volume and pressure parameters of the sealing element are changed dynamically. By controlling the hydraulic fluid volume in the sealing element, the device can transition between expanded (sealing) and deflated (retrieval) states, resolving the contradiction between reliable isolation and easy retrieval
2Duration of action of stationary object
If swellable material is used to inflate the rubber casing, then the sealing element can maintain expansion, but precise electronic control is lost
Solution Approach 1:
The passive chemical swelling mechanism is replaced with an active electronic control system. A pump, controlled by a microcontroller, regulates hydraulic fluid flow to the sealing element, enabling precise electronic control while maintaining the sealing duration needed for wellbore isolation
Solution Approach 2:
The system incorporates feedback control through a microcontroller that monitors pump operation and sealing element status. This enables precise control of the sealing element's inflation and deflation cycles, allowing the device to maintain sealing for required durations while being electronically controllable
3Adaptability or versatility
If multiple sealing devices are placed along a single string, then zonal isolation is improved, but control complexity increases
Solution Approach 1:
The control system is segmented into independent units, with each sealing device having its own pump and microcontroller. This modular approach allows multiple sealing devices to be placed along a single string for enhanced zonal isolation while keeping each unit's control simple and manageable
Solution Approach 2:
Each sealing device unit is designed as a universal module that can function independently or in coordination with other units. The standardized pump-microcontroller-sealing element configuration allows multiple devices to work together for complex zonal isolation scenarios without proportionally increasing overall system 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
This solution provides precise control over sealing and unsealing operations, allowing for reliable zonal isolation and fluid management, enhancing the efficiency and flexibility of wellbore operations by enabling electronic inflation and deflation of the sealing device.
Implementation Method 1
an expandable sealing element that is inflated by a fluid being pumped into the expandable sealing element
Implementation Method 2
the fluid can be released from the expandable sealing element to deflate the expandable sealing element
Implementation Method 3
The inflation and deflation of the expandable sealing element is controlled by an electronics package disposed on, adjacent to, or in close proximity of the sealing device
Data Source
AI summary
Sealing devices such as packers comprise an expandable sealing element that is inflated and/or deflated by an electrically-activated pump disposed in a wellbore so that the sealing element can be set and retrieved from the wellbore. The pump is disposed downhole in close proximity to the expandable sealing element and is electronically associated with a surface processing unit located at the surface of the wellbore. In certain embodiments, an electric motor electronically associated with the surface processing unit drives the pump to flow a fluid into a chamber of the expandable sealing element to inflate the expandable sealing element and pumps the fluid out of the chamber of the expandable sealing element to deflate the expandable sealing element. Multiple sealing elements can be disposed on a tool or work string and all can be addressable and individually and separately controlled by the surface processing unit.