Expandable Downhole Apparatus with Non-Concentric Deformable Chambers
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Solution Overview
Problem
Current sand control and wellbore support methods in the energy and water industries are operationally intensive, capital-intensive, and expensive, requiring large amounts of specialized materials and labor, and struggle with zonal isolation and permeability modification in varying rock conditions.
Innovation Solution
A downhole apparatus comprising a base pipe with non-concentric fluid pressure deformable chambers that can be inflated to increase diameter, providing support to the wellbore wall and allowing for controlled radial stress application to modify rock permeability and optimize fluid production, using materials like steel tubes and elastomers to accommodate varying rock types and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gravel-packing is used to support the wellbore face, then sand control is achieved, but the operation becomes capital-intensive and expensive
Solution Approach 1:
The patent employs an expandable tubular member that radially expands to contact and support the wellbore face, replacing the need for gravel-packing materials. The tubular member acts as a flexible shell that can be deployed in a compact state and expanded to provide continuous structural support, eliminating the operational complexity of pumping thousands of barrels of completion fluids and hundreds of tonnes of gravel.
2Reliability
If expandable completions are used to minimize annular void, then wellbore support is improved, but the operation remains intensive and expensive
Solution Approach 1:
The expandable tubular member is designed to be nested within a deployment device during conveyance, allowing the large-diameter supported structure to be transported in a compact state through the wellbore. The tubular member is then expanded radially outward to provide wellbore support, achieving the same support function as traditional expandable completions but with simplified operational requirements and reduced equipment needs.
3Reliability
If gravel-packing is used for sand control, then sand retention is achieved, but zonal isolation becomes difficult
Solution Approach 1:
The expandable tubular member serves multiple functions simultaneously: it provides sand control by filtering formation fluids, supports the wellbore face structurally, and enables zonal isolation through its ability to be positioned and expanded at different depths. This multi-functional design eliminates the need to choose between sand control and zonal isolation capabilities that plagues traditional gravel-packing methods.
4Reliability
If large GP treatments are pumped downhole, then sand control is achieved, but equipment investment and labor requirements increase
Solution Approach 1:
The invention extracts and eliminates the need for large volumes of gravel material and completion fluids from the sand control process. Instead of pumping thousands of barrels of fluids and hundreds of tonnes of gravel downhole, the system uses a mechanically expandable tubular structure that provides sand control through its physical barrier and filtering capability, dramatically reducing the quantity of substances required.
5Reliability
If the tubular member is expanded radially, then wellbore support is improved, but the apparatus complexity increases
Solution Approach 1:
The tubular member transitions from a static, compact configuration during conveyance to a dynamic, expanded configuration during operation. This dynamic transformation allows the same structure to serve dual purposes: as a compact deployable element and as a large-diameter support structure, reducing the need for multiple different apparatus components and simplifying the overall system design.
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 apparatus enables efficient and cost-effective wellbore support with minimal intervention, allowing for variable radial stress application to enhance rock failure strength and reduce permeability loss, optimizing fluid production and accommodating different rock types and conditions.
Implementation Method 1
chambers mounted externally thereon, the chambers being deformable from a first configuration to a second configuration by inflation
Implementation Method 2
the chambers being deformable from a first configuration to a second configuration by inflation
Implementation Method 3
allowing for controlled radial stress application to modify rock permeability and optimize fluid production
Implementation Method 4
modify rock permeability
Data Source
Figure 1~2
Figure 3~4B
Figure 5~6
AI summary
Downhole apparatus comprises a base pipe and a plurality of non-concentric pressure deformable chambers mounted externally on the pipe. The chambers may be inflated to increase the diameter of the apparatus and engage and a surrounding bore wall..