Expandable Liner Tieback Connection for Wellbore Sealing
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Solution Overview
Problem
Conventional methods for connecting tubular members in a wellbore, such as using polished bore receptacles (PBRs), are prone to damage from downhole tools and debris, leading to sealing failures and require additional components like anchors and packers, which can leak, especially in harsh environments.
Innovation Solution
A method and apparatus that utilize an expandable tool with a tieback profile device and depth latch arrangement to expand the first tubular member into recesses of the second tubular member, creating a metal-to-metal seal without the need for PBRs or associated components, using fluid pressure to achieve elastic and plastic deformation for a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polished bore receptacle (PBR) is used to connect tubular members, then a sealed connection is formed, but the PBR is susceptible to damage from downhole tools and debris, leading to sealing failures
Solution Approach 1:
The connection system is divided into two main segments: an expandable tubular member with external expansion features and a receptacle with internal recesses. The expansion features are segmented to engage with multiple recesses, distributing the connection forces and creating multiple sealing points, which enhances reliability while protecting against localized damage.
Solution Approach 2:
The receptacle is designed with recesses that anticipate and accommodate the expansion features before actual connection occurs. This pre-positioned geometry provides a cushioning effect that absorbs impact forces from downhole tools and debris, preventing damage to sealing surfaces while maintaining the ability to form a reliable seal when expanded.
2Adaptability or versatility
If conventional PBR connection methods are used, then thermal expansion and contraction can be accommodated, but the seals wear and fail over time due to movement
Solution Approach 1:
The connection system transitions from a static sealed interface to a dynamic expandable structure. The expandable tubular member can adjust its diameter to accommodate thermal expansion and contraction of the tieback liner, while the engaged recesses maintain a stable metal-to-metal connection that does not wear, eliminating the seal failure issue.
Solution Approach 2:
The elastomeric seal system is replaced with a metal-to-metal engagement system. Instead of relying on elastomer seals that wear from movement, the invention uses the structural engagement between expansion features and recesses to provide both the sealing function and the mechanical accommodation for thermal movement, eliminating wear and failure.
3Stability of the object's composition
If additional components like anchors and packers are used with PBR, then connection stability is improved, but the complexity of the system increases and leakage risks increase
Solution Approach 1:
The invention merges multiple functions into a single integrated system. The expandable tubular member and receptacle combination provides both the connection stability previously requiring separate anchors and packers, and the sealing function of the PBR. This consolidation reduces component count and eliminates leakage paths associated with multiple interfaces.
Solution Approach 2:
The expandable tubular member with engagement features serves multiple functions simultaneously: it provides mechanical anchoring through expansion, creates a sealed connection through metal-to-metal engagement, and accommodates thermal movement. This multi-functionality eliminates the need for separate specialized components, reducing overall system complexity while maintaining stability.
4Temperature
If the PBR allows thermal expansion movement, then thermal effects are accommodated, but the seals wear and ultimately fail
Solution Approach 1:
The connection system transitions from a static sealed interface to a dynamic expandable structure. The expandable tubular member can adjust its diameter to accommodate thermal expansion and contraction of the tieback liner, while the engaged recesses maintain a stable metal-to-metal connection that does not wear, eliminating the seal failure issue.
Solution Approach 2:
The system changes the physical state of the connection from a fixed elastomeric seal to an expandable metal structure. By changing the diameter parameter of the tubular member through expansion, the system accommodates thermal movement while maintaining a durable metal-to-metal interface that is not subject to wear from repeated movement.
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 a durable, high-pressure-resistant metal-to-metal seal that minimizes wear and eliminates the need for elastomers and additional components, enhancing reliability and performance in harsh environments by anchoring the tubing against thermal loads and withstanding high burst and collapse loads.
Implementation Method 1
using fluid pressure to achieve elastic and plastic deformation for a secure connection
Implementation Method 2
using fluid pressure to achieve elastic and plastic deformation for a secure connection
Implementation Method 3
using fluid pressure to achieve elastic and plastic deformation for a secure connection
Data Source
Figure 1~2
Figure 3~5
AI summary
A method of connecting a first tubular member to a second tubular member located in a wellbore, the second tubular member including an upper end portion which has a greater diameter than the diameter of the first tubular member, the method comprising: lowering the first tubular member into the wellbore until the first tubular member is located at least within the bore of the upper end portion of the second tubular member; and expanding the first tubular member until the first tubular member is sealingly connected to the second tubular member.