Expandable Packer Mandrel with Axially Movable Support Ring
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Solution Overview
Problem
Existing expandable open hole packers face challenges in achieving reliable seals due to dimensional differences between tubulars, limited sealing contact pressure, and potential damage during deployment, which can lead to increased operator costs and inefficiencies in well completion processes.
Innovation Solution
The design incorporates a mandrel expansion mechanism that converts radial expansion into rotational movement of fingers attached to a ring, allowing the sealing element to conform to irregular borehole shapes and enhance sealing contact pressure, with a support ring that aids in maintaining the seal and resisting pressure differentials, and an external ring that extends into the sealing element to prevent sliding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mandrel expansion is used to increase sealing contact pressure, then sealing reliability is improved, but the dimensional difference between tubular drift diameter and set dimension creates deployment problems
Solution Approach 1:
The packer is divided into multiple expandable segments or zones along the mandrel. Each segment can be expanded independently or in sequence, allowing the tubular to progressively increase in diameter rather than requiring a single large expansion step. This segmentation enables the packer to navigate through smaller clearances initially, then expand to the full set dimension at the deployment location, resolving the contradiction between deployment ease and sealing reliability.
Solution Approach 2:
The packer transitions from a dynamic, collapsible state during deployment to a static, expanded state during operation. The mandrel is designed to be flexible and compressible during run-in, allowing it to pass through tight clearances, then undergo controlled expansion at the set location to achieve the final sealing dimension. This dynamic behavior resolves the contradiction by allowing easy deployment followed by reliable sealing.
2Reliability
If swelling material is used to make a seal, then sealing contact pressure is improved, but the process is time consuming and increases operator cost
Solution Approach 1:
The invention replaces the chemical/swelling-based sealing mechanism with a mechanically-driven expansion system. Instead of relying on time-consuming material swelling to generate sealing contact pressure, the packer uses mechanically actuated expansion elements that can be rapidly deployed through controlled mandrel expansion. This substitution eliminates the time delay associated with swelling while maintaining or improving sealing contact pressure, directly resolving the contradiction between sealing reliability and time efficiency.
Solution Approach 2:
The invention changes the fundamental parameter of how sealing contact pressure is generated - from time-dependent material swelling to instantaneous mechanical force application. By using mechanically actuated expansion elements that can be quickly deployed, the system transforms the sealing process from a slow, time-consuming operation to a rapid, on-demand action, resolving the contradiction between achieving reliable seals and minimizing operational time.
3Reliability
If spring outwardly expanding packer cups are used, then sealing capability is improved, but potential damage during run in can destroy their ability to seal
Solution Approach 1:
The packer incorporates protective features such as drift shoulders, protective sleeves, or energy-absorbing elements that cushion the impact and distribute loads during run-in operations. These pre-installed protective features absorb potential damage before it reaches the sealing elements, allowing the packer to navigate through the wellbore safely while maintaining its sealing capability intact for deployment.
Solution Approach 2:
The sealing elements are designed with dynamic characteristics that allow them to remain flexible and protected during run-in, then activate their sealing function only when needed. The elements can compress or flex during deployment to avoid damage, then expand to their full sealing capacity once positioned correctly, resolving the contradiction between protection during run-in and sealing capability during operation.
4Adaptability or versatility
If tubular expansion with exterior rings is used to extend reach, then adaptability to wellbore shape is improved, but the ramp structure adds complexity and limits radial enhancement
Solution Approach 1:
The packer uses multiple independent expansion elements or segments distributed along the mandrel rather than a single continuous ramp structure. Each segment can expand independently to adapt to local wellbore conditions, providing the necessary adaptability without requiring a complex continuous ramp mechanism. This segmentation reduces overall device complexity while maintaining or improving adaptability to irregular wellbore shapes.
Solution Approach 2:
The invention employs flexible sealing elements or membranes that can conform to irregular wellbore shapes without requiring rigid ramp structures. These flexible components naturally adapt to the wellbore geometry through their inherent compliance, eliminating the need for complex mechanical ramp structures while maintaining adaptability to non-circular or irregular borehole cross-sections.
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 enables rapid formation of a reliable seal without relying on swelling processes, reduces the risk of damage during deployment, and effectively enhances sealing contact pressure, allowing for efficient well completion without delays, while accommodating non-round borehole shapes and varying pressure differentials.
Implementation Method 1
Shrinkage of the mandrel axially due to radial expansion brings a ring on the mandrel outer surface under the fingers
Implementation Method 2
the fingers get plastically deformed in an outward radial direction to push out the sealing element
Data Source
AI summary
An open hole packer uses mandrel expansion and a surrounding sealing element that can optionally have a swelling feature and further a seal enhancing feature of a ring with an internal taper to match an undercut on the mandrel exterior. As a swage progresses to the taper at the transition between the ring and the extending flat fingers, the fingers get plastically deformed in an outward radial direction to push out the sealing element. Shrinkage of the mandrel axially due to radial expansion brings a ring on the mandrel outer surface under the fingers to act as a support for the fingers against the seal which is pushed against the open hole. Mirror image orientations are envisioned to aid in retaining pressure differentials in opposed directions. Another external mandrel ring extends into the seal to keep its position during differential pressure loading.