Expandable Packer Assembly with Segmented Setting Collet
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Solution Overview
Problem
Existing packer systems used in wellbore operations, such as swellable and hydraulic pressure-actuated packers, face challenges in efficient and timely isolation of well zones due to slow actuation times and potential component failure under strain.
Innovation Solution
A packer system with a setting assembly that includes a packer mandrel, activation collet, and setting collet, which utilizes shear devices to transition from a run-in to a setting position, allowing external hydraulic pressure to expand an expandable packer for rapid zone isolation, reducing strain on components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a swellable packer is used to isolate zones, then the packer can be actuated by contact with a catalyst, but the actuation time becomes excessively long (days or weeks)
Solution Approach 1:
The patent replaces the chemical swelling mechanism with a mechanical expansion system. The packer includes an expandable element with radially extending arms that can be mechanically actuated by a setting tool, eliminating the need for catalyst contact and lengthy swelling periods. This mechanical substitution achieves rapid zone isolation while maintaining reliability.
Solution Approach 2:
The patent employs a hydraulic setting mechanism where fluid pressure is applied through a setting tool to expand the packer element. The hydraulic system uses fluid pressure to force the expandable element outward against the wellbore wall, achieving rapid and reliable zone isolation without the time-consuming chemical swelling process.
2Loss of time
If hydraulic pressure is increased from the surface to actuate the packer, then the packer can be set quickly, but the work string and components are placed under strain that may lead to failure
Solution Approach 1:
The patent segments the pressure application process into controlled stages. The setting tool includes a body with a bore that directs hydraulic pressure locally to the packer element rather than applying system-wide pressure. This segmentation allows the packer to be actuated quickly while limiting the strain on the work string and other components, preventing failure.
Solution Approach 2:
The setting tool acts as an intermediary device between the surface hydraulic system and the packer element. It includes a body with a bore that receives hydraulic fluid and directs it to expand the packer in a controlled manner. This intermediary function allows rapid packer setting while protecting the work string from excessive strain that would lead to failure.
3Reliability
If a setting assembly with multiple collets and shear devices is used, then the packer can be set with reduced component strain, but the device complexity increases
Solution Approach 1:
The setting assembly is segmented into functional modules: an activation collet with activation profile for initial positioning, a setting collet with shifting profile for final setting, and shear devices that connect these components. Each segment performs a specific function, allowing the complex setting sequence to be managed through modular, reliable components that reduce overall system strain.
Solution Approach 2:
The activation collet and activation profile perform preliminary positioning of the setting assembly on the packer mandrel before the final setting action. This preliminary action ensures proper alignment and reduces strain during the subsequent setting operation. The shear devices are pre-positioned to fail at specific points, enabling controlled transition from run-in to setting position without excessive force.
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
Enables rapid and reliable zone isolation in wellbore operations, enhancing the efficiency and safety of gravel packing by minimizing the time required for packer actuation and reducing the risk of component failure.
Implementation Method 1
One type of packer that is commonly used is a swellable packer that actuates when placed in contact with a catalyst.
Implementation Method 2
enabling the setting assembly to move from the intermediate position to a setting position where fluid within a bore of the setting mandrel can flow through the setting port to expand the expandable packer
Data Source
AI summary
A packer system includes a packer assembly and a setting assembly. The packer assembly includes a packer mandrel that includes a shifting profile and an activation profile formed on an inner surface of the packer mandrel and an expandable packer. The setting assembly is positionable within a bore of the packer mandrel and includes a setting mandrel, an activation collet positioned about the setting mandrel and engageable with the activation profile to shear a first shear device and enable the setting assembly to move from a run-in position to an intermediate position, and a setting collet positioned about the setting mandrel and engageable with the shifting profile to shear a second shear device and enable the setting assembly to move from the intermediate position to a setting position where fluid within a bore of the setting mandrel can flow through the setting port to expand the expandable packer.