Expandable Sleeve Swage Mechanism for Downhole Zone Isolation
Solution Overview
Problem
The 'plug and perf' method for creating openings in a production liner for fluid injection into a formation is time-consuming due to the individual operation and removal of perforation guns and plugs, which limits the efficiency of the fracturing process.
Innovation Solution
A downhole tool with an expandable sleeve and swages that deform radially to engage a surrounding tubular, allowing for fluid isolation and fracture creation without the need for individual perforation guns and plugs, utilizing a setting tool to expand the sleeve and apply a gripping and sealing feature for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plug and perf method is used with individual perforation guns and plugs, then fluid isolation and fracture creation can be achieved, but the process becomes extremely time-consuming
Solution Approach 1:
The patent combines multiple functions (isolation, perforation, fracturing) into a single integrated tool assembly. The expandable sleeve with swages performs both isolation and perforation in one deployment, eliminating the need for separate plug installation and gun operation steps, thereby dramatically reducing process time while maintaining fluid isolation capability
Solution Approach 2:
The expandable sleeve is deployed in advance to establish isolation before perforation occurs. The sleeve expands and engages the tubular wall, creating the isolation barrier beforehand, allowing subsequent perforation and fracturing operations to proceed without interruption or additional isolation steps
2Adaptability or versatility
If individual plugs are installed and removed for each zone, then zone isolation is achieved, but the complexity of operations increases
Solution Approach 1:
The expandable sleeve tool assembly serves multiple functions: it provides zone isolation by engaging the tubular wall, performs perforation through the integrated gun, and enables fracturing. This multi-functional design eliminates the need for separate plug installation, gun deployment, and plug removal operations, reducing operational complexity while maintaining adaptability for different zones
Solution Approach 2:
The tool assembly is designed with modular components including the expandable sleeve, swages, and integrated gun system. Each component performs a specific function but works together as a unified system, allowing the tool to be deployed as a single unit that handles multiple zones through sequential operation rather than multiple separate interventions
3Reliability
If plugs are left in place after fracturing, then zone isolation is maintained, but production of hydrocarbons is blocked
Solution Approach 1:
The expandable sleeve is designed to be temporarily deployed for isolation and perforation purposes, then removed after the fracturing operation is complete. This extraction of the isolation device after use allows hydrocarbon production to proceed without blockage, while the isolation function was maintained during the critical fracturing phase
Solution Approach 2:
The expandable sleeve transitions from a deployed state providing isolation to a removed state allowing production. The dynamic nature of the tool - being installable and removable - resolves the contradiction between maintaining isolation and enabling production, as the tool adapts its presence based on operational requirements
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 enhances the efficiency of the fracturing process by reducing the time required for zone isolation and fluid communication, allowing for more rapid and effective fracture creation and hydrocarbon production.
Implementation Method 1
The first and second swages are configured to move toward one another in the bore, such that the first and second swages deform end portions of the expandable sleeve radially outwards and into engagement with a surrounding tubular
Implementation Method 2
a first swage positioned at least partially within the bore and including a valve seat configured to receive an obstructing member, such that the obstructing member and the first swage substantially prevent fluid communication through the bore
Data Source
AI summary
A downhole tool and a tool assembly, of which the downhole tool includes an expandable sleeve defining a bore extending axially therethrough, a first swage positioned at least partially within the bore and including a valve seat configured to receive an obstructing member, such that the obstructing member and the first swage substantially prevent fluid communication through the bore when the obstructing member is seated in the valve seat, and a second swage positioned at least partially within the bore. The first and second swages are configured to move toward one another in the bore, such that the first and second swages deform end portions of the expandable sleeve radially outwards and into engagement with a surrounding tubular, and the expandable sleeve, in an expanded configuration in which the end portions engage the surrounding tubular, defines an unexpanded portion between the expanded end portions.