Expandable Well Sleeve for Simpler Annular Barrier Isolation
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Solution Overview
Problem
Existing packers or annular barriers in wells require complex valve assemblies that shift fluid communication multiple times, leading to high manufacturing costs and the need for customization for each borehole size.
Innovation Solution
A completion component with an expandable sleeve and a first connection part that can slide along an axial extension, allowing for simple shifting of fluid communication and expansion, reducing manufacturing costs while maintaining reliability, and featuring a design that minimizes thinning and burst risks through compression forces and pressure compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex valve assemblies are used to shift fluid communication multiple times, then reliability of zone isolation is improved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The completion component is divided into distinct functional segments: a packer element for zone isolation and a port collar element for fluid communication control. This segmentation allows each element to perform its specific function independently, eliminating the need for complex integrated valve assemblies while maintaining reliability.
Solution Approach 2:
The port collar element is designed to be movable rather than fixed, allowing it to shift between different positions to control fluid communication. This dynamic element replaces complex valve assemblies by using simple positional changes to achieve the required fluid communication shifts during run-in-hole, expansion, and cementing operations.
2Ease of operation
If complex valve assemblies are used for multiple fluid communication shifts, then operational control is improved, but ease of manufacture deteriorates due to customization requirements
Solution Approach 1:
The completion component combines multiple functions into a single standardized device: the packer element provides zone isolation while the port collar element controls fluid communication. This universal design allows the same component to be used across different borehole sizes without customization, improving ease of manufacture while maintaining operational control.
Solution Approach 2:
The port collar element automatically shifts to appropriate positions based on operational conditions without requiring external valve control mechanisms. The component self-regulates fluid communication during different operational phases, eliminating the need for complex externally-controlled valve assemblies and reducing manufacturing costs.
3Stability of the object's composition
If expandable sleeve is fixed at both ends, then structural stability is improved, but thinning effect during expansion increases and burst risk increases
Solution Approach 1:
The second end part of the expandable sleeve is designed to be movable rather than fixed, allowing it to slide along the axial extension during expansion. This dynamic design reduces the thinning effect by accommodating the radial expansion through axial movement, thereby reducing burst risk while maintaining structural stability.
Solution Approach 2:
The movable second end part acts as a counterbalancing element that compensates for the thinning effect during expansion. By allowing axial movement, it creates a mechanical advantage that distributes the expansion forces more evenly, counteracting the thinning and reducing the risk of bursting.
4Strength
If movable second end part is used to reduce thinning effect, then sleeve strength is improved, but device complexity increases
Solution Approach 1:
The movable second end part is integrated with the port collar element, combining the function of reducing thinning effect with the function of controlling fluid communication. This merging approach allows the device to achieve improved sleeve strength without adding separate complex components, as the port collar's movement serves dual purposes.
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 solution provides a cost-effective, reliable annular barrier with simplified fluid communication shifting, enabling efficient cementing and zone isolation with reduced manufacturing costs and enhanced durability against pressure fluctuations.
Implementation Method 1
an expansion opening in the tubular metal part through which fluid may enter the annular space in order to expand the expandable sleeve
Implementation Method 2
the second end part is slidable along the axial extension, and wherein the completion component further comprises a first connection part having a first condition in which the first connection part is fixedly arranged along the axial extension and a second condition in the first connection part is slidable along the axial extension
Data Source
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AI summary
The present invention relates to a completion component for providing an annular barrier in a well between a first well tubular metal structure and an inner face of a borehole or a second well tubular metal structure for providing zone isolation between a first zone and a second zone of an annulus, comprising a tubular metal part for mounting as part of the first well tubular metal structure, the tubular metal part having an axial extension and an outer face, an expandable sleeve surrounding the tubular metal part and having a first end part and a second end part, an outer face facing towards the inner face of the borehole or the second well tubular metal structure, and an inner face facing the outer face of the tubular metal part, an annular space between the expandable sleeve and the tubular metal part, and an expansion opening in the tubular metal part through which fluid may enter the annular space in order to expand the expandable sleeve, wherein the first end part of the expandable sleeve is fixedly fastened with the tubular metal part and the second end part is slidable along the axial extension, and wherein the completion component further comprises a first connection part having a first condition in which the first connection part is fixedly arranged along the axial extension and a second condition in the first connection part is slidable along the axial extension, the second end part of the expandable sleeve abutting and being slidable in relation to the first connection part. Moreover, the present invention also relates to a downhole system and a cementing method of providing cement in an annulus between the well tubular metal structure and a wall of a borehole or a second well tubular metal structure.