Inflatable Packer Seal With Particulate Media And Pressure Regulator

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Solution Overview

Problem

Current sealing technologies in the hydrocarbon recovery industry, such as packers, face challenges in maintaining reliable performance across varying environments and pressures, particularly in ensuring adequate expansion and retention of particulate matter for effective sealing.

Innovation Solution

A seal design featuring a mandrel, a radially disposed impermeable element, a chamber, and a pressure regulator that expands the element to a threshold pressure using fluid pressure, followed by deposition of resilient particulate matter to ensure secure sealing, with a screen to prevent particulate escape and a check valve to maintain seal integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional packers are used for sealing in hydrocarbon recovery, then sealing function is provided, but reliable performance across varying environments and pressures cannot be maintained

Engineering Contradiction:

Improvesealing performanceVSAvoidenvironmental adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The packer element's physical state is changed from conventional solid/rubber material to a particulate matter configuration. The particulates are suspended in a fluid carrier and can transition from a fluid state during installation to a solidified state during operation, adapting to varying pressure and temperature environments while maintaining reliable sealing performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The seal structure combines multiple materials: particulate matter (such as resin beads or ceramic particles), a fluid carrier (liquid or gas), and optionally a solidifying agent. This composite system provides both the flexibility needed for installation and the rigidity required for high-pressure sealing, resolving the contradiction between reliability and environmental adaptability

Inventive Principle:

Principle #40Composite materials

2Reliability

If particulate matter is used to fill the seal element, then sealing integrity is improved, but particulate escape and improper retention become problems

Engineering Contradiction:

Improvesealing integrityVSAvoidparticulate escape

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The packer element utilizes a porous structure formed by the particulate matter packed within the element. The porous configuration allows the particulates to be retained within the element structure while maintaining sealing integrity. The porosity is controlled to prevent particulate escape through the element walls while still allowing the element to conform to the wellbore geometry

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

A screen or filter medium is introduced as an intermediary between the particulate matter and the external environment. This screen prevents particulate escape while allowing the particulates to be properly retained and distributed within the element during the setting process, eliminating the harmful effect of particulate leakage

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If the seal is expanded using fluid pressure alone, then installation is simplified, but adequate contact pressure against the structure may not be achieved

Engineering Contradiction:

Improveinstallation simplicityVSAvoidcontact pressure

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

Fluid pressure (hydraulic or pneumatic) is applied to expand the packer element against the wellbore structure. The fluid carrier suspends the particulate matter and transmits pressure uniformly throughout the element, simplifying installation while achieving adequate contact pressure through the incompressible nature of the fluid medium

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The particulate matter undergoes a parameter change from a suspended fluid state during expansion to a compacted solid state after setting. This phase transition allows the element to maintain adequate contact pressure against the structure while simplifying the installation process, as the particulates self-pack and stabilize after the initial fluid-driven expansion

Inventive Principle:

Principle #35Parameter changes

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 ensures reliable and long-lasting sealing by ensuring full expansion and retention of particulate matter, enhancing the seal's resistance to pressure reversals and maintaining sealing integrity through resilient particulate material and regulated fluid pressure.

Implementation Method 1

pressurizing the seal with a particulate laden fluid; expanding the seal to an intended final set of dimensions

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Implementation Method 2

depositing the particulate in the seal

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS8490688B2Methodology for setting of an inflatable packer using solid media

Publication Date: 2013.07.23 BAKER HUGHES CO

AI summary

A seal includes a mandrel; an element disposed radially adjacent the mandrel; a chamber defined between the mandrel and the element; and a pressure regulator in fluid communication with the chamber, the regulator configured to resist fluid flow to a selected threshold pressure related to element expansion and method.