Metal Deformable Packer for Compact Annular Sealing
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Solution Overview
Problem
Conventional packers require significant size/real estate to activate, increasing operational complexity and cost, and existing perforations in casings can lead to pressure depletion and uncertainty in re-entry operations, especially in horizontal wells.
Innovation Solution
A deformable element configured to flex across an annulus based on pressure applied to its inner surface, utilizing seals, flex joints, and a body with tapered portions to create a seal without increasing the tool's outside diameter or decreasing its inner diameter, allowing for a smaller footprint and efficient sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional packer is used to seal across the annulus, then sealing is achieved, but the tool requires significant size/real estate and increases operational complexity
Solution Approach 1:
The deformable element is constructed with a flexible body comprising a proximal end, a distal end, and a stem, allowing it to flex and deform under pressure to seal across the annulus. This flexible structure eliminates the need for complex piston mechanisms while achieving reliable sealing through material deformation rather than mechanical expansion.
Solution Approach 2:
The deformable element transitions from a straight configuration to a bowed configuration in response to pressure applied to its inner surface. This dynamic response allows the element to automatically adapt to sealing requirements without complex control systems, reducing operational complexity while maintaining sealing reliability.
2Reliability
If a conventional packer is used to seal across the annulus, then sealing is achieved, but the outside diameter must increase or inner diameter decrease
Solution Approach 1:
The deformable element utilizes the pressure dimension to achieve sealing. By applying pressure to the inner surface, the element bows outward in the radial dimension to contact the annulus, eliminating the need to increase the tool's outside diameter or decrease its inner diameter while still achieving effective sealing.
Solution Approach 2:
The flexible body with integrated stem allows the element to deform and contact the annulus without requiring a larger tool footprint. The material flexibility enables sealing through deformation rather than through increased dimensional size, maintaining a compact tool design.
3Reliability
If pressure is applied to activate a conventional packer, then sealing is achieved, but significant force is required
Solution Approach 1:
The deformable element changes its physical state from straight to bowed configuration in response to pressure application. This parameter change allows the element to utilize the applied pressure more efficiently, requiring less activation force than conventional packers that must overcome rigid structural resistance to expand.
Solution Approach 2:
The dynamic deformation of the flexible body allows it to progressively engage with the annulus as pressure is applied, distributing the activation force more efficiently. This dynamic response reduces the peak force requirement compared to conventional packers that require sudden, high-force expansion.
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 deformable element effectively seals across the annulus, reducing the need for additional space and maintaining internal diameter, while preventing pressure depletion and ensuring reliable re-entry operations.
Implementation Method 1
a deformable element that is configured to flex across an annulus responsive to being introduced to pressure force
Implementation Method 2
the deformable element may be configured to flex outward across an annulus
Implementation Method 3
The flex joints may be configured to create weak points where the deformable element may flex outward across the annulus, which may allow the deformable element to bend but not break
Implementation Method 4
The seals may be positioned on a proximal and distal end of an inner surface of the body against an outer surface of the tool
Implementation Method 5
The tapered portions may be configured to increase and decrease, the diameter across the body to reduce the diameter across the stem, respectively
Data Source
AI summary
A tool with a deformable element that is configured to flex across an annulus based on a force being applied to an inner surface of the deformable element. The deformable element may be configured to be positioned within a chamber that is covered by a first rupture disc. The deformable element may include seals, flex joints, and a body.