Modular Wellbore Seal Assembly for Extended Zone Isolation
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Solution Overview
Problem
Conventional wellbore sealing devices face limitations in deployment length and conveyance due to surface equipment constraints, making it difficult to efficiently isolate zones in wellbores, especially when the zone requiring isolation is longer than the length accommodated by standard lubricators.
Innovation Solution
A wellbore zone isolation system comprising interlocking sealing elements with anchor elements at opposing ends, allowing for separate conveyance and assembly to form a zonal barrier that can span several hundred or over a thousand feet, using anchor seals and straddle seals that cooperate to prevent fluid migration, with modular and interchangeable designs for flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional sealing devices are used, then deployment is simpler with single-unit design, but the length is limited by surface equipment constraints
Solution Approach 1:
The sealing device is divided into multiple modular sealing elements that can be conveyed separately and assembled downhole. Each sealing element contains anchor elements and sealing components that interlock with adjacent elements, enabling the creation of a continuous seal over extended wellbore zones while maintaining manageable individual component sizes for conventional conveyance equipment.
2Adaptability or versatility
If the sealing device length is increased to cover longer zones, then zone isolation capability is improved, but conveyance into the well becomes more difficult
Solution Approach 1:
The system divides the sealing function into discrete, conveyable modules that can be deployed through standard equipment and assembled in situ, overcoming the limitation of surface equipment conveyance capacity while achieving extended zone isolation.
Solution Approach 2:
Multiple sealing elements are nested or stacked within the wellbore, with each element containing anchoring and sealing components that deploy upon activation. The modular elements can be conveyed in a compact configuration and expanded to form the full sealing structure downhole.
3Reliability
If multiple anchoring operations are performed for long zones, then seal reliability is improved, but deployment time and cost increase
Solution Approach 1:
Multiple sealing elements are combined into a continuous interlocking assembly that provides distributed anchoring and sealing along the entire isolated zone. The elements connect through mechanical interlocks that engage in a single deployment operation, eliminating the need for multiple separate anchoring trips while maintaining reliable sealing throughout the zone.
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 efficient isolation of wellbore sections under pressure by forming a fluid barrier that can accommodate longer lengths than conventional systems, reducing the need for frequent anchoring operations and enhancing deployment efficiency and cost-effectiveness.
Implementation Method 1
Each anchor element sealingly engages a wellbore tubular
Implementation Method 2
The interlocking sealing elements do not engage any portion of wellbore between the opposing ends
Data Source
Figure 1
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AI summary
An apparatus for providing zonal isolation in a wellbore includes a plurality of interlocking sealing elements having anchor elements at the opposing ends. Each anchor element sealingly engages a wellbore tubular whereas the interlocking sealing elements do not engage any portion of wellbore therebetween. In one exemplary application utilizes a wellhead and lubricator positioned over a wellbore under pressure and a conveyance device for conveying equipment into the wellhead. The first anchor, the second anchor and the plurality of interlocking sealing elements are separately conveyed into the wellbore with the conveyance device and sequentially assembled in the wellbore to provide zonal isolation.