Morphable Metal Packer Sealing Irregular Boreholes
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Solution Overview
Problem
Existing packers face challenges in sealing irregular borehole surfaces and providing expansion for sealing over a desired length, especially when using metal seals, and require mechanical expansion tools that cannot seal against open boreholes effectively.
Innovation Solution
A morphable tubular metal member is expanded radially using fluid pressure, which undergoes plastic deformation to match the borehole surface, creating a seal and acting as a packer with gripping elements that engage the cylindrical structure, and additional elastomeric bands enhance the seal and load-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal expandables are used to create seals between tubular members, then sealing effectiveness between tubulars is improved, but sealing capability against irregular borehole surfaces deteriorates
Solution Approach 1:
The packer utilizes plastic deformation as a parameter change mechanism. The metal tubular is plastically deformed radially outward to conform to irregular borehole surfaces, then elastic deformation occurs upon contact with the borehole wall. When pressure is released, the metal structure returns to its original dimensions, creating a seal against the plastically deformed surface. This combination of plastic and elastic deformation enables effective sealing against irregular surfaces.
2Reliability
If expander tools are used to expand metal members, then seals between tubular members are created, but the ability to provide expansion for packer formation deteriorates
Solution Approach 1:
The invention extracts the expansion function from a separate expander tool and integrates it directly into the metal tubular structure. The tubular itself is designed to be plastically deformed radially outward to form the packer, eliminating the need for a separate expander tool to be drawn through the entire tubular member. This integration simplifies the operation while maintaining seal creation capability.
3Reliability
If elastomeric seals are used to isolate annulus sections, then sealing is achieved, but chemical injection compatibility deteriorates
Solution Approach 1:
The invention employs a composite sealing mechanism combining metal and elastomer materials. The metal tubular provides the primary seal against irregular surfaces and chemical resistance, while elastomeric bands are applied to the outer surface to enhance sealing and provide chemical injection compatibility. This composite approach leverages the strengths of both materials.
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 morphable packer effectively seals against irregular surfaces and maintains the seal even after pressure release, providing a reliable isolation barrier with improved load-carrying capacity and ease of deployment.
Implementation Method 1
Sufficient hydraulic fluid pressure is applied to move the metal portion outwards and cause the metal portion to morph itself onto the generally cylindrical structure
Implementation Method 2
The metal portion undergoes plastic deformation and, if morphed to a cylindrical metal structure, the metal structure will undergo elastic deformation to expand by a small percentage as contact is made
Implementation Method 3
the metal structure will undergo elastic deformation to expand by a small percentage as contact is made. When the pressure is released the metal structure returns to its original dimensions and will create a seal against the plastically deformed metal portion
Implementation Method 4
additional elastomeric bands enhance the seal and load-carrying capacity
Data Source
AI summary
A morphable packer and method of setting the packer in a wellbore. The packer is a tubular member having a throughbore with a central portion having a greater diameter than each end portion with tapered portions there between. Gripping elements are arranged on the tapered portions. Morphing of the tubular member creates a seal between the central portion and an outer cylindrical structure, such as a wellbore or casing, and the gripping elements are moved radially outwards to engage with the cylindrical structure. The gripping elements act as slips which are activated by morphing the tubular member. Embodiments are described with the tubular member being a sleeve on a base pipe and, additionally, sealing and securing features in the form of elastomeric bands, lugs and wedges.