Morphed Isolation Barrier Sleeve for Wellbore Sealing
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Solution Overview
Problem
Existing methods for creating a seal in wellbores using metal sleeves are complex, costly, and can damage the mandrel due to welding, and assessing joint quality is challenging without interfering parts.
Innovation Solution
A morphed isolation barrier is formed using a sleeve body made from multiple materials with different properties, welded together before assembly, allowing for efficient expansion and sealing without requiring welds on the assembled barrier, and enabling quality control before integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to secure the sleeve to the mandrel in the assembled barrier, then the sleeve is fixed in position, but the mandrel is damaged due to heat from welding
Solution Approach 1:
The welds are performed on the sleeve before the sleeve is assembled to the mandrel. This preliminary action allows the welding to be completed without the mandrel present, thereby avoiding heat damage to the mandrel while still achieving the necessary joint strength between the sleeve and end members.
Solution Approach 2:
The manufacturing process is segmented into separate steps: first welding the sleeve to end members independently, then assembling the complete unit to the mandrel. This segmentation separates the welding operation from the mandrel, eliminating the harmful thermal effect on the mandrel while maintaining structural integrity.
2Reliability
If multiple fittings and welding components are used to mount the sleeve on the tubular body, then secure fixing and sealing is achieved, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The sleeve, end members, and welds are combined into a pre-assembled unit before being mounted to the mandrel. This merging reduces the number of separate components and assembly steps required during final installation, simplifying the overall process while maintaining secure fixing and sealing through the integrated construction.
Solution Approach 2:
The complex welding and sealing operations are performed in advance during sleeve assembly, rather than during final installation. This preliminary action transfers the complexity to the manufacturing stage, allowing for simpler and faster field assembly while ensuring reliable fixing and sealing through pre-established connections.
3Reliability
If the sleeve is expanded using fluid pressure, then the sleeve morphs onto the borehole wall to create a seal, but the expansion process requires a sealed chamber which adds assembly complexity
Solution Approach 1:
The sealed chamber is integrated into the sleeve assembly itself, with the chamber space formed between the sleeve and the end members that are already welded to the sleeve. This merging eliminates the need for separate chamber components, reducing assembly complexity while maintaining the sealed environment necessary for effective sleeve expansion and sealing against the borehole wall.
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, efficient, and reliable sealing mechanism that maintains structural strength, avoids mandrel damage, and allows for precise quality assessment of welds, reducing assembly complexity and costs.
Implementation Method 1
a metal sleeve is forced radially outwardly by the use of fluid pressure acting directly on the sleeve. Sufficient hydraulic fluid pressure is applied to move the sleeve radially outwards and cause the sleeve to morph itself onto the generally cylindrical structure
Implementation Method 2
The sleeve undergoes plastic deformation and, if morphed to a generally 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 sleeve
Data Source
AI summary
An assembly and method of manufacturing an assembly for use as an isolation barrier to be run in and secured within a well. The assembly has a sleeve member positioned on the exterior of a tubular body, fixed at each end to create a chamber therebetween. Fluid can enter the chamber through a port in the tubular body to morph the sleeve member against a larger diameter surface in the well. The sleeve member is formed of at least two materials, welded together and machined before being arranged on the tubular body. One material is more expandable than the other so as to morph more easily. The sleeve is connected to the tubular body by screw threads and seals. Initial construction of the sleeve member allows welding, inspection and machining without affecting the tensile strength of the tubular body or complete assembly.