Expandable Packer Bag Polymer Injection Sealing

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Solution Overview

Problem

Inflatable packers used in downhole hydrocarbon recovery operations have expansion limits, leading to potential failure and insufficient contact with the wellbore, which can result in washout areas and ineffective sealing.

Innovation Solution

A packer bag with a flexible composite wall and skeleton wire is deployed in a deflated configuration around a deployment tool, and a polymer filler material is injected to expand the packer bag, providing a robust and secure seal by expanding to fit larger well diameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If inflatable packers are used to seal wellbore sections, then zonal isolation can be achieved, but expansion limits are reached leading to insufficient contact with wellbore and potential failure

Engineering Contradiction:

Improvesealing reliabilityVSAvoidadaptation to wellbore diameter

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The packer system changes from a fixed expansion limit design to a variable expansion capacity by using polymer filler material that can be injected in varying quantities. The packer can expand beyond traditional limits by controlling the amount of polymer material injected, allowing adaptation to different wellbore diameters and maintaining reliable sealing contact.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite polymer filler material consisting of expandable polymer beads or granules that can be injected into the packer. This composite material provides both structural support and expansion capability, allowing the packer to achieve and maintain contact with the wellbore wall beyond traditional expansion limits while ensuring reliable sealing.

Inventive Principle:

Principle #40Composite materials

2Reliability

If packer expansion is increased to improve wellbore contact, then sealing effectiveness improves, but risk of failure increases due to exceeding expansion limits

Engineering Contradiction:

Improvesealing effectivenessVSAvoidpacker structural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The system transitions from a binary state (expanded/not expanded) to a continuous expansion state by controlling polymer material injection volume. This allows the packer to achieve optimal expansion for effective sealing while maintaining structural integrity by avoiding excessive expansion beyond design limits.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The injection system provides feedback control by monitoring the injection pressure and volume of polymer material. This feedback mechanism allows real-time adjustment of expansion force, ensuring the packer achieves sufficient contact for effective sealing while preventing over-expansion that could compromise structural integrity.

Inventive Principle:

Principle #23Feedback

3Reliability

If polymer filler material is injected to expand packer bag, then firm contact with wellbore is achieved, but device complexity increases due to additional canisters and injection mechanisms

Engineering Contradiction:

Improvewellbore contact firmnessVSAvoidinjection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The polymer filler material system is self-service in that the material itself performs the expansion function without requiring complex external actuation mechanisms. The polymer beads or granules automatically expand upon injection, filling the packer bag and pushing against the wellbore wall, thereby simplifying the overall system while achieving firm contact.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system uses hydraulic injection of polymer material through canisters, leveraging fluid pressure to deliver the expansion medium. This hydraulic approach provides a relatively simple and reliable method for expanding the packer compared to mechanical actuation systems, reducing overall device complexity while ensuring firm wellbore contact.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 allows for reliable zonal isolation and well segmentation by ensuring a firm contact with the wellbore, preventing washout and enhancing sealing efficiency, even in aggressive downhole environments.

Implementation Method 1

injecting a polymer filler material from the at least one canister into the packer bag until the packer bag expands to seal the downhole location

Methodology Applied

Scientific EffectPolymer expansion:

Data Source

PatentUS11591880B2Methods for deployment of expandable packers through slim production tubing

Publication Date: 2023.02.28 SAUDI ARABIAN OIL CO

AI summary

A method includes wrapping a packer bag around a deployment tool, providing at least one canister in fluid communication with the packer bag, sending the packer bag around the downhole tool to a downhole location in a well, and injecting a polymer filler material from the at least one canister into the packer bag until the packer bag expands to seal the downhole location.