Retrievable Packer Bypass Valve for Controlled Hydrocarbon Recirculation
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Solution Overview
Problem
Existing well testing methods face safety risks and loss of control during hydrocarbon removal due to the inability to activate backup circulating sleeves if the primary rupture disk fails, leading to uncontrolled gas release and potential obstructions during re-engagement of rams.
Innovation Solution
A retrievable packer apparatus with a bypass channel and wireless-controlled bypass valve, allowing controlled fluid circulation across the packer element, enabling safe recirculation of hydrocarbons without disengaging rams, using acoustic or electromagnetic signals to manage fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rupture disk is used to activate backup circulating sleeves, then hydrocarbons can be removed from the tubing string, but control is lost if the primary rupture disk fails
Solution Approach 1:
A bypass channel is introduced as an intermediary pathway that allows fluid communication between the annulus and tubing string when the primary rupture disk fails. This bypass channel, controlled by a bypass valve, serves as a mediator to restore control and enable hydrocarbon removal when the primary activation mechanism is compromised.
Solution Approach 2:
The bypass channel and bypass valve are pre-configured as a backup mechanism before the primary rupture disk can fail. This prior cushioning ensures that if the primary activation fails, the bypass system is already in place to take over, preventing loss of control during hydrocarbon removal operations.
2Productivity
If rams are disengaged to access gas below the packer, then gas cap can be removed, but safety risks increase due to potential obstructions during re-engagement
Solution Approach 1:
The bypass channel acts as an intermediary pathway that allows gas cap removal operations to proceed without disengaging the rams. By providing an alternative route for fluid communication, the bypass system eliminates the need to disengage rams, thereby removing the safety risks associated with potential obstructions during re-engagement.
Solution Approach 2:
The bypass valve and channel are prepared in advance as a ready-to-use alternative pathway. When gas cap removal is needed, the bypass system can be activated immediately without requiring ram disengagement, thus preventing the harmful situation of potential obstructions during re-engagement operations.
3Reliability
If a bypass channel is added to the packer apparatus, then control and safety are improved, but device complexity increases
Solution Approach 1:
The bypass channel and bypass valve are designed to serve multiple functions: they provide backup activation for circulating sleeves, enable gas cap removal, and maintain control during well testing. This multi-functionality justifies the added complexity by delivering multiple reliability improvements from a single structural addition.
Solution Approach 2:
The bypass system is segmented into distinct components (bypass channel, bypass valve, control mechanism) that can be independently managed and controlled. This segmentation allows for precise control over when and how the bypass function is activated, improving reliability while keeping the complexity manageable through modular design.
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
Enhances safety and control during well testing by allowing controlled recirculation of hydrocarbons, maintaining well integrity and reducing the risk of uncontrolled gas release, while facilitating easier handling and retrieval.
Implementation Method 1
using acoustic or electromagnetic signals to manage fluid flow
Implementation Method 2
using acoustic or electromagnetic signals to manage fluid flow
Data Source
AI summary
An apparatus comprising a mandrel (51, 251, 351) having a main longitudinal direction and defining a throughbore in that direction and a packer element (52, 352) mounted thereon. A seal bore extension (122) is attached, directly or indirectly, to the mandrel, and defines a bore (122b) in the main longitudinal direction. A floating seal (60) is provided between the bore of the seal bore extension and an internal moveable tube/stinger (120). A bypass channel (54, 254) extends across the packer element between an upper bypass port (50U, 250U) and a lower bypass port (50L, 250L), generally in said longitudinal direction. A bypass valve (55, 255) controls said upper or lower bypass port. The valve may move more than once and may be a multi-cycle valve. An electronic communication device (56a, 256) comprising a wireless receiver is configured to receive wireless signals such as EM or acoustic, to control the bypass valve. In this way the safety of well testing can be improved.