Packer System Load Bypass for Slip Expansion Control

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Solution Overview

Problem

Conventional packer systems face challenges in preventing premature expansion of the lower slip device due to downhole hydraulic pressure, which can lead to unstable sealing and failure in setting the packer system at the intended location.

Innovation Solution

The packer system incorporates a setting sleeve that can transition between a bypass position and a released position, allowing the load from the setting piston to be bypassed from the lower slip device to the lower cone, seal member, and upper cone, thereby preventing premature expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the lower slip device is made strong to resist transition to the expanded position, then the packer system can maintain structural integrity during setting, but the downhole hydraulic pressure required to set the packer system increases excessively

Engineering Contradiction:

Improvelower slip device strengthVSAvoidhydraulic pressure requirement

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The packer system is divided into two separate slip devices (upper slip device and lower slip device) that can expand independently at different times. The upper slip device expands first during the setting operation, while the lower slip device remains in the retracted position until after the setting operation is complete. This segmentation allows the lower slip device to be weaker since it only needs to expand after the upper slip device has already provided structural support.

Inventive Principle:

Principle #1Segmentation

2Use of energy by moving object

If the lower slip device is made weak to expand easily, then the packer system can be set with lower hydraulic pressure, but the lower slip device may expand prematurely at unintended locations in the wellbore

Engineering Contradiction:

Improvehydraulic pressure requirementVSAvoidpremature expansion prevention

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The upper slip device is designed to expand first during the setting operation, performing the preliminary action of establishing structural support and sealing before the lower slip device expands. This preliminary expansion of the upper slip device creates the necessary conditions (reduced hydraulic pressure, structural stability) that prevent premature expansion of the lower slip device while allowing it to be weaker and expand more easily when intended.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the full hydraulic pressure is applied to the lower slip device during setting, then the lower slip device can be expanded to grip the wellbore walls, but the lower slip device receives excessive pressure that causes unstable sealing

Engineering Contradiction:

Improvelower slip device expansionVSAvoidsealing stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The expansion of slip devices occurs in a periodic sequence rather than simultaneously. The upper slip device expands first during the setting operation when full hydraulic pressure is applied, then the lower slip device expands afterward when hydraulic pressure has been reduced. This periodic action ensures that each slip device expands under appropriate pressure conditions, preventing unstable sealing while maintaining ease of operation.

Inventive Principle:

Principle #19Periodic action

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

This solution effectively prevents premature expansion of the lower slip device, allows for reliable setting of the packer system at the intended location, and reduces the risk of failure by distributing the hydraulic pressure more effectively across the packer components.

Implementation Method 1

downhole hydraulic pressure is used for upward pushing tubulars at the bottom of the packer system

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Data Source

PatentUS12215564B2Packer system with load bypass to prevent premature expansion

Publication Date: 2025.02.04 CNPC USA CORP

AI summary

The packer system includes a packer mandrel, an upper support or gage ring, a seal member, an upper slip device, an upper cone, a lower cone, a lower slip device, a setting sleeve, and a setting piston. The seal member has a run-in position and a set position. The set position seals against a borehole at a location in a borehole. The setting sleeve has a bypass position to transfer load of the setting piston away from the lower slip device and to the lower cone, the seal member, and the upper cone to set the seal member and upper slip device before the lower slip device. The setting sleeve has a released position to separate from the setting piston so that the load of the setting piston can finally be applied on the lower slip device for expansion of the lower slip device at the proper time and location.