Expandable Metal Packer Pressure Control Valve
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Solution Overview
Problem
Existing expandable metal packers in well applications face challenges in controlling pressure acting on the metal membrane, which can lead to difficulty in expansion and susceptibility to damage.
Innovation Solution
A system comprising an expandable metal packer with a pressure control device, such as a valve, that can be actuated between different operational positions to control fluid communication and pressure within the packer, ensuring proper expansion and sealing without permanent fluid communication between the base pipe and the annulus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluid pressure is applied to expand the metal membrane packer, then the packer achieves sealing engagement with the wellbore surface, but the pressure becomes difficult to control and the metal membrane is susceptible to damage
Solution Approach 1:
An elastomeric element is introduced as an intermediary between the fluid pressure source and the metal membrane. The elastomeric element first expands to engage the wellbore surface, then transmits controlled pressure to the metal membrane, preventing direct exposure to uncontrolled fluid pressure while achieving reliable sealing engagement
Solution Approach 2:
The elastomeric element serves as a cushioning layer that is expanded before the metal membrane. This pre-expansion absorbs excess pressure and protects the metal membrane from damage while ensuring the packer achieves proper sealing engagement with the wellbore surface
2Ease of operation
If fluid communication is established between the base pipe and annulus for expansion, then the metal sleeve can be expanded, but permanent fluid communication may cause pressure control issues
Solution Approach 1:
The system transitions from a static fluid communication path to a dynamic controlled path. The valve system dynamically opens fluid communication during expansion operations, then closes it afterward, allowing the metal sleeve to be expanded while preventing permanent fluid communication that would cause pressure control issues
Solution Approach 2:
Fluid communication is temporarily established before the expansion operation to enable metal sleeve expansion, then is closed afterward. This preliminary opening of the fluid path allows proper expansion while preventing permanent communication that would compromise pressure control reliability
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 pressure control device effectively manages pressure within the packer, ensuring reliable expansion and sealing, while preventing damage to the metal membrane and improving the differential pressure rating of the packer.
Implementation Method 1
the pressure acting on the metal membrane can be difficult to control
Implementation Method 2
an expandable metal packer or packers use a deformable metal membrane which is deformed permanently by the pressure of inflating fluid
Implementation Method 3
each packer comprises an elastomeric element which may be expanded radially into sealing engagement with the surrounding borehole surface
Data Source
Figure 1
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Figure 6
AI summary
A technique facilitates utilization of a packer (34) in a borehole (32) or within other tubular structures. The packer may be constructed for mounting about a generally tubular base pipe (36). The packer generally comprises a metal sleeve (40) combined with extremities (44) located at each axial end of the metal sleeve. The metal sleeve (40) maintains a seal once expanded to a surrounding wellbore wall, e.g. a casing wall. For example, the metal sleeve (40) may be combined with an elastomer along its exterior, the elastomer sealing against the surrounding wellbore wall when the metal sleeve is radially expanded. Additionally, a device, e.g. a valve (62), is employed to control the pressures acting on the metal sleeve. For example, the device may be in the form of a valve operable (62) to control pressures acting on the metal sleeve (40) while running-in- hole, during expansion of the metal sleeve, and after setting of the packer.