Downhole Packer Setting Assembly with Controlled Hydraulic Actuation

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Solution Overview

Problem

Current downhole packer setting systems lack control over the actuation rate, which can lead to suboptimal sealing and longevity due to fixed timing mechanisms that do not adapt to changing well formation conditions.

Innovation Solution

A method and assembly that allow for controlled setting of downhole bridge plugs or packers by using a hydraulic setting tool and a slow, remotely driven pressure-building device to manage the application of hydraulic pressure, enabling partial setting with initial pressure and complete setting with higher pressure, thus allowing for adjustable actuation rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fixed metering system is used to control the actuation rate, then the setting process is slowed down, but the system cannot adapt to changing well formation conditions

Engineering Contradiction:

Improveseal durabilityVSAvoidadaptability to well conditions

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies a dynamic control system where the actuation rate can be adjusted in real-time based on well formation conditions. The system transitions from a fixed metering system to a controllable system that can modify the rate of hydraulic pressure application, allowing operators to optimize the setting process for different geological conditions while maintaining reliable sealing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the parameter of hydraulic pressure application rate from fixed to variable. By controlling the rate at which hydraulic pressure is applied to actuate the sealing element and slips, the system can adapt to different well formation conditions, improving both seal durability and adaptability simultaneously.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If hydrostatic pressure alone is used to set the packer, then the system is simple, but the actuation rate cannot be controlled

Engineering Contradiction:

Improvesystem simplicityVSAvoidactuation rate control

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent introduces a controllable pressure application device as an intermediary between the hydraulic pressure source and the packer components. This mediator allows precise control over the rate of pressure application and actuation, enabling operators to optimize the setting process without significantly complicating the overall system design.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces the simple hydrostatic pressure system with a controlled pressure application system that uses hydraulic actuators and flow control mechanisms. This substitution provides actuation rate control while maintaining relative system simplicity through the use of standard hydraulic components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the actuation process is completed quickly, then productivity is high, but seal longevity is compromised

Engineering Contradiction:

Improvesetting speedVSAvoidseal longevity

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent applies periodic or staged action in the actuation process, where hydraulic pressure is applied in controlled increments rather than continuously at maximum rate. This allows the sealing element to set progressively, maintaining seal longevity while achieving acceptable productivity through optimized timing and rate control.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system dynamically adjusts the actuation rate during the setting process, starting with faster initial actuation and then slowing down as the sealing element engages with the wellbore. This dynamic control optimizes both productivity and seal longevity by matching the actuation speed to the sealing process requirements.

Inventive Principle:

Principle #15Dynamics

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 enables precise control over the actuation rate of packer components, improving seal durability and adaptability to varying well conditions by allowing for slower and more controlled completion of the setting process.

Implementation Method 1

partially setting the bridge plug or packer with a first hydraulic pressure

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Implementation Method 2

completing the setting of the bridge plug or packer with the second hydraulic pressure

Methodology Applied

Scientific EffectHydrostatic pressure: Pressure Increase

Implementation Method 3

a slow remotely driven pressure-building device in operable communication with the setting tool capable of supplying pressure greater than hydrostatic pressure

Methodology Applied

Scientific EffectHydraulic press: Hydraulic Press

Data Source

PatentUS7681651B2Downhole bridge plug or packer setting assembly and method

Publication Date: 2010.03.23 BAKER HUGHES CO

AI summary

Disclosed herein is a method of elongating a setting time of a bridge plug or packer. The method includes, positioning the bridge plug or packer in a desired position within a wellbore, partially setting the bridge plug or packer with a first hydraulic pressure, controlling remotely a rate of application of a second hydraulic pressure, and completing the setting of the bridge plug or packer with the second hydraulic pressure, the second hydraulic pressure being greater than the first hydraulic pressure.