Downhole Packer Staged Setting with Flow Choke
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Solution Overview
Problem
Hydraulic set packers fail to set effectively in high flow rate environments, leading to damage and failure due to rapid fluid flow into the annulus and lossy formations during the setting process.
Innovation Solution
A packer design with a staged setting sequence, where the slip element is actuated first to anchor the packer, followed by the packing element, and incorporating a choke element that restricts flow before the packing element sets, reducing the flow rate and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the packer is set in high flow rate environments, then the setting process can be completed, but the rapid fluid flow causes damage and failure of the packer
Solution Approach 1:
The choke element is deployed before the packing element sets to reduce the flow rate in advance. This preliminary action of flow restriction prevents the harmful high flow rate from damaging the packing element during the setting process, allowing reliable setting in high flow rate environments.
Solution Approach 2:
The setting process is divided into stages: first the choke element restricts flow, then the packing element sets. This segmentation of the setting sequence allows each component to function optimally without being damaged by high flow rates, improving overall reliability.
2Reliability
If the packing element is compressed outward toward the tubing in high flow rates, then the packer seals the annulus, but the rapid fluid flow causes damage and failure
Solution Approach 1:
The choke element is activated before the packing element compression to reduce flow rate in advance. This preliminary flow restriction protects the packing element from damage during compression, enabling effective sealing even in high flow rate conditions.
Solution Approach 2:
The choke element creates a counter-action to the high flow rate by restricting flow before the packing element sets. This preliminary anti-action neutralizes the harmful effect of high flow rates on the packing element, allowing successful sealing.
3Productivity
If fluid flows rapidly down the casing into lossy formations, then the fluid communication is maintained, but the packer setting fails due to high flow rate
Solution Approach 1:
The choke element restricts flow rate before the packer setting process completes, creating a controlled environment for setting. This preliminary flow control allows the packer to set reliably while maintaining the ability to communicate fluid production after setting.
Solution Approach 2:
The flow rate is dynamically controlled during the setting process using the choke element. The system transitions from high flow rate (maintaining productivity) to restricted flow rate (ensuring reliable setting), then returns to normal operation after setting completes.
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 packer effectively sets in high flow rates without damage by staging the movement of components and using a choke element to restrict flow, ensuring proper setting and reducing the risk of failure.
Implementation Method 1
The setting element can comprise a piston disposed in a chamber in communication with hydraulic pressure so that the piston can be movable in the downhole direction in response to the hydraulic pressure in the chamber.
Implementation Method 2
In a second stage, after the first stage, in response to the movement of the setting element in the downhole direction, the packing element is compressible outward toward the tubing.
Implementation Method 3
The slip element is disposed on the packer toward the downhole end and is moveable outward toward the tubing in a first stage in response to the movement of the setting element in the downhole direction.
Data Source
AI summary
A packer is used for setting downhole in tubing subject to downhole flow at a high flow rate. The packer includes a setting element, a slip element, and a packing element. The setting element is disposed on the packer toward an uphole end and is activated hydraulically to move in a downhole direction toward a downhole end of the packer. The slip element is disposed toward the downhole end and is moveable outward toward the tubing in a first stage in response to the movement of the setting element. The packing element is disposed on the other elements and is at least partially carried by the setting element. The packing element is compressible outward toward the tubing in a second stage, after the first stage, in response to the movement of the setting element. Additionally, a choke ring or other element disposed on the packer at least downhole of the packing element can move outward toward the tubing in response to the setting movement to restrict the downhole flow in the annulus to a lower flow rate.