Packer Assembly Thermal Expansion Buffers

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Solution Overview

Problem

Packer assemblies in oil and gas exploration face premature actuation due to thermal expansion in extreme downhole conditions, leading to compressive loads and potential buckling or deformation, which can result in unintended displacement and reduced operational efficiency.

Innovation Solution

Incorporation of sacrificial members between packer assembly elements that are designed to destruct upon exposure to critical temperatures or axial loads, providing a void equivalent to the thermal expansion of packer components, thus preventing excessive compressive forces and maintaining assembly integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If packer assembly components are made rigid and closely fitted to ensure structural integrity, then strength and reliability are improved, but thermal expansion causes excessive compressive forces and premature actuation

Engineering Contradiction:

Improvepacker assembly operational reliabilityVSAvoidcompressive force from thermal expansion

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The patent incorporates sacrificial members (buffer elements) between packer components before deployment. These buffer elements are positioned in advance to absorb thermal expansion forces, preventing excessive compressive forces from developing between rigid components. The buffer elements act as pre-positioned cushions that accommodate dimensional changes during temperature transitions.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The sacrificial members serve as intermediary elements between rigid packer assembly components. These intermediaries absorb the thermal expansion effects, mediating the interaction between components that would otherwise be in direct contact. The buffer elements transfer and dissipate expansion forces, preventing direct force transmission between critical packer components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Force

If sacrificial members are added to absorb thermal expansion, then compressive forces are reduced, but device complexity increases

Engineering Contradiction:

Improvecompressive force reductionVSAvoidpacker assembly structure complexity

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent employs sacrificial members that are intentionally designed as temporary, consumable elements. These buffer elements are relatively simple in construction and are meant to be consumed or degraded after serving their purpose of absorbing thermal expansion forces. By using simple, disposable buffer elements rather than complex permanent mechanisms, the overall device complexity is minimized while still achieving the force reduction objective.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Length of stationary object

If buffer elements are positioned between packer components, then thermal expansion clearance is provided, but manufacturing precision requirements increase

Engineering Contradiction:

Improveclearance for thermal expansionVSAvoidbuffer element positioning precision

Core Design Contradiction:

Length of stationary objectVSManufacturing precision

Solution Approach 1:

The patent utilizes buffer elements with varying properties (such as different material compositions, densities, or compressibility characteristics) to accommodate thermal expansion. By changing the parameters of the buffer elements rather than relying solely on precise positioning, the design provides thermal clearance through material property adjustments. This approach reduces the stringency of manufacturing precision requirements compared to purely geometric solutions.

Inventive Principle:

Principle #35Parameter changes

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 sacrificial members effectively mitigate thermal expansion-induced compressive loads, preventing premature actuation of packers and ensuring reliable operation in high-temperature, high-pressure environments by absorbing the expansion, thereby maintaining the structural integrity and operational efficiency of the packer assembly.

Implementation Method 1

sacrificial members disposed between elements that interact upon actuation of the packer. The sacrificial members are configured to destruct by melting, collapse, or disintegration upon exposure to a critical temperature or a selected axial load

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10240428B2Packer assembly with thermal expansion buffers and isolation methods

Publication Date: 2019.03.26 HALLIBURTON ENERGY SERVICES INC

AI summary

Systems, methods, and apparatuses for accommodating thermal expansion in a tool string are disclosed. Exemplary systems include one or more sacrificial members placed between or adjacent elements of the tool string that are expected to expand when subjected to high temperatures. The sacrificial members are configured to destruct upon exposure to a control signal or a critical temperature or load. Destruction of the sacrificial members provides additional clearance for adjacent elements to expand.