Downhole Packer Valve Assembly for Casing Integrity Testing
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Solution Overview
Problem
Casing integrity testing for wells undergoing cyclic steam stimulation is costly and requires a workover rig, necessitating the removal and reinstallation of production tubing and testing equipment, which results in lost or delayed production.
Innovation Solution
A downhole packer assembly with a selective fluid bypass that allows for steam injection and casing pressure testing without the need for a workover rig, enabling the assembly to remain in the well and perform integrity testing without prior removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a workover rig is used to perform casing integrity testing, then the casing integrity can be tested, but the production tubing and pumping equipment must be removed and reinstalled, resulting in lost or delayed production
Solution Approach 1:
The packer assembly is designed to perform multiple functions: it can provide a fluid seal for production operations and simultaneously serve as a testing surface for casing integrity testing. The valve assembly can selectively bypass fluid around the seal assembly during production, and the same assembly provides a downhole surface for pressure testing during integrity testing, eliminating the need for separate testing equipment
Solution Approach 2:
The packer assembly acts as an intermediary device that enables casing integrity testing without requiring removal of production tubing. The valve assembly controls fluid flow to create a bypass passageway around the seal assembly, allowing pressure to be applied for testing while the packer remains in place, thus mediating between production operations and testing requirements
2Reliability
If a workover rig is used to perform casing integrity testing, then the casing integrity can be tested, but the operation becomes costly and time-consuming
Solution Approach 1:
The packer assembly is pre-configured with a valve assembly and seal assembly that can be activated to provide a testing surface. The valve assembly can be actuated to bypass fluid around the seal assembly, creating the necessary conditions for integrity testing without requiring prior removal of equipment or deployment of additional tools
Solution Approach 2:
The same packer assembly that is installed for production operations is used for integrity testing, eliminating the need for separate testing equipment and procedures. This multi-functional design reduces both the time and cost associated with testing operations
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
Enables efficient steam injection and casing pressure testing, reducing operational costs and minimizing production downtime by allowing the packer assembly to remain in the well, thus eliminating the need for frequent rig operations.
Implementation Method 1
A hydraulic control line is in fluid communication with the piston assembly. The hydraulic control line is operable to apply hydraulic pressure to bias the piston assembly in a first direction
Implementation Method 2
urging the valve assembly to the closed position, which is in opposition to a biasing force of the spring in a second direction
Data Source
AI summary
A downhole packer assembly for steam injection and casing pressure testing. The downhole packer assembly includes a housing assembly having intake and discharge ports. A seal assembly is positioned around the housing assembly between the intake and discharge ports and is operable to provide a fluid seal with a casing string. A mandrel is positioned within the housing assembly forming a micro annulus therewith and providing an internal pathway for fluid production therethrough. A valve assembly is disposed between the housing assembly and the mandrel and is operable between closed and open positions by a piston assembly such that the intake and discharge ports and the micro annulus provide a bypass passageway for steam injection around the seal assembly when the valve assembly is open and the seal assembly provides a downhole surface for pressure testing of the casing string uphole thereof when the valve assembly is closed.