Downhole Packer Assembly With Variable Tubular Spacing
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Solution Overview
Problem
Existing downhole packer assemblies struggle to evenly expand metal patches in well tubular structures, with central parts fully expanded while ends remain under-expanded, causing flow restrictions.
Innovation Solution
A downhole packer assembly with two expandable tubular elements and a central body, where fluid pressure differentials control the expansion of the tubular elements relative to each other, allowing for sequential and uniform expansion of the metal patch ends and central part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single expandable tubular element is used to expand a long metal patch, then the device complexity is reduced, but the expansion uniformity deteriorates because the central part is fully expanded while the ends remain under-expanded
Solution Approach 1:
The single expandable tubular element is divided into multiple segments (first and second expandable tubular elements) that can be independently controlled. Each segment corresponds to a specific region of the metal patch (central part and end parts), allowing differentiated expansion control to achieve uniform expansion across the entire patch length.
2Manufacturing precision
If multiple expandable tubular elements are used to expand a long metal patch, then the expansion uniformity is improved, but the device complexity increases
Solution Approach 1:
The distances between the first and second expandable tubular elements are made variable through a dynamic adjustment mechanism. This allows the spacing between elements to be changed during the expansion process, enabling coordinated expansion of different patch regions while maintaining manageable device complexity through a single adjustable mechanism rather than multiple independent systems.
3Device complexity
If the expandable tubular elements are positioned close together, then the device complexity is reduced, but the expansion coverage deteriorates because the ends of the patch cannot be sufficiently expanded
Solution Approach 1:
The adjustment mechanism enables the expandable tubular elements to dynamically change their spacing from a compact initial position to an extended operational position. This dynamic adjustment allows the elements to cover the entire patch length including the ends, achieving sufficient expansion coverage without requiring a permanently complex multi-position structure.
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
Ensures complete expansion of the metal patch, eliminating flow restrictions by uniformly expanding the central and end parts of the patch, enhancing fluid flow through the well tubular structure.
Implementation Method 1
fluid pressure differentials control the expansion of the tubular elements relative to each other
Implementation Method 2
an expandable tubular element may be inflated in order to expand the metal patch
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A downhole packer assembly for expansion of a metal patch in a well downhole in a well tubular metal structure, comprising a body part having a longitudinal extension and a central part, a first expandable tubular element surrounding the body part and being connected with the body part on one side of the central part, and having a first outer face, a second expandable tubular element surrounding the body part, being connected with the body part on an opposite side of the central part, and having a second outer face, a metal patch, having a first end, a second end, an inner face and an outer face configured to face and abut the well tubular metal structure, and having a first predefined length, wherein the metal patch surrounds the first expandable tubular element and the second expandable tubular element, wherein the first expandable tubular element is arranged at a first distance from the second expandable tubular element in the longitudinal extension in a first operational state, and wherein the first expandable tubular element is arranged at a second distance from the second expandable tubular element in the longitudinal extension in a second operational state, where the second distance is larger than the first distance.