Downhole Packing Element Backup System with Nested Rings
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Solution Overview
Problem
Existing packing element systems for wellbores face challenges in effectively isolating zones due to inadequate sealing mechanisms, particularly in compressing and expanding to engage the inner wellbore surfaces efficiently.
Innovation Solution
The packing element system incorporates a support system with spacer rings, mesh rings, and petal rings that compress radially outward to engage the wellbore inner surfaces, utilizing a combination of materials like metals and elastomers to facilitate a secure seal, with the rings being nested and indexed for optimal alignment and coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packing elements with metal petal back-ups are used, then structural support is provided, but sealing efficiency is inadequate due to inconsistent contact with wellbore surfaces
Solution Approach 1:
The support system is segmented into multiple functional components: spacer rings for positioning, mesh rings for radial expansion, and petal rings for conformal contact. Each segment performs a specific function to collectively improve sealing efficiency while maintaining manageable complexity through modular design.
Solution Approach 2:
The support components are nested concentrically around the packing element, with inner and outer spacer rings containing mesh rings, which in turn contain petal rings. This nested arrangement allows compact storage during run-in and systematic deployment during setting, improving sealing without excessive complexity.
2Reliability
If the packing element is compressed axially to engage the wellbore, then sealing contact is achieved, but the transition from run-in to set position is difficult
Solution Approach 1:
The support system transitions from a compact dynamic configuration during run-in to an expanded static configuration during setting. The spacer rings maintain spacing dynamically, while the mesh and petal rings expand radially when compressed axially, automatically transitioning the system state based on applied load without complex control mechanisms.
Solution Approach 2:
The spacer rings are pre-positioned to maintain optimal spacing between components during run-in, and the petal rings are pre-configured to rotate outward when compressed. This preliminary arrangement ensures smooth transition to the set position without binding or misalignment, improving ease of operation.
3Reliability
If multiple back-up elements are added to improve sealing, then sealing efficiency increases, but device complexity increases
Solution Approach 1:
Multiple support functions are merged into integrated components. The mesh ring combines radial expansion capability with structural support, while the petal rings combine conformal contact with radial positioning. This merging achieves improved sealing efficiency without proportionally increasing component count, as each multi-functional element replaces what would otherwise require separate components.
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 configuration enhances the sealing efficiency by ensuring consistent contact with the wellbore surfaces, maintaining a reliable seal under axial loads and facilitating the transition from the run-in to the set position, thereby effectively isolating zones within the wellbore.
Implementation Method 1
Each end of packing element 212 includes housing or support 213 to facilitate elastic expansion of packing element 212 away from mandrel 211 when an axial load is placed on packing element 212 at axial load points 214
Implementation Method 2
In certain embodiments, the lower end of one or more of the mesh ring(s) and/or petal ring(s) rotate outwardly toward the casing and, in certain embodiments, engage the casing to facilitate creation of the seal
Data Source
AI summary
Downhole tool packing element systems comprise a sealing element having a support system. The support system can include one or more of a first spacer ring, a second spacer ring, a third spacer ring, a mesh ring, and one or more petal rings. One or more of these components can be disposed at one or both of the upper end and/or lower end of the sealing element. When compressed, the sealing element is moved radially outward to engage an inner wall surface of a wellbore due to compressive forces of the one or more spacer ring(s), mesh ring, and/or petal ring(s). The lower end of one or more of the mesh ring(s) and/or petal ring(s) rotate outwardly toward the casing and engage the casing to facilitate creation of the seal.