Phase-Change Retention Material for Settable Wellbore Packer Unsetting
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Solution Overview
Problem
Existing devices in the resource recovery industry face challenges in unsetting processes, particularly with nickel alloys, where cutting is difficult, shear release systems limit tension, and shifting systems can cause inadvertent movement of tubing strings.
Innovation Solution
A settable device with a radially enlargeable portion and a force retention pathway using a material that retains force in solid form but disengages when in fluid form, allowing for easy unsetting by transitioning the material to a fluid state, which is achieved by creating a temperature greater than its melting point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cut system is used to unset the packer, then the packer can be retrieved, but cutting nickel alloy is inherently difficult and requires precise tool location
Solution Approach 1:
The patent changes the physical state parameter of the retention material from solid to liquid by heating, which fundamentally alters the unsetting mechanism from mechanical cutting to thermal phase change. This eliminates the need for precise mechanical cutting of nickel alloy while achieving the same unset function.
Solution Approach 2:
The patent replaces the mechanical cutting system with a thermal system. Instead of using a cutting tool to mechanically sever the nickel alloy, the system uses heat to melt the retention material, causing it to flow and release the packer. This substitution eliminates the complexity of precise mechanical cutting.
2Ease of operation
If shear release systems are used, then unsetting is simple, but the tension that can be put on the packer is limited without causing inadvertent shearing
Solution Approach 1:
The patent changes the retention mechanism from mechanical shear strength to thermal phase change. By heating the retention material to its melting point, the system transitions from a shear-based retention mechanism to a flow-based release mechanism, allowing high tension to be applied during setting without risk of inadvertent shearing.
3Ease of operation
If a shifting system is used to unset the packer, then the packer can be retrieved, but the tubing string uphole of the packer will need to be pulled before removal
Solution Approach 1:
The patent extracts the retention function from the tubing string structure itself and places it in a separate meltable material component. This allows the packer to be unset independently by melting the retention material, eliminating the need to pull the entire tubing string uphole before packer removal.
4Ease of operation
If shear release systems are used, then unsetting is simple, but inadvertent shearing can occur under high tension
Solution Approach 1:
The patent changes the retention mechanism from mechanical shear to thermal phase change. By controlling the temperature parameter, the system can reliably maintain retention under high tension (solid state) and reliably release when needed (liquid state), eliminating the risk of inadvertent shearing that plagues shear-based systems.
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 higher tensile load management and easier retrieval of devices without shearing or unintended shifting, allowing for more efficient and reliable unsetting processes.
Implementation Method 1
transitioning the material to a fluid state, which is achieved by creating a temperature greater than its melting point
Implementation Method 2
allowing the material to flow thereby disengaging force retention
Data Source
AI summary
A settable device including a radially enlargeable portion, a force retention pathway operably connected to the radially enlargeable portion to maintain a setting force to the radially enlargeable portion, a material disposed within the force retention pathway of the device, the material retaining force when in solid form and disengaging force retention when in fluid form.