Pressure Controlled Piston Sleeve for Hydraulic Packer Sealing
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Solution Overview
Problem
Conventional hydraulic fracturing systems rely on drag force to set packers, which can be unreliable and cause packers to unset if fluid flows into the tool, necessitating a system that can seal based on pressure differential and linear force instead.
Innovation Solution
A tool with a piston sleeve that moves to seal restrictive ports based on a pressure differential and a linear force, allowing for resettable and repeatable operation independent of drag force through the inner diameter, featuring a check valve configuration with a piston sleeve, linear adjustable member, filter, and adjustable vents and ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional drag force is used to set packers, then the tool can be set by flowing liquid over the valve, but the packers become unset if fluid flows into the distal end of the tool
Solution Approach 1:
The patent inverts the conventional valve operation by using a piston sleeve that moves counter to the fluid flow direction to seal restrictive ports. Instead of relying on drag force from fluid flowing in one direction, the system uses pressure differential to move the piston sleeve against the flow, creating a reliable seal that prevents fluid from entering the distal end and unsetting the packers.
Solution Approach 2:
The patent replaces the conventional drag-based mechanical sealing system with a pressure-controlled piston sleeve system. The piston sleeve is actuated by pressure differential between chambers rather than relying on fluid drag force, providing more reliable and controllable sealing that maintains packer set status even when fluid flows into the distal end of the tool.
2Adaptability or versatility
If a piston sleeve is used to seal restrictive ports based on pressure differential, then the tool becomes resettable and repeatable, but the system complexity increases with additional chambers and components
Solution Approach 1:
The piston sleeve serves multiple functions: it acts as a seal for restrictive ports, a valve control mechanism, and a pressure differential indicator. The linear adjustable member provides both sealing and force application functions. This multi-functionality reduces the need for separate components, managing system complexity while enabling resettable and repeatable operation.
Solution Approach 2:
The system uses the pressure differential generated by fluid flow itself to actuate the piston sleeve and control the sealing action. The fluid pressure that would otherwise cause problems (flowing into the distal end) is harnessed to control the piston sleeve movement, making the system self-regulating and enabling automatic reset capability without requiring external control mechanisms.
3Reliability
If the piston sleeve moves counter to fluid flow to seal restrictive ports, then reliable sealing is achieved, but the force required to move the piston sleeve increases
Solution Approach 1:
The linear adjustable member positioned within the first pressure chamber provides a counterbalancing force to the piston sleeve. This member can be adjusted to provide the necessary force to move the piston sleeve counter to the fluid flow direction, overcoming the increased force requirement while maintaining reliable sealing action.
Solution Approach 2:
The system prepares for the increased force requirement by incorporating an adjustable force application mechanism (linear adjustable member) that can be pre-configured with the appropriate spring constant or mechanical advantage. This allows the system to generate the necessary force to move the piston sleeve against the fluid flow before the sealing action is needed, ensuring reliable operation.
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 reliable sealing and unsealing of the tool based on fluid flow and pressure differentials, preventing packer unset and allowing for controlled fluid flow rates, enhancing the stability and efficiency of hydraulic fracturing processes.
Implementation Method 1
The piston sleeve may be configured to move based on a pressure differential between a first pressure chamber and a second pressure chamber
Implementation Method 2
The linear adjustable member may be configured to apply a linear force against the piston, wherein the force is configured to move the piston sleeve towards the distal end of the tool
Data Source
AI summary
The present application describes methods and systems for a tool with a new check valve. The check valve may include a piston sleeve that is configured to move towards the proximal end of the tool to seal restrictive ports in a center of the tool responsive to creating a force on the piston sleeve. In embodiments, the movement of the piston sleeve may be counter to the flow of fluid through an inner diameter of the tool, such that the tool may be resettable and repeatable based on fluid flow and/or pressure differentials and not based on drag force through an inner diameter of the tool.