Roll-Out Load Ring Expansion for Horizontal Wellbore Sealing
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Solution Overview
Problem
Existing wellbore sealing and gripping technologies, such as those using slips and elastomers or solid metal tubes, are unreliable due to potential material extrusion or mechanical integrity loss, limiting their ability to maintain a seal in horizontal wellbores.
Innovation Solution
A roll-out apparatus with a load ring that expands by bending, featuring a slot system to grip and seal against the wellbore wall, utilizing an energizing ring to enlarge the outer circumference and create a secure engagement without stretching, and optionally incorporating textured surfaces or additional components for enhanced friction and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If slips and elastomers are pushed towards the wellbore using a cone and compression system, then gripping and sealing actions are performed, but the elastomers may extrude during use and lose their ability to seal
Solution Approach 1:
The patent replaces the elastomer-based mechanical sealing system with a solid expandable tube system. The solid tube is stretched radially outward to contact the wellbore wall, providing sealing and gripping actions without the extrusion problems of elastomers. This substitution of material state (from flexible elastomer to solid metal) eliminates the harmful extrusion behavior while maintaining the necessary sealing function.
Solution Approach 2:
The patent changes the physical state parameter of the sealing material from flexible elastomer to solid metal tube. The solid tube is then elastically deformed (stretched) radially outward to engage with the wellbore wall. This parameter change from soft/flexible to hard/solid state eliminates extrusion while allowing controlled deformation during installation.
2Reliability
If a solid metal tube is stretched to perform gripping and sealing actions, then the tube expands radially, but the tube loses mechanical integrity when stretched too much
Solution Approach 1:
The patent applies partial action by stretching the solid tube only to the extent necessary to engage with the wellbore wall, avoiding excessive deformation that would compromise mechanical integrity. The tube is stretched radially outward just enough to contact and grip the wellbore, maintaining sufficient strength for the intended application while achieving the necessary gripping action.
3Reliability
If additional materials are stretched to achieve sealing, then sealing capability is improved, but the complexity of the system increases
Solution Approach 1:
The solid expandable tube performs multiple functions simultaneously: it provides gripping action against the wellbore wall, creates sealing contact, and serves as a structural support element. By making the tube universal and multi-functional, the patent eliminates the need for separate sealing components, reducing system complexity while maintaining or improving sealing capability.
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
The roll-out apparatus provides reliable sealing and gripping capabilities, allowing for effective diversion of fluids and supporting downhole tools without requiring additional materials to be stretched, and can be made from materials that degrade or dissolve in the well environment.
Implementation Method 1
The outer surface of the energizing ring is configured to contact the inner surface of the load ring to enlarge the outer circumference of the load ring in a radial direction
Implementation Method 2
The slot enables the load ring to roll-out or enlarge by bending, when energized on an inner surface of the load ring
Implementation Method 3
The outer surface of the load ring may include a textured surface configured to engage and grip the inner surface of the subterranean well
Data Source
AI summary
A roll-out apparatus, method, and system is disclosed for deployment in a subterranean well at a setting location. The roll-out apparatus, method, and system includes a load ring and an energizing ring. The load ring may include an outer surface having an outer circumference and a slot extending through the entire wall thickness that follows a circuitous path from a front face to a back face of the load ring. The energizing ring includes an outer surface configured to contact an inner surface of the load ring to enlarge the outer circumference of the load ring in a radial direction. This causes the outer surface of the load ring to seal to an inner surface of the subterranean well at the setting location.