Segmented Backup Ring for Downhole Packer Extrusion Control

Solution Overview

Problem

Packer systems in the drilling and completion industry face challenges with extrusion gaps under high differential pressure, affecting their performance and pressure rating, particularly in open hole and cased hole environments.

Innovation Solution

A downhole system featuring a packer assembly with a backup ring composed of nested leaves that radially expand to form a circular shape, minimizing extrusion gaps and accommodating various tubular diameters through a nested and interlocking design, which includes receiving and insertion sections for each leaf, and is supported by guide and support rings for controlled expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional backup rings are used to limit extrusion gaps, then pressure rating is improved, but device complexity and inability to accommodate various tubular diameters worsen

Engineering Contradiction:

Improvepressure ratingVSAvoidaccommodation of various tubular diameters

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The backup ring is divided into multiple segmented leaves that can independently expand and conform to different tubular diameters. Each leaf acts as an independent segment that can be positioned and expanded to match the specific diameter of the tubular, allowing the backup ring to adapt to various sizes while maintaining structural integrity and pressure containment capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The backup ring segments are arranged in a nested configuration where multiple leaves are stacked concentrically. This nested structure allows the segments to expand radially outward in a controlled manner, enabling the backup ring to accommodate different tubular diameters while maintaining the necessary strength to prevent extrusion gaps under high pressure.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If backup rings are added to prevent extrusion gaps, then pressure rating is improved, but device complexity worsens

Engineering Contradiction:

Improvepressure ratingVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The backup ring is divided into multiple segmented leaves that can independently expand and conform to different tubular diameters. Each leaf acts as an independent segment that can be positioned and expanded to match the specific diameter of the tubular, allowing the backup ring to adapt to various sizes while maintaining structural integrity and pressure containment capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The backup ring transitions from a static, rigid structure to a dynamic, expandable structure. The segmented leaves can radially expand and contract, allowing the backup ring to adapt its size and shape to match different tubular diameters. This dynamic capability enables a single backup ring design to serve multiple applications without requiring multiple fixed-size backup rings.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If high expansion capability is achieved, then adaptability to various tubular diameters is improved, but manufacturing precision requirements worsen

Engineering Contradiction:

Improveaccommodation of various tubular diametersVSAvoidsegment dimensional precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The backup ring is divided into multiple segmented leaves that can independently expand and conform to different tubular diameters. Each leaf acts as an independent segment that can be positioned and expanded to match the specific diameter of the tubular, allowing the backup ring to adapt to various sizes while maintaining structural integrity and pressure containment capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The backup ring design allows for variation in segment parameters such as thickness, length, and radial expansion capability. By adjusting these parameters, the backup ring can be optimized for different applications and tubular diameters. The segmented structure enables local parameter optimization without requiring high precision across the entire ring, as each segment can be independently manufactured and adjusted.

Inventive Principle:

Principle #35Parameter changes

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 system effectively eliminates or limits extrusion gaps, enhances the pressure rating, and allows for high expansion capabilities, making it suitable for a wide range of tubular diameters while maintaining strength and potential reusability.

Implementation Method 1

Upon radial expansion of the backup ring, the plurality of nested leaves fan out in the circumferential direction

Methodology Applied

Scientific EffectRadial expansion:

Implementation Method 2

Each leaf includes a receiving section and an insertion section, the receiving section receiving an insertion section of an adjacent leaf

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS10760369B2Variable radius backup ring for a downhole system

Publication Date: 2020.09.01 BAKER HUGHES CO

AI summary

A downhole system includes a packer assembly including a backup ring. The backup ring includes a plurality of nested leaves nested sequentially in a circumferential direction with adjacent circumferentially positioned leaves to collectively form a substantially circular shape. Each leaf includes a receiving section and an insertion section, the receiving section receiving an insertion section of an adjacent leaf. Upon radial expansion of the backup ring, the plurality of nested leaves fan out in the circumferential direction.