Segmented Anti-Extrusion Ring for Retrievable Packer Seals
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Solution Overview
Problem
Packer elements in downhole operations are prone to extrusion under high pressure and force, leading to seal failure and potential irretrievable components due to contamination and spring failure of current anti-extrusion devices.
Innovation Solution
A packer assembly with an anti-extrusion ring comprising a first and second ring segment, a spring channel, and retention bolts, which expands radially to form a seal while protecting the spring from contamination and maintaining component integrity through retention bolt connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If anti-extrusion rings with springs are used to prevent packer element extrusion, then extrusion resistance is improved, but reliability deteriorates due to spring contamination and failure
Solution Approach 1:
The spring is extracted from the contaminated external environment and placed inside a protected spring channel. The channel acts as a barrier that isolates the spring from drilling fluids, debris, and other contaminants that would otherwise cause spring failure. This extraction maintains the anti-extrusion function while eliminating the reliability issue caused by environmental exposure.
Solution Approach 2:
The spring channel serves as an intermediary structure between the spring and the external environment. It mediates the conflict by providing a protected pathway that allows the spring to perform its anti-extrusion function while shielding it from contaminants. The channel walls act as a barrier that prevents direct contact between the spring and harmful external factors.
2Reliability
If anti-extrusion devices are used to prevent packer element extrusion, then seal integrity is improved, but retrievability deteriorates due to irretrievable components falling downhole
Solution Approach 1:
The retention bolts are designed to be recoverable with the packer element during retrieval operations. Unlike traditional anti-extrusion devices that may leave fragments downhole, the retention bolts can be fully retrieved along with the packer element, maintaining both seal integrity and retrievability. This principle ensures that no components are abandoned in the wellbore.
3Reliability
If packer elements are compressed under high pressure, then seal effectiveness is improved, but extrusion risk increases
Solution Approach 1:
The anti-extrusion ring is segmented into multiple sections with retention bolts positioned at intervals. This segmentation allows the structure to distribute and manage the high compression forces more effectively, preventing localized extrusion while maintaining overall seal effectiveness. The segmented design with retention bolts provides multiple reinforcement points along the packer element.
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
Prevents extrusion of packer elements, maintains seal integrity under high pressure, and ensures retrievability by preventing components from falling downhole, even in the event of spring failure.
Implementation Method 1
a spring disposed in a spring channel
Implementation Method 2
the packer element expands radially outwards towards the surrounding casing. The expansion results in the packer contacting the casing and creating a seal
Data Source
AI summary
Embodiments of the present disclosure relate to a packer assembly. The packer assembly includes a tubular body, a mandrel circumferentially surrounding the tubular body, a gauge ring, an anti-extrusion ring, a force ring, and a packer element. The anti-extrusion ring includes a first ring comprising a plurality of first ring segments, a second ring comprising a plurality of second ring segments, a spring disposed in a spring channel, and a plurality of retention bolts. Each first ring segment includes a first ring segment spring channel and a retention bolt connector. Each second ring segment includes a second ring segment spring channel and a retention bolt expansion channel formed through the second ring. The spring channel comprises the first ring segment spring channels and the second ring segment spring channels. The retention bolts are disposed in the retention bolt expansion channel and coupled to the retention bolt connector.