Segmented Wellbore Expander Reducing Friction Forces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for radially expanding tubular elements in wellbores face high expansion forces due to friction and non-uniform expansion, and existing systems lack the ability to accommodate local wellbore diameter variations.
Innovation Solution
A method using an expander with segments that move axially between retracted and expanded positions, eliminating the need for a bladder and allowing for uniform expansion, with varying expansion strokes to accommodate wellbore diameter variations, utilizing a hydraulic actuator and multiple expansion cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conical expander is pulled or pushed through the tubular element, then the tubular element is expanded, but extremely high expansion forces are required to overcome friction between the expander cone and the tubular element
Solution Approach 1:
The expander is divided into multiple segments that can move independently relative to each other along the axial direction. This segmentation allows the expansion force to be distributed across multiple contact points rather than concentrated at a single cone-tubular interface, reducing the frictional resistance and required expansion force.
Solution Approach 2:
The segments are designed to move dynamically along the axial direction during the expansion process. By allowing axial movement of segments, the system adapts to the tubular element's geometry and reduces frictional contact, enabling expansion with lower forces compared to a static conical expander.
2Reliability
If segments are moved by inflating a bladder, then the tubular element is expanded, but the bladder becomes damaged after repeated expansion cycles and segments may not expand uniformly
Solution Approach 1:
The bladder component is completely removed from the expansion mechanism. Instead of using a bladder to inflate and move segments, the invention employs direct axial movement of segments through mechanical means, eliminating the bladder's vulnerability to damage from repeated cycles while simplifying the overall system.
Solution Approach 2:
The hydraulic/pneumatic bladder system is replaced with a purely mechanical segment movement system. The segments are moved axially through direct mechanical action rather than through fluid pressure, improving reliability and eliminating the need for a bladder while maintaining the ability to achieve uniform expansion.
3Adaptability or versatility
If an expander cone is used to expand the tubular element, then the element reaches the diameter of the expander cone, but the system lacks the possibility to accommodate local variations of the wellbore diameter
Solution Approach 1:
The expander is segmented into multiple independently movable sections that can adjust their radial position axially. This allows different segments to accommodate local variations in wellbore diameter while maintaining uniform expansion characteristics across the entire tubular element, as each segment can adapt to its local environment independently.
Solution Approach 2:
The dynamic axial movement capability of the segments enables the expander to adapt to varying wellbore conditions. By allowing segments to move axially, the system can conform to local diameter variations while maintaining controlled, uniform expansion through coordinated segment movement, achieving both adaptability and precision.
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
This method reduces the need for high expansion forces and ensures uniform expansion, accommodating local wellbore diameter variations, thereby improving the efficiency and effectiveness of tubular element expansion.
Implementation Method 1
utilizing a hydraulic actuator and multiple expansion cycles
Data Source
AI summary
A method is provided of radially expanding a tubular element (56) in a well-bore using an expander located in the tubular element, the expander (40) comprising an expansion member (48) and a plurality of segments (50) spaced in circumferential direction around the expansion member, the segments being movable between a radially retracted position and a radially expanded position by axial movement of the expansion member relative to the segments. The method includes a plurality of successive expansion cycles, wherein each expansion cycle comprises the steps of: (a) moving the expander (40) in axially forward direction through the tubular element (56) whereby the segments (56) are in the radially retracted position; and (b) radially expanding the tubular element by moving the segments to the radially expanded position by axially moving the expansion member relative to the segments.