Self-Locking Packer Carrier for Liner Hanger Systems

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Solution Overview

Problem

Conventional liner hanger systems have weakened mandrel structures due to grooves and slots above the slips, leading to lower burst and collapse ratings, which can be mitigated by positioning the packer below the slips in a packer-down configuration, but require a reliable locking mechanism to maintain sealing integrity and resist vibrational forces.

Innovation Solution

A self-locking packer carrier with an integrated locking mechanism that locks directly to the packer cone after sealing, eliminating backlash, accommodating liner stretch, and withstanding pump-out loads, while maintaining sealing integrity by using outer diameter compression splines and a hardened tooth profile to securely engage the packer cone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the packer is located above the slips in conventional liner hanger systems, then the sealing function is achieved, but the mandrel structure is weakened due to multiple grooves and slots leading to lower burst and collapse ratings

Engineering Contradiction:

Improvesealing integrityVSAvoidburst and collapse ratings

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent inverts the conventional arrangement by positioning the packer below the slips instead of above them. This inversion allows the mandrel to maintain full wall thickness without grooves and slots, maximizing burst and collapse ratings while the packer still achieves its sealing function against the casing wall.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces a new dimensional arrangement by placing the packer in a different spatial position relative to the slips (below instead of above), creating a packer-down configuration that resolves the structural weakness issue while maintaining sealing capability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If a packer-down configuration is used to maximize wall thickness and burst ratings, then strength is improved, but a reliable locking mechanism is required to maintain sealing integrity under vibrational forces and pump-out loads

Engineering Contradiction:

Improveburst and collapse ratingsVSAvoidsealing integrity under vibration and load

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The packer carrier includes a locking mechanism that preliminarily engages with the packer cone before the packer is fully set. This preliminary locking action prevents backlash and ensures the packer remains securely positioned under subsequent vibrational forces and pump-out loads, maintaining sealing integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The locking mechanism is designed to self-lock onto the packer cone through a tooth profile engagement that automatically secures the packer carrier in place. This self-service locking action eliminates the need for additional locking components or operations, while ensuring the packer remains firmly positioned against the casing.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If grooves and slots are added to the mandrel for slip engagement, then the liner hanger can be properly positioned and supported, but the mandrel strength and burst ratings are reduced

Engineering Contradiction:

Improveliner hanger positioning and supportVSAvoidmandrel burst and collapse ratings

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent extracts the grooves and slots from the mandrel structure by positioning the packer below the slips. This extraction eliminates the structural weaknesses caused by grooves and slots in the high-stress mandrel region, while the slips remain able to engage with the casing for proper positioning and support.

Inventive Principle:

Principle #2Taking out (Extraction)

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 self-locking packer carrier enhances the sealing performance, increases vibrational resistance, and maintains sealing integrity under varying downhole conditions, achieving higher burst and collapse ratings by maximizing wall thickness and eliminating pressure weaknesses in the liner hanger system.

Implementation Method 1

The self-locking packer carrier includes a locking mechanism that locks the packer carrier directly to the packer cone after the sealing element is set

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Implementation Method 2

outer diameter compression splines and a hardened tooth profile to securely engage the packer cone

Methodology Applied

Scientific EffectRadial load transmission: Mechanical Force

Data Source

PatentUS10605019B2Self-locking packer carrier

Publication Date: 2020.03.31 INNOVEX INTERNATIONAL INC

AI summary

A self-locking packer carrier includes an integrated locking mechanism that locks the packer carrier directly to the packer cone after the sealing element is fully set. The integrated locking mechanism may include one or more compression splines extending from a packer carrier base in a radially outward direction to engage a casing after the attached sealing element has created a fluid tight seal, and a tooth profile formed along an inner diameter of the packer carrier base to lock the packer carrier to the packer cone in response to a compression force transferred to the base via the splines. The integrated locking mechanism is designed to eliminate backlash on the liner hanger system, increase vibrational resistance, accommodate liner stretch, withstand pump-out loads, and tolerate liner movement while maintaining sealing integrity.