Shape Memory Alloy Packer Cup Seal for Deviated Wellbores

Solution Overview

Problem

Cup seals used in wellbore isolation can be damaged in deviated wellbores due to dragging on the tubular wall, especially when their open end is oriented in the same direction during run-in, leading to ripping or inversion.

Innovation Solution

A shape memory alloy packer cup is reformed into a cylindrical shape during run-in with opposed end rings that extend radially to protect the cup, and upon thermal stimulation, it reverts to a functional cup seal shape, with optional elongated protective elements that bend outwardly to prevent abrasion and maintain differential pressure sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the cup seal is run in with its open end oriented in the same direction as the surrounding tubular, then the cup seal can be easily installed, but it will be damaged by dragging on the tubular wall in deviated wellbores

Engineering Contradiction:

Improveinstallation easeVSAvoiddamage resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The cup seal is pre-formed into a cylindrical shape during manufacturing that is optimized for run-in protection. This preliminary shaping allows the cup to be dragged through deviated wellbores without damage, and the cylindrical shape is later transformed into the functional cup shape in-place using thermal stimulation after installation

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the cup seal is formed to its functional shape before run-in, then it can seal effectively, but it will be damaged by abrasion in deviated wellbores

Engineering Contradiction:

Improvesealing effectivenessVSAvoidabrasion damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The cup seal is pre-formed into a cylindrical shape during manufacturing that is optimized for run-in protection. This preliminary shaping allows the cup to be dragged through deviated wellbores without damage, and the cylindrical shape is later transformed into the functional cup shape in-place using thermal stimulation after installation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cup seal utilizes shape memory alloy material properties that allow it to change shape in response to temperature changes. The cup is run in a cylindrical shape and then thermally stimulated to transform into the functional cup shape with the sealing rim, changing its geometric parameters from a protected cylindrical configuration to an operative cup configuration

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If the cup seal is run in a smaller cylindrical shape, then it can be protected during delivery, but it cannot seal against the surrounding tubular until activated

Engineering Contradiction:

Improvedamage protectionVSAvoidsealing capability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The cup seal utilizes shape memory alloy material properties that allow it to change shape in response to temperature changes. The cup is run in a cylindrical shape and then thermally stimulated to transform into the functional cup shape with the sealing rim, changing its geometric parameters from a protected cylindrical configuration to an operative cup configuration

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical expansion mechanisms with thermal stimulation. Instead of using mechanical force to expand the cup seal into its functional shape, the invention uses heat to trigger the shape memory effect, causing the cup to automatically transform from its compressed cylindrical run-in shape to its expanded functional sealing shape

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution effectively prevents damage to the cup seal during run-in and ensures reliable sealing in deviated wellbores by maintaining the cup's integrity and functionality upon thermal activation, allowing it to engage the wellbore effectively.

Implementation Method 1

A shape memory alloy packer cup reformed for run in into a cylindrical shape about a mandrel with opposed end rings that extend radially further out during run in to protect the cup. Upon application of a thermal stimulus the cup reverts to a functional cup seal shape

Methodology Applied

Scientific EffectShape memory alloy: Shape Memory Alloy

Implementation Method 2

Upon application of a thermal stimulus the cup reverts to a functional cup seal shape by engaging the rim and parts of the cup to the surrounding wellbore. The stimulus is provided with well fluids or artificially through heaters or other techniques

Methodology Applied

Scientific EffectThermal stimulus: Heating

Data Source

PatentUS9163474B2Shape memory cup seal and method of use

Publication Date: 2015.10.20 BAKER HUGHES CO

AI summary

A packer cup assembly uses a shape memory alloy packer cup reformed for run in into a cylindrical shape about a mandrel with opposed end rings that extend radially further out during run in to protect the cup. Upon application of a thermal stimulus the cup reverts to a functional cup seal shape by engaging the rim and parts of the cup to the surrounding wellbore. The shape change can also involve a shortened axial dimension that results in the cup shape moving away from the end ring to which it is unattached. The stimulus is provided with well fluids or artificially through heaters or other techniques. External elongated protective elements can be provided to overlay the cup seal during run and bend outwardly with the cup seal during reversion to its functional shape.