Straddle Packer Bi-Directional Setting and Velocity Bypass
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Solution Overview
Problem
Existing straddle packers for wellbore pressure isolation are unreliable due to operational issues, particularly in long, highly-diverted lateral wellbores, where a single pressure cylinder module is needed to set packer elements effectively without loss of functionality.
Innovation Solution
A straddle packer with a multicomponent mandrel and a pressure cylinder module that expands bi-directionally, using high-pressure fluid to compress packer elements, and a velocity bypass system to manage fluid flow and ensure reliable setting and resetting of the packer elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a single pressure cylinder module is used to set packer elements, then the device length is reduced and operability is maintained, but the reliability under high downhole pressure conditions may be compromised
Solution Approach 1:
The pressure cylinder is segmented into two functional ends: an upper end with an upper piston and a lower end with a lower piston. Each piston independently compresses one packer element (upper packer element and lower packer element respectively). This segmentation allows a single pressure cylinder module to effectively set both packer elements under high downhole pressure conditions, maintaining reliability while reducing overall device length.
Solution Approach 2:
The system changes the pressure parameter by introducing high-pressure fluid through fluid ports into the pressure cylinder. This pressure change causes the pistons to move and compress the packer elements. The ability to control pressure parameters enables reliable packer setting with a compact single-module design.
2Productivity
If packer elements are compressed using high-pressure fluid, then the setting speed and efficiency are improved, but the risk of the packer becoming stuck increases
Solution Approach 1:
The velocity bypass system dynamically adjusts fluid flow based on operating conditions. During normal operation, fluid flows through the velocity bypass to prevent pressure buildup that could cause the packer to stick. The system transitions between different flow states (bypass active vs. bypass closed) to maintain productivity while reducing sticking risk.
Solution Approach 2:
The velocity bypass acts as an intermediary fluid path between the pressure cylinder and the external environment. It provides an alternative route for fluid to escape, mediating between the need for high pressure to set packers efficiently and the need to prevent pressure-induced sticking.
3Speed
If the packer is designed for rapid depressurization and resetting, then the operational speed is improved, but the structural complexity increases
Solution Approach 1:
The velocity bypass system is designed to automatically activate during depressurization operations without requiring external control. When fluid pressure decreases, the bypass automatically opens to facilitate rapid pressure equalization. This self-service mechanism enables fast resetting while minimizing the need for complex control systems.
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 allows for reliable pressure isolation in wellbores by compressing packer elements using a single pressure cylinder module, enabling efficient well stimulation or remediation treatments while minimizing the risk of the packer becoming stuck, and facilitating rapid depressurization and resetting.
Implementation Method 1
a pressure piston that reciprocates within a pressure cylinder, the pressure piston including pressure cylinder fluid ports that permit fluid flowing through the active mandrel tube fluid ports to enter the pressure cylinder and simultaneously urge the pressure cylinder wall and the pressure piston to move in opposite directions
Implementation Method 2
a velocity bypass valve having the flow rate threshold, whereby fluid pumped through the completion tubing string into the multicomponent mandrel flows through the at least one mandrel flow sub nozzle and the velocity bypass valve until a flow rate of the fluid exceeds the flow rate threshold
Data Source
AI summary
A straddle packer has a multicomponent mandrel with an active mandrel component. A pressure cylinder module reciprocates in opposite directions within a limited range over the active mandrel component. When fluid is pumped through a tubing string into the straddle packer, a piston of the pressure cylinder module is urged in one direction along an axis of the active mandrel component while a cylinder wall of the pressure cylinder module is urged in an opposite direction along the axis to simultaneously compress spaced-apart packers of the straddle packer to a packer set condition.