Swellable Elastomer Packer Conduit for Zonal Isolation
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Solution Overview
Problem
Existing wellbore packers with alternate flow paths struggle to maintain effective annular barriers and fluid seals due to issues such as reduced swelling performance, improper sealing, and increased deployment times, particularly when using swellable elastomer systems in multi-zone completion systems.
Innovation Solution
The apparatus features a tubular body with an expanding element and a conduit that varies the secondary flow path along its longitudinal direction, allowing for improved operation of the expanding element while maintaining the annular barrier and sealing functions, even with the provision of a secondary flow path, by redirecting fluid flow and redistributing it radially to minimize the conduit's impact on the expanding element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conduit defining a secondary flow path is provided through the swellable elastomer packer, then gravel pack operations and alternate flow paths are enabled, but the swelling performance and sealing effectiveness are reduced
Solution Approach 1:
The packer is segmented into multiple independent swellable elastomer elements (first swellable elastomer element and second swellable elastomer element) separated by a gauge ring. This segmentation allows each element to function independently for sealing while the conduit passes through them to provide alternate flow paths. The segmentation enables the system to maintain both sealing capability and gravel pack functionality without compromising overall performance.
Solution Approach 2:
The conduit is positioned at a specific radial location within the packer assembly, and the swellable elastomer elements are configured to swell locally around the conduit while maintaining sealing contact with the wellbore. This local quality approach allows the conduit to define alternate flow paths through specific regions without preventing the elastomer from achieving effective seal elsewhere in the annulus.
2Ease of manufacture
If the conduit is positioned radially outward to enable gravel flow, then gravel pack operations are improved, but the annular barrier effectiveness is compromised
Solution Approach 1:
The conduit is nested within the swellable elastomer elements, which are in turn contained within the gauge ring and tubular body assembly. This nested configuration allows the conduit to be positioned radially outward for effective gravel pack delivery while the swellable elastomer elements maintain their sealing function around the conduit. The gauge ring provides an additional containment structure that ensures annular barrier integrity is maintained despite the conduit's radial position.
3Reliability
If the swellable elastomer volume is increased to improve sealing, then annular barrier effectiveness is enhanced, but deployment time and complexity increase
Solution Approach 1:
The packer uses dynamically swellable elastomer elements that expand upon contact with wellbore fluids or activation. This dynamic swelling allows the system to achieve effective sealing with initially compact elements, reducing deployment complexity and time. The elastomer elements naturally expand to fill the annular space around the conduit and achieve seal, eliminating the need for complex deployment mechanisms for large-volume elements.
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 configuration enables effective annular barrier and sealing functions, enhancing the swelling performance and deployment efficiency of swellable elastomer packers, allowing for reliable zonal isolation and gravel pack operations in wellbore systems.
Implementation Method 1
The expanding element is formed from a swellable elastomer or rubber and is selected to increase in volume on exposure to a triggering fluid, which may be a hydrocarbon fluid or an aqueous fluid or brine. Alternatively, the elastomer may be selected to increase in volume on exposure to another triggering mechanism, such as heat or pressure.
Implementation Method 2
The conduit is arranged to vary the secondary flow path along a longitudinal direction of the apparatus... by redirecting fluid flow and redistributing it radially to minimize the conduit's impact on the expanding element
Data Source
AI summary
An apparatus for use in a wellbore is described, the apparatus having a tubular body and a throughbore which defines a primary fluid path through the apparatus. An expanding element is disposed around the tubular body and is configured to provide an annular barrier in a space between the tubular body and a surrounding wall. A conduit defining a secondary flow path through the apparatus is provided, and is configured to be in fluid communication with at least one alternate path, such as a shunt tube. The conduit is arranged to vary the secondary flow path along a longitudinal direction of the apparatus, for example to redirect the flow path to a radial position closer to the tool body. The conduit is configured to have a reduced effect on the operation of the expanding element, while still allowing the conduit to be coupled to alternate flow paths of adjacent apparatus.