Swellable Packer Fluid Diffusion Control

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Solution Overview

Problem

Existing swellable packers used in downhole environments swell rapidly when exposed to hydrocarbon-based fluids, limiting the time available for completion operations, as they typically expand within one to two days, necessitating a solution for delayed and controlled swelling.

Innovation Solution

A completion tool featuring a swellable element encapsulated by a degradable textile-based composite protective layer, which inhibits fluid diffusion and can be tuned for controlled swelling by adjusting the formulation and thickness of the protective layer, composed of a polymeric binder and textile substrate, allowing for delayed swelling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a swellable element is exposed to downhole fluid, then the swellable element swells rapidly to seal the borehole, but the swelling occurs too quickly (within one to two days) to allow sufficient time for completion operations

Engineering Contradiction:

Improvesealing effectivenessVSAvoidtime for completion operations

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

A protective layer acts as an intermediary between the downhole fluid and the swellable element. This layer initially prevents fluid contact, allowing time for completion operations, then degrades to permit fluid penetration and subsequent swelling when needed

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective layer is applied to the swellable element before deployment, creating a pre-configured delay mechanism that automatically activates upon exposure to downhole conditions, eliminating the need for active control during operations

Inventive Principle:

Principle #10Preliminary action

2Duration of action of moving object

If the protective layer is made thicker to extend delay time, then the swelling is delayed longer, but the device complexity increases

Engineering Contradiction:

Improvedelay timeVSAvoidprotective layer structure

Core Design Contradiction:

Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The degradation time of the protective layer is controlled by changing material parameters such as polymer composition, crosslink density, and layer thickness, allowing precise tuning of delay time without fundamentally changing the device structure

Inventive Principle:

Principle #35Parameter changes

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 delays the swelling of the swellable element, providing additional time for completion operations by preventing premature expansion, with the protective layer degrading to allow controlled swelling over several days, enhancing operational flexibility.

Implementation Method 1

a protective layer disposed on a surface of the swellable element and configured to inhibit diffusion of a downhole fluid to the swellable element

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

allowing the swellable element to swell upon contact with a downhole fluid permeated through the protective layer

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS10961427B2Completion tools with fluid diffusion control layer

Publication Date: 2021.03.30 BAKER HUGHES CO

AI summary

A completion tool comprises a mandrel; a swellable element disposed about the mandrel; and a protective layer disposed on a surface of the swellable element and configured to inhibit diffusion of a downhole fluid to the swellable element; the protective layer comprising a degradable textile-based composite.