Swelling Delay Cover for Downhole Packer Positioning

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Swelling packers often swell too quickly, preventing proper positioning before they can be advanced to the desired location in the wellbore, as existing solutions like external coatings with slower-swelling materials or diffusion regulation are labor-intensive and inconsistent.

Innovation Solution

A tubular cover made from materials like PTFE, PET, or FEP is shrink-fitted over the swelling element, formulated to break down at temperatures slightly below expected downhole temperatures, providing a 48-hour delay before swelling occurs, allowing the packer to be properly positioned without damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If the swelling packer is run into the wellbore, then it can be positioned at the desired location, but it swells too quickly and cannot be advanced to the proper location

Engineering Contradiction:

Improveswelling delay timeVSAvoidpositioning capability

Core Design Contradiction:

Loss of timeVSEase of operation

Solution Approach 1:

An outer cover is placed over the swelling element before running the packer into the wellbore. This cover prevents premature swelling during insertion and positioning, allowing the packer to be advanced to the desired location without expanding. The cover is removed or degraded at the target location, enabling the swelling element to then expand and seal.

Inventive Principle:

Principle #10Preliminary action

2Loss of time

If an outer layer of slower-swelling material is used to regulate diffusion, then swelling delay is achieved, but the process is labor-intensive and inconsistent

Engineering Contradiction:

Improveswelling delay timeVSAvoidcoating application

Core Design Contradiction:

Loss of timeVSEase of manufacture

Solution Approach 1:

The outer cover is designed as a disposable protective element that is easily applied and removed. Rather than using complex multi-layer coatings with hardeners and fiberglass materials that require labor-intensive application, this cover serves its protective function during insertion and is then discarded or degraded at the target location, simplifying the manufacturing and application process.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If the packer sealing element is compressed longitudinally to force out the cover, then sealing contact is achieved, but the cover must be mechanically compromised which is problematic for corrosive materials

Engineering Contradiction:

Improvesealing effectivenessVSAvoidcorrosion resistance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of using mechanical compression to force the sealing element through the cover (which risks compromising the cover's corrosion resistance), the patent employs thermal energy. The packer includes a heating element that thermally degrades or melts the cover material, allowing the sealing element to expand and seal without mechanical force that could damage the corrosion-resistant properties of the cover.

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 cover remains impervious until attacked by well temperatures and fluids, ensuring the swelling element can seal effectively at the desired location without mechanical compromise, offering a cost-effective and reliable solution for high-temperature applications.

Implementation Method 1

The material is formulated to break down at temperatures slightly below the expected downhole temperatures so that ideally the packer has about 48 hours of swelling delay

Methodology Applied

Scientific EffectThermal degradation: Pyrolysis

Implementation Method 2

The cover is preferably formed into a tubular shape and shrink fit to the swelling element

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS8118092B2Swelling delay cover for a packer

Publication Date: 2012.02.21 BAKER HUGHES CO

AI summary

A swelling packer is covered with a material that is preferably in a tubular form and slipped over the swelling element to be shrink fit with applied heat. The material is formulated to break down at temperatures slightly below the expected downhole temperatures so that ideally the packer has about 48 hours of swelling delay which is normally a time period long enough to allow it to be properly located without it swelling so much as to cause it to be damaged by running in. Various polymers can be used to make an imperious covering for run in that on the way starts to break down. Ideally the material for the cover disappears about the time of sealing or shortly thereafter.