Swelling Packer Element Axial Cone Boost Mechanism
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Solution Overview
Problem
Sealing elements that swell for downhole applications face issues with reduced grip and potential leakage due to softening upon swelling, especially under temperature fluctuations and differential pressure variations, necessitating a boost in sealing force to maintain integrity.
Innovation Solution
A packer design that employs a cone-shaped sleeve driven axially to enhance the set force of the swollen element, using stored or applied forces, with a ratchet lock to prevent reverse motion, and various triggers for initiating the boost force, such as springs, hydrostatic pressure, or applied forces, to minimize relative movement between the element and the cone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a swelling element is used to achieve quick setting and sealing contact, then the setting time is reduced and sealing contact is obtained quickly, but the element becomes softer upon swelling and loses grip under temperature fluctuations or pressure variations
Solution Approach 1:
The cone-shaped boost device is pre-positioned and pre-loaded with stored energy (spring, hydrostatic pressure, or applied force) before the swelling element is installed. When triggered, this pre-prepared boost device immediately applies axial force to the swelling element, compensating for the softening effect and maintaining sealing integrity without requiring additional setting time.
Solution Approach 2:
The invention changes the force application parameter by introducing a mechanical boost device that applies additional axial force to the swelling element. This parameter change compensates for the reduction in grip strength caused by swelling, maintaining the sealing force despite the element's softened state.
2Force
If a cone-shaped boost device is driven axially to enhance sealing force, then the gripping force is improved, but the device complexity increases due to additional components and mechanisms
Solution Approach 1:
The cone-shaped boost device serves multiple functions: it applies axial boost force to enhance sealing, its tapered surface engages with the swelling element to prevent radial extrusion, and it can be integrated with existing packer components. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
The swelling element itself serves to engage with the tapered surface of the cone-shaped boost device, providing self-containing and self-positioning functionality. The element's swelling action naturally creates engagement with the taper, reducing the need for additional locking or retention mechanisms.
3Force
If the cone is driven between the element and mandrel to apply boost force, then the sealing grip is enhanced, but the risk of relative movement between the cone and element increases
Solution Approach 1:
The cone-shaped boost device utilizes a tapered surface geometry that creates increasing mechanical interlocking as the swelling element expands. The curved tapered surface ensures that the swelling element naturally conforms to and locks against the cone, minimizing relative movement while applying boost force.
Solution Approach 2:
The tapered surface of the cone acts as an intermediary between the axial boost force and the radial sealing force. This intermediate geometric feature converts the axial driving motion into radial engagement pressure, ensuring stable relative positioning while maintaining enhanced grip force.
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 enhanced sealing force ensures improved grip and reduced leakage by maintaining engagement between the swelling element and the cone, even under varying well conditions, thereby enhancing the sealing integrity.
Implementation Method 1
a sealing element that swells where the setting force is enhanced beyond the swelling with an applied force
Implementation Method 2
The power behind the cone can come from a variety of sources such as a spring, hydrostatic pressure, or applied forces
Implementation Method 3
The power behind the cone can come from a variety of sources such as a spring, hydrostatic pressure, or applied forces
Implementation Method 4
The movement of the cone is locked to prevent reversal of its motion when the packer is set
Data Source
AI summary
A packer that uses an element that swells to the set position is disclosed having a device that boosts the set force of the swollen element against the borehole. The force is axially applied at one end or two and preferably comprises a cone driven by a stored or applied force such that the cone is driven between the element and the mandrel that supports the element. Initiation of the boost force can be varied in its timing and the power behind the cone can come from a variety of sources such as a spring, hydrostatic pressure, or applied forces, to name a few. The movement of the cone is locked to prevent reversal of its motion when the packer is set. The swelling enhances the engagement of the element to the cone to minimize relative movement between them.