Accelerating Swelling Rate in Subterranean Packers
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Solution Overview
Problem
The swelling rate of subterranean packers and screens made of swelling materials is often slow, necessitating the completion of swelling before subsequent operations can commence, which delays subsequent tasks and incurs additional costs.
Innovation Solution
Embedding reactants and a catalyst in the swelling material, allowing an exothermic reaction to occur at the desired location, or incorporating metallic, ferromagnetic particles or electrically conductive resins/polymer in the swelling material for induction heating to accelerate the swelling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If swelling material is used for packers and screens, then the material can conform to the borehole shape and provide sealing or screening function, but the swelling rate is very slow which delays deployment and subsequent operations
Solution Approach 1:
The patent changes the temperature parameter by introducing heat sources (exothermic reactions or induction heating) to accelerate the swelling process. The swelling material's swelling rate is directly influenced by temperature, and by controlling temperature through chemical reactions or electromagnetic induction, the patent achieves faster deployment while maintaining the sealing function.
Solution Approach 2:
The patent utilizes the phase transition or structural transformation of swelling materials when heated. The material transitions from a compact state during deployment to an expanded swollen state when exposed to heat, enabling rapid conforming to the borehole shape without waiting for slow natural swelling.
2Speed
If heat is added externally using heaters run in on wireline or embedded in the packer, then the swelling rate can be accelerated, but the installed cost increases and the heating process becomes more complex
Solution Approach 1:
The patent employs self-service heating mechanisms where the system generates its own heat internally. Exothermic chemical reactions occur within the packer structure, or induction heating coils are integrated into the swelling material itself, eliminating the need for external heating equipment and reducing operational complexity.
Solution Approach 2:
The patent replaces mechanical heating systems (external heaters on wireline) with chemical or electromagnetic heating methods. Induction heating uses electromagnetic fields to directly heat ferromagnetic particles embedded in the swelling material, while exothermic reactions use chemical energy, both substituting complex mechanical heating infrastructure.
3Productivity
If more heat is applied to accelerate swelling, then subsequent operations can commence sooner, but the energy consumption increases and cost rises
Solution Approach 1:
The patent converts the typically wasted energy of exothermic chemical reactions into useful heating energy for accelerating swelling. By embedding reactants that naturally generate heat during their reaction, the system captures this thermal energy and directs it toward the swelling process, turning a potentially harmful uncontrolled reaction into a beneficial heating source.
Solution Approach 2:
The patent introduces ferromagnetic particles or electrically conductive resins as intermediaries between the induction heating source and the swelling material. These intermediaries efficiently absorb electromagnetic energy and convert it to heat, which is then transferred to the swelling material, improving energy transfer efficiency and reducing overall energy consumption.
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 accelerated swelling process reduces the time required for deployment, enabling faster commencement of subsequent operations downhole with reduced costs by generating heat internally and directly where needed.
Implementation Method 1
incorporating metallic, ferromagnetic particles or electrically conductive resins/polymer in the swelling material for induction heating to accelerate the swelling process
Implementation Method 2
reactants that create an exothermic reaction plus a catalyst, if needed, are allowed to come into contact upon placement at the desired location
Data Source
AI summary
The swelling rate of a swelling packer element or a conforming foam screen material is accelerated with heat. In one variation reactants that create an exothermic reaction plus a catalyst, if needed, are allowed to come into contact upon placement at the desired location. The heat accelerates the swelling process and cuts the time to when the next operation can commence downhole.