Testable Isolation Packer with Bypass and Pressure Verification
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Solution Overview
Problem
Conventional methods for installing multiple isolation packers in a well do not allow for individual pressure testing of each packer, making it impossible to confirm if each packer has been properly set and sealed against the wellbore casing.
Innovation Solution
A testable isolation packer system with upper and lower packer elements, a bypass system, and a testing subassembly that allows for pressure testing after packer deployment, ensuring proper sealing by maintaining constant pressure between the packer elements and the wellbore casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional installation method is used to set all isolation packers at one time, then installation efficiency is improved, but the ability to individually pressure test each packer is lost
Solution Approach 1:
The packer system is divided into independent testable units, where each packer can be individually pressure tested through its own testing subassembly. This segmentation allows verification of each packer's sealing integrity while maintaining the overall efficiency of setting multiple packers simultaneously, as each unit operates independently during testing.
Solution Approach 2:
A testing subassembly acts as an intermediary component between the completion string and the annulus space. This intermediary enables pressure delivery to the annulus space for testing purposes without interfering with the primary function of the packer elements, allowing verification while maintaining installation efficiency.
2Reliability
If individual pressure testing of each packer is enabled, then verification of packer setting is improved, but device complexity increases
Solution Approach 1:
The testing subassembly is designed as a multi-functional component that serves both as a structural element of the packer system and as a pressure delivery mechanism. This universal component performs multiple functions including supporting the completion string, sealing the annulus, and enabling pressure testing, thereby reducing overall system complexity despite adding verification capability.
Solution Approach 2:
The testing subassembly merges the pressure testing function with the existing packer structure. By combining the testing capability into the packer element itself rather than adding separate external testing equipment, the system achieves verification functionality while minimizing the increase in device complexity.
3Productivity
If bypass system is used during packer setting, then fluid displacement is improved, but pressure testing capability may be compromised
Solution Approach 1:
The bypass system is designed to be dynamically controllable, allowing it to be opened during the setting phase for efficient fluid displacement and then closed during the pressure testing phase. This dynamic operation enables the system to switch between fluid displacement mode and pressure testing mode, maintaining both functionalities without compromise.
Solution Approach 2:
The bypass system performs preliminary fluid displacement action during packer setting before pressure testing begins. By completing the fluid displacement function first through the open bypass, the system prepares the annulus space for subsequent pressure testing, ensuring both functions are performed in the optimal sequence.
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
Enables reliable verification of packer element sealing, preventing issues like sand production and water breakthrough by confirming proper packer setting and sealing during installation.
Implementation Method 1
A packer may be set between zones in order to seal them from one another... applying a force to an elastomeric element of the packer. The elastomeric element of the packer may be the portion that creates an annular seal between the completion string and the wellbore casing.
Implementation Method 2
In the test mode, pressure can be delivered into the annulus space between the packer outside diameter, casing inside diameter, and packer elements. The pressure directed to the annulus space between the packer elements is used to indicate to a well operator whether the packer elements are maintaining a constant pressure therebetween.
Data Source
AI summary
Certain aspects are directed to a testable isolation packer that sets and provides the ability to test upper and lower packer elements. In one aspect, the testable isolation packer includes at least two packer elements, a packer element setting system, a bypass system, and a testing subassembly. The testing subassembly generally includes a moveable element with an outer port and a sealing element, an inner mandrel with an inner port, and a shear mechanism to cause travel of the moveable element close the bypass system and to open the testing subassembly.