Wave Seal Packer Expansion Rate via Curved Geometry

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Solution Overview

Problem

Current liner packer seals in the drilling and completion industry face challenges with premature degradation due to caustic fluids, high temperatures, and high pressures, and require improved expansion rates to enhance operational efficiency and reduce maintenance costs.

Innovation Solution

The introduction of a wave seal packer with a waveform shape that radially encircles a tubular, utilizing materials with varying expansion rates and a composite intermediate spacer to enhance weld quality and expandability, allowing for a higher expansion rate without compromising sustainability in downhole environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional circular packer design is used, then structural simplicity is maintained, but expansion rate is limited and plastic deformity increases

Engineering Contradiction:

Improveexpansion rateVSAvoidpacker structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The packer employs a waveform cross-sectional geometry with alternating peaks and valleys instead of a traditional circular shape. This curved geometric configuration enables the packer to expand more efficiently by distributing deformation across the wave structures, reducing plastic deformity while achieving higher expansion rates during setting operations

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Productivity

If wave portion with alternating portions is introduced, then expansion rate increases and plastic deformity reduces, but manufacturing complexity increases

Engineering Contradiction:

Improveexpansion rateVSAvoidpacker manufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The packer body is divided into alternating uphole portions and downhole portions that form the waveform pattern. Each portion can be manufactured separately and then assembled, with the uphole portions connecting to downhole portions through welding or mechanical joints, facilitating modular manufacturing of the complex waveform structure

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If composite intermediate spacer is used, then weld quality and expandability are enhanced, but device complexity increases

Engineering Contradiction:

Improveweld qualityVSAvoidcomposite structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A composite intermediate spacer component is introduced between the wave portion and other packer components. This intermediate spacer serves as a mediator that facilitates welding operations and enhances expandability, acting as a buffer or transition element that improves the overall performance of the packer assembly during installation and setting

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The intermediate spacer is constructed from composite materials or a combination of different materials that provide both structural integrity and enhanced welding properties. This composite construction allows the spacer to withstand downhole conditions while facilitating quality welds and optimal expansion behavior

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9234403B2Downhole assembly

Publication Date: 2016.01.12 BAKER HUGHES CO

AI summary

A downhole assembly includes a wave seal packer including a wave portion having a wave form shape in an un-expanded condition. The wave portion configured to radially encircle a tubular with alternating and interconnected uphole and downhole portions. The packer having a substantially uniform internal radius in the un-expanded condition.