Wellbore Isolation Tool Slip Extrusion Limiting
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Solution Overview
Problem
Existing wellbore isolation tools face issues with unwanted extrusion of elastomeric sealing elements due to setting forces and pressures, which can compromise temperature and pressure limits, and dissolvable extrusion limiters made of certain materials are prone to manufacturing difficulties and operational failures.
Innovation Solution
A wellbore isolation tool with an elastomeric sealing element in direct contact with an expandable slip mechanism, constructed from dissolvable metal materials, limits extrusion by radially expanding slips to grip the casing, allowing for efficient operation and removal, and utilizing a chemical solution to dissolve components for retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If dissolvable materials are used for extrusion limiters, then the isolation tool can be removed by dissolution, but the extrusion limiter is prone to manufacturing difficulties and operational failures
Solution Approach 1:
The patent changes the material parameter from dissolvable materials to non-dissolvable metal materials (such as stainless steel, nickel alloy, or cobalt alloy) for the extrusion limiter, while maintaining the ability to remove the isolation tool through other means (mechanical retrieval or drilling). This resolves the contradiction by eliminating manufacturing and operational issues associated with dissolvable materials while preserving removability.
2Object-affected harmful factors
If cone-shaped rigid extrusion limiters are used, then extrusion is reduced, but the isolation tool cannot be easily removed and reused
Solution Approach 1:
The patent employs slips that can change their state from a collapsed configuration (during deployment) to an expanded configuration (during setting). The extrusion limiter is integrated with these dynamic slips, allowing the entire assembly to be retrieved by collapsing the slips and redeployed by expanding them again. This resolves the contradiction by making the rigid extrusion limiter part of a dynamic system that enables retrieval and reuse.
3Adaptability or versatility
If the isolation tool is made retrievable for reuse, then operational flexibility is improved, but the tool complexity increases
Solution Approach 1:
The patent integrates multiple functions into the slip assembly: the slips serve both as setting mechanisms (to expand and set the isolation tool in the wellbore) and as retrieval mechanisms (to collapse and enable removal). The extrusion limiter is integrated with the slips, combining extrusion prevention with the setting/retrieval functions. This multi-functionality reduces overall device complexity while maintaining retrievability and reuse capability.
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 solution effectively limits extrusion, maintains operational integrity under high pressures, and facilitates easy removal and reuse or dissolution of the isolation tool, enhancing operational efficiency and reliability.
Implementation Method 1
At least a portion of the wellbore isolation tool is constructed of a dissolvable metal material and may be dissolved when exposed to a chemical solution
Data Source
AI summary
A downhole wellbore isolation tool includes an elastomeric sealing element for engaging a casing member or another tubular member in a wellbore. The isolation tool includes one or more expandable slips for gripping the tubular member and holding the isolation tool in place. The sealing element has an axial end in direct contact with an abutment surface of the expandable slip such that the slip limits, if not eliminates, unwanted extrusion of the sealing element, e.g., upon setting of the isolation tool. The expandable slips may be constructed of a plurality of slip elements, and the elastomeric sealing element may flow into gaps defined between the slip elements when the isolation tool is set. The slip segments and other components of the isolation tool may be constructed of a dissolvable material to facilitate removal of the isolation tool from the wellbore.