Wireless Casing Packer for Adaptive Annulus Pressure Control
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Solution Overview
Problem
Existing casing annulus control systems in hydrocarbon wells face challenges in managing pressure variations due to thermal effects and leaks, leading to potential failure and compromised well integrity and safety.
Innovation Solution
A casing packer apparatus with a mandrel, packer element, expansion mechanism, bypass conduit, and wireless-controlled bypass valve, allowing selective sealing or unsealing of the casing annulus to manage pressure and fluid flow, utilizing wireless activation and sensors for real-time control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the casing annulus is sealed to isolate pressure, then well integrity is improved, but pressure build-up may cause casing failure
Solution Approach 1:
The bypass valve transitions from a static sealed state to a dynamic controllable state, allowing the system to adapt between sealing and pressure relief modes based on real-time pressure conditions, resolving the contradiction between maintaining well integrity and preventing pressure build-up
Solution Approach 2:
The wireless communication system provides real-time feedback on pressure conditions and valve status, enabling remote monitoring and adaptive control of the bypass valve to maintain optimal pressure management while ensuring well integrity
2Reliability
If the packer element is set to seal the annulus, then fluid flow control is improved, but the system loses flexibility in pressure management
Solution Approach 1:
The system transitions from a static packer setting to a dynamic bypass valve control mechanism, enabling the annulus to switch between sealed and open states without requiring packer re-setting, thereby maintaining fluid flow control while gaining pressure management flexibility
Solution Approach 2:
The bypass valve acts as an intermediary mechanism between the sealed annulus and the formation, providing a controlled pathway for pressure management that complements the packer's sealing function without compromising fluid flow control
3Adaptability or versatility
If wireless control is added to the bypass valve, then operational flexibility is improved, but device complexity increases
Solution Approach 1:
The wireless communication system replaces complex mechanical control linkages with electromagnetic signal transmission, reducing mechanical complexity while enhancing remote operation capability and operational flexibility
Solution Approach 2:
The wireless controller integrates multiple functions including valve actuation, status monitoring, and diagnostic capabilities into a single multi-functional device, reducing overall system complexity while improving operational versatility
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
Enhances well integrity and safety by optimizing annulus pressure management, enabling flexible control of fluid flow, reducing the need for high-pressure casing specifications, and allowing for remote operation and monitoring.
Implementation Method 1
an expansion mechanism comprising a piston configured to move the packer element from a first position, radially outwards to a second position
Implementation Method 2
a bypass valve controlling said bypass conduit... selectively seal or optionally unseal the casing annulus from the formation
Implementation Method 3
a wireless receiver to receive wireless signals to control the bypass valve
Data Source
AI summary
A casing packer apparatus (P) comprising a mandrel (2) having a longitudinal throughbore, a packer element (6) mounted on the mandrel, and an expansion mechanism comprising a piston (11, 12) configured to move the packer element from a first position radially outwards to a second position. A bypass conduit (25) extends generally in said longitudinal direction, from one side of an outer sealing face of the packer element to an opposite side of the outer sealing face, and a bypass valve (41) controls said bypass conduit. The bypass valve is controlled by signals received via a wireless receiver (40). The casing packer can be deployed as an integral part of the casing string and used to control pressure build-up in the casing annulus.