Downhole seal element formed from a nanocomposite material

Abstract

A seal element (70) for providing a static or dynamic seal between two components (74, 78) in a downhole tool includes a polymer host material (212) and a plurality of nanostructures (220) forming a nanocomposite material (210). The polymer host material (212) has a plurality of regions of free volume (222) that receive the nanostructures (220). The nanostructures (220) and the polymer host material (212) form interfacial interactions that improve the useful life of the seal element (70) by minimizing seal failures associated with explosive decompression, extrusion, spiral failure, abrasion, temperature degradation and the like.

Description

TECHNICAL FIELD OF THE INVENTION [0001] The present invention relates, in general, to a seal element and backup system for use in downhole tools positioned within a wellbore that traverses a subterranean hydrocarbon bearing formation and, in particular, to a downhole seal element formed from a nanocomposite material including a polymer host material and a nanomaterial. BACKGROUND OF THE INVENTION [0002] Without limiting the scope of the present invention, its background will be described with reference to explosive decompression of static seals, as an example. [0003] A seal is a device used to close a gap or make a joint fluid-tight with respect to both liquids and gases. For example, static seals involve sealing surfaces that do not move relative to one another and dynamic seals involve sealing surfaces that do move relative to one another. In particular, static seals are zero-leakage barriers that provide a long-term complete physical barrier in a potential leakage path to which t...

AI Technical Summary

Benefits of technology

[0008] Accordingly, the present invention provides a downhole seal element that comprises a material which minimizes the effects of explosive decompression. The downhole seal element of the present invention minimizes the critical pressure and the flaw size of the seal element while improving the shear modulus. The seal element of the present invention overcomes the limitations of the existing seals by utilizing a nanocomposite material comprising a polymer and a nanomaterial.

[0009] In one aspect, the present invention is directed to a seal element for providing a seal between two components in a downhole tool. The seal element is formed from a polymer host material having a nanomaterial integrated therewith to form a nanocomposite material. The nanomaterial in combination with the polymer not only minimizes the likelihood of explosive decompression, but also improves a variety of additional seal properties, thereby preventing numerous types of downhole seal failures such as extrusion, spiral failure, abrasion, temperature degradation and the like.

Problems solved by technology

Despite their dependability and reliability, static seals in oil-field equipment can be damaged by explosive decompression when the pressure on the system containing the static seals is released.

If the system containing the static seals is depressurized too rapidly, the liquids and gases that enter these void sites in the static seal can cause damage which is typically exhibited by surface blisters, ruptures and fractures.

Internal damage may also accompany the surface damage and occur without external evidence thereof.

The critical pressure and flaw size are inherent properties of the static seal that have proven difficult to improve.

The reinforcing seals have shown themselves to costly and inadequate, however.

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