Bidirectional Seal Testing for Downhole Gauge Integrity
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Solution Overview
Problem
Existing well completion hardware, particularly test gauges and carriers, are prone to leaks due to their susceptibility to improper assembly and lack of independent seal testing, leading to significant costs and potential loss of well control during high-pressure operations.
Innovation Solution
A seal assembly with multiple test port devices and unidirectional seals allows for independent testing of each seal from both bore and annular sides, ensuring reliable sealing before deployment by using oppositely oriented unidirectional seals with dedicated test ports to detect seal failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a test gauge is incorporated into production tubing with manual assembly at surface, then testing capability is provided, but reliability of sealing deteriorates due to susceptibility to improper assembly and lack of downhole actuation
Solution Approach 1:
The seal assembly is segmented into multiple independent seals (first seal and second seal) with separate test ports, allowing independent testing of each seal. This segmentation enables verification of sealing integrity for each individual seal rather than testing the combined system only, thereby improving reliability while maintaining testing capability
Solution Approach 2:
The invention enables preliminary testing of seals at the surface before deployment into the well. By providing test ports that allow pressure testing of seals in advance, the system performs the sealing verification action before the seals are exposed to high-pressure downhole conditions, preventing premature failure
2Reliability
If multiple seals are used at the gauge interface, then sealing reliability improves, but ability to independently test each seal deteriorates
Solution Approach 1:
Each seal is equipped with its own dedicated test port (first test port for first seal, second test port for second seal), segmenting the testing capability to match the segmented sealing function. This allows independent testing of each seal without requiring complex disassembly or interfering with other seals, maintaining both reliability and testability
Solution Approach 2:
The test ports are designed to serve dual functions: they can be used to test the integrity of their associated seal and also to detect failures of adjacent seals through pressure differential detection. This multi-functionality reduces the need for separate testing mechanisms for each seal, simplifying the overall testing system while maintaining the ability to independently verify each seal
3Ease of manufacture
If manual assembly of gauge and carrier is performed at surface, then ease of assembly improves, but sealing quality deteriorates due to lack of downhole actuation to ensure maximum seal
Solution Approach 1:
The sealing precision is verified through preliminary pressure testing at the surface using the test ports before deployment. This preliminary action detects any assembly deficiencies immediately rather than allowing them to manifest as failures under downhole pressure, ensuring high sealing quality while maintaining simple manual assembly procedures
Solution Approach 2:
The test ports enable the assembly itself to verify its own sealing integrity through simple pressure testing operations. The system performs self-verification of seal quality without requiring complex external testing equipment or procedures, maintaining ease of assembly while ensuring sealing precision
Data Source
AI summary
A seal assembly made up of multiple opposite oriented unidirectional seals. The assembly includes a dedicated test port for each of the unidirectional seals. Thus, a first test port may be directed at the first seal such that if the first seal leaks, the second seal is configured to collapse and allow a second test port coupled thereto to detect the leak of the first seal. By the same token, the first test port may be used to detect any leak in the second seal which is detectable as the first seal collapses as a result of the leak. This unique type of architecture allows for a reliable manner of testing a multiple seal assembly that may be prone to leaks from multiple directions, for example from either a bore or an annular side of a tubular. This renders the bidirectionally testable seal configuration beneficial for incorporation into downhole completions hardware such at the location of a test gauge secured to a carrier device.