Two-Part Bonded Seal Assembly for Low-Force Downhole Sealing
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Solution Overview
Problem
Existing elastomeric sealing elements in subterranean wells require high forces for expansion and curing, which can lead to material degradation and reduced seal integrity, especially in high-pressure and high-temperature environments, and are often permanent, requiring costly removal methods.
Innovation Solution
An elastomeric seal assembly with a primary chamber and a second chamber containing an elastomeric hardener, where an external force deforms the shell and crushes the separating wall to mix the components, allowing for in-place curing and reduced expansion forces, enabling bi-directional sealing and easy deployment in irregular annuli.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high forces are applied to expand elastomeric sealing elements, then the seal integrity is improved, but material degradation occurs and reliability decreases
Solution Approach 1:
The sealing element is divided into two separate chambers: a first chamber containing the elastomeric compound and a second chamber containing the elastomeric hardener. This segmentation allows the components to be transported separately without premature reaction, and enables controlled mixing only when needed, avoiding the need for high expansion forces that would cause material degradation.
Solution Approach 2:
The elastomeric compound and hardener are prepared and positioned in separate chambers before deployment. The compound is pre-positioned in the first chamber while the hardener is stored in the second chamber, ready for mixing. This preliminary arrangement allows the sealing element to be deployed without high forces, with mixing occurring only when the chambers are brought into contact during setting.
2Reliability
If elastomeric sealing elements are made permanent for well life, then production isolation is improved, but removal cost and complexity increase
Solution Approach 1:
The sealing element utilizes controllable curing parameters through the two-chamber system. The elastomeric compound remains uncured during deployment and can be cured on-demand when the hardener is mixed with it. This parameter control allows the seal to be temporary or permanent based on operational needs, enabling easy removal if required while maintaining production isolation when needed.
3Productivity
If elastomeric compound and hardener are mixed before deployment, then curing is accelerated, but premature hardening occurs during transport
Solution Approach 1:
The sealing element is divided into two separate chambers: a first chamber containing the elastomeric compound and a second chamber containing the elastomeric hardener. This segmentation allows the components to be transported separately without premature reaction, and enables controlled mixing only when needed, preventing premature hardening during transport while allowing rapid curing when deployed.
Solution Approach 2:
A partition wall acts as an intermediary barrier between the elastomeric compound and hardener during transport. This partition prevents direct contact and premature reaction while allowing both components to be contained within the same sealing element structure. When deployment occurs, the partition is removed or breached, enabling controlled mixing and rapid curing.
4Reliability
If high expansion forces are used to deploy sealing elements, then seal contact is improved, but operational complexity and equipment requirements increase
Solution Approach 1:
The sealing element employs a dynamic setting mechanism where the elastomeric compound is injected into the first chamber and then mixed with the hardener from the second chamber to cure in place. This dynamic approach eliminates the need for high expansion forces and complex deployment equipment, as the sealing element sets in position through controlled chemical reaction rather than mechanical expansion.
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 allows for efficient, low-stress deformation and curing of the seal, providing durable, bi-directional sealing with reduced operational forces and adaptability to various well conditions, avoiding material degradation and costly removal methods.
Implementation Method 1
an elastomeric compound deployed in one chamber and an elastomeric hardener stored in the other chamber
Implementation Method 2
the elastomeric compound hardens after the elastomeric hardener has reacted with the elastomeric compound
Implementation Method 3
an external force is applied to the seal assembly to elastically deform the seal assembly
Data Source
AI summary
A seal assembly and methods of use, wherein the seal assembly is formed of an elastomeric enclosure within which a primary cavity is defined. A second cavity in the form of a crushable container is deployed within the primary chamber. An elastomeric compound is contained in one cavity and an elastomeric hardener contained in the other cavity. Upon application of an external force to the elastomeric enclosure, the enclosure is elastically deformed from a first shape to a second shape, wherein the second shape positions the elastomeric enclosure into a sealing configuration between adjacent annular surfaces. The external force also crushes the container, to cause mixing of the elastomeric compound and elastomeric hardener. Once the reaction is complete, the hardened compound retains the deformed shape of the elastomeric enclosure to maintain a seal between the annular surfaces.