BOP Packer Assembly with Composite Inserts

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Solution Overview

Problem

Blowout preventers (BOPs) face durability issues due to elastomeric packer material extrusion and inadequate sealing across a range of pipe diameters, particularly with variable bore packers, which suffer from either insufficient support or increased force requirements, leading to incomplete closure and seal failure.

Innovation Solution

A packer assembly with an elastomeric body and embedded exterior and interior inserts that move to seal around tubular members, reducing extrusion and enhancing durability by filling gaps between inserts and pipes, allowing for sealing across various diameters without excessive force.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If low durometer packer material is used to seal around a range of pipe diameters, then sealing capability across various pipe sizes is improved, but the packer suffers from lack of support during loading process

Engineering Contradiction:

Improvesealing capability across pipe diametersVSAvoidpacker support during loading

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The packer assembly combines elastomeric material with rigid inserts to create a composite structure. The elastomeric body provides sealing capability across various pipe diameters, while the rigid inserts embedded within provide structural support during loading, resolving the contradiction between adaptability and strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The packer is segmented into multiple functional components: the elastomeric sealing body and separate rigid support inserts. This segmentation allows each component to perform its specialized function - the elastomeric material conforms to different pipe sizes while the rigid inserts provide localized support where needed.

Inventive Principle:

Principle #1Segmentation

2Strength

If increased durometer packers are used to provide support during loading, then structural support is improved, but more force is needed to form a seal resulting in incomplete closure and seal failure

Engineering Contradiction:

Improvepacker support during loadingVSAvoidforce required to form seal

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The composite structure distributes the loading forces to the rigid inserts while allowing the elastomeric sealing surfaces to maintain their compliance. This enables adequate support during loading without requiring excessive closing force, as the rigid inserts bear the structural load rather than the sealing material itself.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The rigid inserts are strategically positioned at specific locations where support is needed during loading, while the elastomeric material maintains its soft, compliant properties at the sealing surfaces. This local differentiation of material properties allows the packer to have both strength and ease of operation.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If traditional single-type inserts are used in packers, then manufacturing simplicity is maintained, but extrusion of elastomeric material occurs between inserts and tubular member

Engineering Contradiction:

Improveinsert manufacturing simplicityVSAvoidprevention of material extrusion

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The insert system is segmented into multiple types with different geometries and materials optimized for specific functions. Some inserts provide structural support while others are designed to prevent extrusion. This segmentation improves reliability without significantly complicating manufacturing, as each insert type can be produced using standard processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple insert materials and geometries are combined within the same packer assembly. Different insert types with complementary properties work together to provide both structural support and extrusion prevention, enhancing reliability while maintaining manufacturing feasibility through modular design.

Inventive Principle:

Principle #40Composite materials

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 packer assembly effectively seals a range of pipe diameters with reduced material extrusion and increased durability, maintaining seal integrity and extending the life expectancy of BOPs by utilizing inserts to support the elastomeric body and prevent material flow.

Implementation Method 1

A packer assembly is disclosed that includes an elastomeric body and a number of inserts positioned within the elastomeric body

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10161212B2Packer assembly with multiple different inserts for blowout preventer

Publication Date: 2018.12.25 CAMERSON INT CORP

AI summary

A blowout preventer (“BOP”) includes a housing comprising a vertical bore extending through the housing and a packer assembly movably positioned within the housing and configured to form a seal within the housing. The packer assembly includes an elastomeric body comprising an elastomeric material, an exterior insert at least partially positioned within the elastomeric body, and an interior insert at least partially positioned within the elastomeric body to diminish extrusion of the elastomeric body when forming the seal.