Dissolvable Rubber Coating for Controlled Downhole Sealing
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Solution Overview
Problem
Dissolvable plugs used in non-conventional oil and gas production face challenges in maintaining effective sealing at high temperature and pressure conditions while needing to dissolve quickly after fracturing operations.
Innovation Solution
A dissolvable polymeric substrate coated with a specific polymer formulation, such as poly-(p-xylylene), is used to form downhole tools that can seal wellbores effectively and dissolve at controlled rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dissolvable elastomer is used to maintain sealing at high temperature and pressure, then sealing reliability is improved, but dissolution speed decreases
Solution Approach 1:
The dissolvable plug is segmented into two functional components: a dissolvable elastomer core for sealing and a polymeric coating layer for controlling dissolution rate. This segmentation allows each component to optimize its function independently while working together to resolve the contradiction between maintaining sealing reliability and achieving controlled dissolution.
Solution Approach 2:
The invention uses a composite structure combining dissolvable elastomer with a polymeric coating material that has different dissolution characteristics. This composite material system allows the elastomer to maintain sealing at high temperature and pressure while the coating controls the overall dissolution rate, preventing premature degradation.
2Productivity
If dissolvable plug is designed to dissolve quickly after fracturing, then productivity is improved, but sealing capability at high temperature and pressure deteriorates
Solution Approach 1:
The invention changes the physical and chemical parameters of the plug by applying a polymeric coating with specific properties (thickness, composition, cross-linking density) that modifies the dissolution kinetics. This parameter adjustment allows the plug to maintain sealing capability during high temperature and pressure fracturing operations while ensuring efficient dissolution after the operation is complete.
Solution Approach 2:
The polymeric coating is applied in advance to the dissolvable elastomer surface before deployment. This preliminary action creates a protective barrier that prevents premature water absorption and dissolution, allowing the plug to maintain its sealing capability during the fracturing operation and only dissolve after the operation is complete.
3Duration of action of stationary object
If polymeric coating is applied to delay dissolution, then sealing duration is extended, but dissolution time increases
Solution Approach 1:
The polymeric coating is applied locally to specific surfaces of the dissolvable elastomer where water absorption would initiate premature dissolution. This localized protection extends sealing duration by preventing water penetration at critical interfaces while maintaining the overall dissolution capability of the elastomer core, thus avoiding excessive delay in dissolution time.
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 coated dissolvable plugs can withstand high temperatures and pressures, maintaining sealing for extended periods and then dissolve efficiently, reducing milling time and costs.
Implementation Method 1
a polymeric coating adhered to at least a portion of the polymeric substrate
Data Source
AI summary
The patent application discloses an apparatus. The apparatus comprises a dissolvable polymeric substrate formed into a downhole tool; and a polymeric coating adhered to at least a portion of the polymeric substrate. The polymeric coating comprises a polymer having the formula:—[R(R1x)(R2y)]n—,wherein R is aryl, or —C(R3p) (R4q)-aryl-C(R5r)(R6s), and n is an integer ranging from 10 to 50,000.