Dissolvable Thread Sealant for High-Pressure Downhole Sealing
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Solution Overview
Problem
Existing downhole tools with dissolvable components face challenges in creating a pressure-tight, leak-free seal at high wellbore pressures, as conventional thread treatments like PTFE tape or pastes either fail to withstand pressures or leave behind residues that can clog equipment.
Innovation Solution
A method involving applying a dissolvable polymer film, such as polyvinyl alcohol (PVA), to the threads of dissolvable threaded components to form a seal that can withstand high pressures and dissolve under conditions that also dissolve the tool components, preventing residue formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thread treatments like PTFE tape or pastes are used, then sealing capability is improved, but residue formation occurs that can clog equipment
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional non-dissolvable thread treatments (PTFE tape, pastes) to a dissolvable polymer film. This changes the material parameter from permanent to temporarily functional, allowing the sealant to dissolve completely after serving its purpose, thereby eliminating residue formation while maintaining sealing capability during the operational phase.
Solution Approach 2:
The dissolvable polymer film functions as a disposable sealing element that performs its sealing duty during wellbore operations and then dissolves away, similar to disposable objects. This eliminates the need for residue removal operations and prevents equipment clogging, while providing reliable sealing when needed.
2Loss of time
If dissolvable materials are used for downhole tools, then tool removal time is reduced, but complete dissolution is not achieved leaving non-dissolvable scraps
Solution Approach 1:
The patent uses composite materials by combining dissolvable polymer materials with appropriate additives and formulations. The thread sealant comprises a dissolvable polymer base material combined with other dissolvable components, creating a composite that maintains functional properties during operation but achieves complete dissolution after use, eliminating non-dissolvable scraps.
Solution Approach 2:
The patent applies parameter changes by selecting and optimizing the chemical composition and molecular structure of the dissolvable polymer materials. By adjusting parameters such as polymer type, molecular weight, and additive composition, the patent achieves complete dissolvability while maintaining the necessary mechanical and sealing properties during wellbore operations.
3Stress or pressure
If high pressure sealing is achieved with conventional materials, then pressure resistance is improved, but material compatibility with dissolvable tools is worsened
Solution Approach 1:
The patent resolves this contradiction by changing the material parameters from conventional non-dissolvable materials to dissolvable polymers with optimized chemical and physical properties. The dissolvable polymer film is formulated to maintain adequate pressure resistance during wellbore operations while being chemically compatible with dissolvable tool materials, achieving both pressure resistance and material compatibility through parameter optimization.
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 provides a reliable, pressure-tight seal capable of withstanding up to 10,000 psig without leaving behind residues, ensuring efficient tool deployment and retrieval by dissolving both the sealant and tool components under appropriate conditions.
Implementation Method 1
dissolving a portion of at least one of the first and second threaded components by contacting the first and second threaded components with a fluid capable of dissolving the first dissolvable material
Data Source
AI summary
Dissolvable thread sealants are useful for forming a pressure-tight seal between dissolvable threaded components, particularly in downhole tools. A film of the dissolvable thread sealant can be formed on the threads of dissolvable threaded components. As the dissolvable threaded components are exposed to fluid under the appropriate conditions and begin to dissolve, the thread sealant becomes exposed to the fluid and, likewise, dissolves. Embodiments of the dissolvable thread sealants are made using polyvinyl alcohol (PVA).