Downhole Gap Sealing Element With Reactive Chemical Cavity
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Solution Overview
Problem
Metal-to-metal sealing systems in downhole wellbores face challenges due to small dimensional deviations between contacting surfaces, which can prevent complete sealing.
Innovation Solution
A malleable sealing element with closed wall cavities containing reactive chemicals that deform to fill dimensional variations in the gap between tubulars, forming a nonflowable element to ensure sealing, even in the presence of inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal-to-metal sealing systems are used, then sealing is achieved between tubulars, but small dimensional deviations in contacting surfaces prevent complete sealing
Solution Approach 1:
The sealing element changes its physical state from a flowable chemical to a nonflowable solid, transforming it into a malleable material that can deform and adapt to dimensional variations in the gap between tubulars, thereby achieving complete sealing despite manufacturing imperfections
Solution Approach 2:
The sealing system combines a malleable member (deformable material) with a chemical that transforms from flowable to nonflowable state, creating a composite sealing element that possesses both initial deformability for adaptation and final rigidity for maintaining seal under pressure
2Adaptability or versatility
If a malleable sealing element with closed wall cavities is used, then dimensional variations in the gap are filled, but the structure becomes more complex
Solution Approach 1:
The sealing element employs a malleable member with closed wall cavities that acts as a flexible container, allowing the structure to deform and conform to irregular gap dimensions while the cavities provide space for the chemical transformation process
3Reliability
If the chemical is reactive to form a nonflowable element, then sealing engagement is maintained under pressure, but the chemical reaction process adds complexity
Solution Approach 1:
The chemical within the closed wall cavity undergoes a phase transition from flowable to nonflowable state through a reactive process, enabling the sealing element to maintain its shape and sealing engagement under downhole pressure conditions
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 effectively maintains sealing engagement by forming a nonflowable element that withstands pressure and enhances sealing pressures, ensuring reliable sealing despite variations in the annular gap dimensions.
Implementation Method 1
The element includes, a malleable member having at least one closed wall cavity therein deformable to fill variations in a dimension of the gap
Implementation Method 2
a chemical disposed within the at least one closed wall cavity being reactive to form a nonflowable element
Data Source
AI summary
A downhole sealing element includes, a malleable member having at least one closed wall cavity therein positionable downhole in a gap defined between downhole members, and a chemical disposed within the at least one closed wall cavity. The malleable member is deformable to fill variations in a dimension of the gap and the chemical is reactive to form a nonflowable element.