Dual-Stage Sealing Interface for Delayed Primary Seal Energization
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Solution Overview
Problem
Existing sealing devices for downhole tools in wellbores face challenges in forming reliable seals under varying fluid pressures and flow rates, particularly with gases, as primary sealing elements often require energization that may be delayed or fail to engage effectively, leading to leaks and potential tool damage.
Innovation Solution
A sealing device with a carrier body and secondary sealing elements that engage primary sealing elements to form a primary seal, providing initial contact pressure and sliding engagement to energize the primary seal, ensuring reliable sealing even at insufficient pressures and flow rates, and incorporating a secondary seal to prevent leakage through open interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a primary sealing element is used to form a seal at the interface, then the seal requires energization to engage effectively, but the energization may be delayed or fail to engage under varying fluid pressures and flow rates
Solution Approach 1:
The carrier body is pre-configured with carrier sealing elements that provide preliminary sealing action before the primary sealing element is fully energized. The carrier body slides into position and the carrier sealing elements make initial contact with the interface, establishing a preliminary seal that prevents leakage while the primary sealing element is being energized by fluid pressure.
Solution Approach 2:
The carrier body acts as an intermediary between the sealing interface and the primary sealing element. It carries the carrier sealing elements that directly contact the interface and provide immediate sealing, while also supporting and positioning the primary sealing element that requires energization. This intermediary structure allows the system to achieve reliable sealing without waiting for the primary element to fully energize.
2Reliability
If a single primary sealing element is used, then the device structure is simpler, but the sealing reliability under varying pressures and flow rates is reduced
Solution Approach 1:
The sealing function is segmented into two distinct components: carrier sealing elements mounted on the carrier body and a separate primary sealing element. The carrier sealing elements provide immediate sealing upon carrier body insertion, while the primary sealing element provides enhanced sealing after energization. This segmentation allows each component to perform its specific function optimally, improving overall reliability without requiring a single complex sealing element.
Solution Approach 2:
The carrier sealing elements provide beforehand cushioning by establishing a preliminary seal before the primary sealing element is fully energized. This preliminary seal acts as a cushion that prevents leakage during the transition period, ensuring continuous sealing protection throughout the energization process and under varying operating conditions.
3Reliability
If the carrier body is made slidable to engage the primary sealing element, then the primary seal can be energized effectively, but the device requires precise sliding engagement mechanism
Solution Approach 1:
The carrier body is designed to slide automatically into the engaged position using the existing fluid pressure and flow conditions in the wellbore environment. The fluid pressure itself provides the force that drives the carrier body into position, where the carrier sealing elements make contact with the interface and energize the primary sealing element. This self-service mechanism eliminates the need for external actuation systems or complex control mechanisms.
Solution Approach 2:
The sliding engagement of the carrier body is achieved through hydraulic or pneumatic forces generated by the downhole fluid flow. The fluid pressure acts on the carrier body to drive it into the sealing position, where the carrier sealing elements contact the interface and energize the primary sealing element. This use of fluid pressure for actuation simplifies the operation and ensures reliable engagement under downhole 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 sealing device ensures effective and redundant sealing across a wide range of pressures and flow rates, preventing leaks and maintaining tool integrity by energizing primary seals through secondary elements, enhancing reliability and tool longevity.
Implementation Method 1
A carrier sealing element is positioned on the carrier body and is configured to seal the interface with a secondary seal
Implementation Method 2
a primary sealing element for forming a primary seal at the interface
Implementation Method 3
a carrier body that is slidable with respect to the interface to engage the primary sealing element and to energize the primary sealing element against the sealing interface
Data Source
AI summary
A sealing device for sealing an interface between a first surface and a second surface includes a primary sealing element for forming a primary seal at the interface and a carrier body that is slidable with respect to the interface to engage the primary sealing element. A carrier sealing element is positioned on the carrier body, and is configured to seal the interface with a secondary seal. The carrier body is slidable to engage the primary sealing element based on the secondary seal sealing the interface.