Elastic Packer for Diverter System Sealing
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Solution Overview
Problem
Conventional diverter systems struggle to form a tight seal with casings of varying diameters, particularly failing to seal 24-inch pipes when using 27.5-inch packing elements, leading to operational challenges, increased costs, and prolonged drilling times.
Innovation Solution
The diverter system incorporates elastic packers with adjustable diameters, utilizing increased gas pressure and enhanced material elasticity to form a tight seal around casings from 24 inches to 36 inches, including a 27.5-inch split insert packing element modified to have a minimum closing diameter of 24 inches, using polymer balloons and helical springs for increased flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a 27.5-inch packing element is used in a conventional diverter system, then the system can seal 26-inch and larger casings, but it cannot seal 24-inch casings, leading to operational failures and delays
Solution Approach 1:
The packing element incorporates elastic elements (springs) that allow the structure to dynamically adjust and deform under pressure. This dynamic capability enables the rigid 27.5-inch packing element to flexibly conform to smaller 24-inch casings, expanding the range of sealable diameters while maintaining sealing reliability through elastic deformation
Solution Approach 2:
The patent changes the physical parameters of the packing element by introducing elastic materials and spring mechanisms. These parameter changes allow the packing element to alter its diameter and shape in response to applied pressure, enabling it to adapt from a fixed 27.5-inch configuration to accommodate varying casing sizes down to 24 inches
2Manufacturing precision
If gas pressure is increased from 750 PSI to 1000 PSI to compress the packing element, then the packing element can deform sufficiently to seal 24-inch casings, but this requires modified equipment and procedures
Solution Approach 1:
The packing element is designed to be self-actuating through the existing hydraulic system. By utilizing the available gas pressure (increased to 1000 PSI) and the elastic properties of the spring-loaded structure, the system automatically achieves the necessary deformation and sealing without requiring external modification or additional actuation mechanisms, thereby maintaining simplicity while achieving precision
3Adaptability or versatility
If the diverter system is modified to seal smaller casings, then the adaptability increases, but the time and cost of modification increases drilling delays
Solution Approach 1:
The elastic elements and spring mechanisms are pre-installed and pre-configured in the packing element during manufacturing. This preliminary action ensures that when the packing element is deployed, it is immediately capable of deforming to seal various casing sizes without requiring on-site modification, thereby eliminating time losses while maintaining adaptability
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
This solution reduces the time and cost associated with drilling operations by enabling the diverter system to efficiently seal 24-inch casings, reducing the risk of packer failure and completing the drilling process in two days instead of three, with significant cost savings and improved safety.
Implementation Method 1
The packing elements can be actuated to adjust their respective diameters by applying a pressure through an external port. Further, the packing elements can be compressed against the casing (for example, using pressurized gas) to form the seal.
Implementation Method 2
the degree of deformation of the packing elements can be increased by increasing a pressure of a gas used to compress the packing elements. For example, the gas pressure can be increased from about 750 pounds-per-square-inch (PSI) to about 1000 PSI.
Data Source
AI summary
A diverter system is configured to control a direction of drilling fluid or gas from a well bore to a surface platform. The diverter system includes a housing configured to receive a casing from a well bore, at least one outlet configured to direct flow of a drilling fluid or gas out of the housing, and a packing element assembly within the housing and coupled to the housing. The packing element assembly includes a first packing element affixed to the housing, the first packing element including at least one balloon configured to expand in response to an actuation input, and a second packing element concentrically within the first packing element, the second packing element including a first half and a second half, the first half coupled to the second half by a plurality of elastic elements.