Expandable Backup Rings for Downhole Bridge Plug Sealing
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Solution Overview
Problem
Downhole bridge plug sealing systems lack enhanced well fluid sealing characteristics, which are necessary for selectively sealing subterranean wells during hydrocarbon production and isolating well segments.
Innovation Solution
The development of backup rings with a circumferentially-expandable design, featuring a beveled ring surface, spiral slots, and expandable ring and sleeve portions, which expand to form a tight seal against the well casing when axial force is applied, enhancing the sealing capability of the downhole bridge plug assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing elements are used in downhole bridge plug assemblies, then the basic sealing function is provided, but enhanced well fluid sealing characteristics are lacking
Solution Approach 1:
The sealing element is divided into multiple functional segments including a primary sealing element, backup rings with beveled surfaces, and expandable ring portions. Each segment performs a specific sealing function, allowing the system to achieve enhanced sealing reliability through coordinated action of discrete components rather than a single complex sealing structure.
Solution Approach 2:
The backup rings are positioned within the sealing element assembly, with expandable ring portions nested inside the primary sealing element structure. The ring sleeves are positioned within the backup rings, creating a nested configuration where smaller sealing components are housed within larger structural elements, maximizing sealing surface area without proportionally increasing overall device volume.
2Reliability
If the backup rings are designed to expand circumferentially to seal against the well casing, then fluid-tight sealing is achieved, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The backup rings are designed with expandable ring portions that can dynamically change their circumferential dimensions in response to axial compression forces. The spiral slots and sleeve slots provide controlled pathways for this expansion, allowing the rings to adapt their shape and size to match the well casing inner diameter, ensuring fluid-tight sealing while maintaining manufacturability through standardized slot patterns.
Solution Approach 2:
The backup rings utilize changes in geometric parameters under load - specifically, the circumferential expansion of the ring portions when axial force is applied. This parameter change allows the rings to transition from a compact transport configuration to an expanded sealing configuration, achieving fluid-tight sealing against the well casing without requiring complex active actuation mechanisms.
3Adaptability or versatility
If the ring sleeve is made at least partially circumferentially-expandable with multiple sleeve slots, then the sealing adaptability to different well casing diameters is improved, but the device complexity increases
Solution Approach 1:
The ring sleeve is segmented into multiple expandable portions separated by sleeve slots, allowing independent expansion of each segment. This segmentation enables the sleeve to adapt to varying well casing diameters by controlling the degree of expansion in different segments, providing versatility while keeping each individual segment relatively simple in structure.
Solution Approach 2:
The ring sleeve serves multiple functions through its expandable design: it provides sealing contact with the well casing, supports the backup ring structure, and adapts to different casing diameters. The same structural feature (expandable segments with slots) accomplishes all these functions simultaneously, reducing overall device complexity compared to having separate components for each function.
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 backup rings effectively seal the annular space between the well casing and the bridge plug assembly, preventing fluid leakage and reinforcing the seal, thus ensuring reliable well operations by forming a fluid-tight and structural barrier against pressure and movement.
Implementation Method 1
An at least partially circumferentially-expanding ring sleeve may extend from the backup ring body
Implementation Method 2
A beveled ring surface may extend from the engaging ring surface
Data Source
AI summary
Backup rings for a sealing element system for a downhole bridge plug assembly may include a circumferentially-expandable backup ring body having an engaging ring surface. A beveled ring surface may extend from the engaging ring surface. An interior ring surface may extend from the beveled ring surface to the engaging ring surface. A ring opening may be formed by the beveled ring surface. A plurality of spiral ring slots may extend through the backup ring body from the engaging ring surface to the beveled ring surface. A plurality of expandable ring portions may extend between the plurality of spiral ring slots. An at least partially circumferentially-expanding ring sleeve may extend from the backup ring body. In some embodiments, an outer width or diameter of the ring sleeve may correspond to an outer width or diameter of the backup ring body. The ring sleeve may include a ring sleeve wall extending from the interior ring surface of the backup ring body. A sleeve interior may be formed by the ring sleeve wall. A plurality of sleeve slots may extend through the ring sleeve wall. The plurality of sleeve slots may communicate with the plurality of spiral ring slots, respectively, in the backup ring body. A plurality of expandable sleeve portions may extend between the plurality of sleeve slots. The plurality of expandable sleeve portions may extend from the plurality of expandable ring portions of the backup ring body.