Expandable Seal Conforming Ribs Wellbore Isolation
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Solution Overview
Problem
Existing expandable seals for oil and gas wells struggle to achieve a reliable seal due to gaps between sealing elements and the wellbore surface, as they do not effectively conform to the shape of the inner wall, leading to leakage and reduced isolation efficiency.
Innovation Solution
The use of conforming ribs made from a softer, more malleable metallic material, such as copper, on an expandable tubular member that can be radially expanded to engage the wellbore surface, closing the extrusion gap and forming a better seal by conforming to the shape of the inner wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing elements are used, then the device structure is simple, but the seal reliability is poor due to gaps between sealing elements and the wellbore surface
Solution Approach 1:
The sealing element is divided into multiple segments or lobes that can independently deform and conform to the wellbore surface. Each segment can move and adapt separately, ensuring complete contact with irregular surfaces and eliminating gaps between sealing elements, thereby improving seal reliability without significantly increasing overall device complexity
Solution Approach 2:
The sealing element transitions from a rigid structure to a dynamic, deformable structure that can adapt its shape during operation. The sealing elements are designed to flex and conform to the wellbore contour when expanded, allowing them to maintain reliable contact with the wellbore surface while accommodating surface irregularities
2Adaptability or versatility
If rigid sealing elements are used, then the manufacturing is easier, but the adaptability to wellbore surface shape is poor
Solution Approach 1:
The sealing elements utilize flexible materials and thin-walled structures that can easily deform to match the wellbore surface contour. These flexible sealing elements are manufactured as pre-formed components with inherent elasticity, allowing them to adapt to various wellbore shapes while maintaining manufacturing simplicity through standardized material selection and forming processes
Solution Approach 2:
The sealing elements are designed to change their physical parameters (shape, volume, rigidity) during operation in response to expansion forces. By controlling the expansion parameters and material properties, the sealing elements can transform from a compact transport state to an expanded conforming state that adapts to the wellbore surface, achieving high adaptability without complex manufacturing
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 ensures a tighter seal by closing the extrusion gap and enhancing the sealing efficiency between the sealing elements and the wellbore surface, effectively isolating different regions of the wellbore, thereby improving the overall sealing performance.
Implementation Method 1
a metallic conforming material formed from a metal such as copper or other metal that is softer or more malleable than the metal forming the tubular member
Data Source
AI summary
Expandable seals have one or more conforming ribs to facilitate creation of a seal to a sealing surface disposed in the well. The conforming ribs comprise a core of material either capped, partially covered by, or entirely covered by a ring. The ring can be formed of a metal that is softer than the metallic core material of each rib. Suitable metals forming the rings include copper formed by metal spun methods. Disposed adjacent to the rings are one or more sealing elements. By moving the rings into the sealing surface during expansion of the expandable seals, the rings close the extrusion gaps between the internal surface of the casing and the expanded tubular member ribs. The rings better conform to the sealing surface of the casing, thereby facilitating the creation of the seal between this sealing surface and each of the sealing elements.