Expandable Downhole Seal With Electrolytic Support Member
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Solution Overview
Problem
Existing sealing systems in boreholes face challenges in controlling the removal of support members to ensure proper isolation, as improper removal rates can lead to inadequate separation of borehole sections, necessitating a support member that can be removed in a controlled fashion.
Innovation Solution
An expandable support member comprising particles with a core and layers of different metals, where the interaction with borehole fluids facilitates controlled electrolytic decomposition, aided by an auxiliary electrode to manage the corrosion rate, allowing for controlled deployment of the expandable component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the support member is removed too quickly, then the expandable component can be deployed faster, but the isolation of borehole sections becomes improper
Solution Approach 1:
The support member's corrosion rate is controlled by changing the chemical composition parameters of the alloy, specifically by incorporating metals with different corrosion potentials in controlled proportions to achieve a selected corrosion rate that enables controlled removal
Solution Approach 2:
The support member is constructed as a composite alloy containing multiple metals with different corrosion potentials (such as zinc, aluminum, magnesium, nickel, copper, or stainless steel) to create a material with tailored corrosion characteristics that enable controlled decomposition
2Duration of action of stationary object
If the support member is made more resistant to corrosion, then it can protect the expandable component longer, but the removal time is delayed
Solution Approach 1:
The corrosion resistance parameter of the support member is precisely adjusted by modifying the alloy composition and the thickness ratios of different metal layers, allowing the support member to maintain optimal protection duration while enabling timely removal
Solution Approach 2:
The support member transitions from a static protective structure to a dynamically degradable structure that maintains its protective function for a predetermined period and then automatically decomposes at a controlled rate to enable expandable component deployment
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
Enables precise control over the decomposition of the support member, ensuring timely and effective isolation of borehole sections by managing the corrosion rate through the composition and structure of the alloy, ensuring the expandable component is deployed only when needed.
Implementation Method 1
the interaction with borehole fluids facilitates controlled electrolytic decomposition
Implementation Method 2
aided by an auxiliary electrode to manage the corrosion rate
Data Source
AI summary
Disclosed herein is an apparatus for use downhole comprising an expandable component; a support member that has a selected corrosion rate; wherein the support member is disposed on the expandable component; where the support member comprises a plurality of particles fused together; the particles comprising a core comprising a first metal; and a first layer disposed upon the core; the first layer comprising a second metal; the first metal having a different corrosion potential from the second metal; the first layer comprising a third metal having a different corrosion potential from the first metal.