Expandable Seal Expansion Limiter for Radial Control

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Solution Overview

Problem

Existing seal designs in the resource exploration and recovery industry face challenges in limiting radial expansion of sealing members to prevent stress and maintain sealing integrity, as metal-to-metal interactions can lead to over-expansion and loss of sealing capability.

Innovation Solution

A seal system with a frusto-conical surface and an expandable seal member, where an expansion limiter is positioned in the recess of the seal support member to limit axial movement, allowing the seal element to continue conforming to the tubular surface while preventing excessive expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If rings are used to limit radial expansion of the seal, then over-expansion is prevented, but the sealing member cannot continue to conform to the tubular surface once ring contact is established

Engineering Contradiction:

Improveseal integrityVSAvoidconforming capability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

A compliant expansion limiter is introduced as an intermediary component between the metallic seal support and the seal member. This expansion limiter acts as a mediator that provides radial support to prevent over-expansion while allowing axial movement, enabling the seal member to continue conforming to the tubular surface. The compliant nature of this intermediary component resolves the contradiction by decoupling the radial constraint function from the axial movement function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The expansion limiter changes its physical parameters (compliance, stiffness) to accommodate both radial constraint and axial movement requirements. By adjusting the compliance parameter of the expansion limiter, the system allows the seal member to maintain conforming capability while preventing excessive radial expansion. This parameter adjustment resolves the contradiction between seal integrity and conforming capability.

Inventive Principle:

Principle #35Parameter changes

2Strength

If metal-to-metal interactions are used between the ring and casing, then structural strength is maintained, but the efficacy of seal integrity is limited due to cessation of conforming

Engineering Contradiction:

Improvestructural strengthVSAvoidseal integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The system employs a composite structure combining metallic components (seal support) with a compliant expansion limiter material that exhibits both strength and compliance. This composite approach allows the metallic seal support to provide structural strength while the compliant expansion limiter material enables continued conforming of the seal member, thereby improving seal integrity without sacrificing structural strength.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If the seal member is allowed to expand freely, then conforming to the tubular surface is maximized, but stress increases leading to cracking of the steel support

Engineering Contradiction:

Improveconforming capabilityVSAvoidsupport integrity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The expansion limiter applies preliminary counter-action to the radial expansion of the seal member. By providing early radial support through the compliant expansion limiter, the system prevents excessive expansion before it can cause cracking of the steel seal support. This preliminary anti-action resolves the contradiction by limiting expansion proactively while allowing sufficient axial movement for conforming.

Inventive Principle:

Principle #9Preliminary anti-action

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 expansion limiter enhances seal integrity by maintaining compressive forces on the seal element, ensuring robust sealing performance even as the seal support expands, thereby reducing stress and preventing cracking.

Implementation Method 1

An expansion limiter is arranged between the seal support and the seal member. The expansion limiter is positioned in the recess of the seal support member to limit axial movement of the seal member relative to the frusto-conical surface.

Methodology Applied

Scientific EffectMechanical constraint:

Implementation Method 2

Radial expansion of the seal brings the sealing member into contact with a structure positioned adjacent to, and radially outwardly of, the conical surface.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS10760371B2System for limiting radial expansion of an expandable seal

Publication Date: 2020.09.01 BAKER HUGHES CO

AI summary

A seal system for downhole use in a surrounding tubular includes a seal support including a frusto-conical surface, and a seal member positioned about the seal support. The seal member includes a seal support member including first side having a recess, a second, opposing side, and a seal element coupled to the second, opposing side. The seal element is engageable with the surrounding tubular. An expansion limiter is arranged between the seal support and the seal member. The expansion limiter is positioned in the recess of the seal support member to limit axial movement of the seal member relative to the frusto-conical surface.