Expandable Sealing Element for Downhole Tool Casing
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Solution Overview
Problem
Existing sealing elements for oil and gas wellbores face challenges in accommodating varying wellbore and casing diameters, as they either fail to expand adequately for larger diameters or are too large to fit through smaller casings, limiting their versatility in different well operations.
Innovation Solution
A sealing element comprising a first and second deformable member with inclined surfaces that radially expand upon compression, allowing for sealing engagement with the wellbore wall, even in casings of varying sizes, by stretching over each other to accommodate different diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a sealing element is sized to fit through a smaller casing, then it can be deployed through the smaller casing, but it is too small to adequately expand to seal the larger size casing
Solution Approach 1:
The sealing element employs a dynamic structure with expandable radially outward fins that can transition from a compact configuration for passage through smaller casings to an expanded configuration for sealing against larger casings. This dynamic adaptability allows the same sealing element to reliably seal different casing sizes without compromising sealing effectiveness.
Solution Approach 2:
The sealing element changes its physical parameters (radial dimension, surface area) by expanding its fins from a compressed state during deployment to an expanded state during sealing. This parameter transformation enables the sealing element to fit through smaller casings while maintaining the capability to seal effectively against larger casings.
2Reliability
If a sealing element is sized to seal a larger casing, then it can adequately seal the larger casing, but it is too large to fit into the smaller casing
Solution Approach 1:
The sealing element's dynamic expandable fin structure allows it to be deployed in a compact form factor that fits through smaller casings, then expanded in-situ to achieve the larger diameter needed for sealing against larger casings. This eliminates the need to choose between sealing capability and deployability.
Solution Approach 2:
The sealing element's fins are configured to nest within each other or collapse into a compact arrangement during deployment through smaller casings, similar to nested dolls. Once positioned, the fins can be expanded outward to achieve the full sealing diameter, allowing the sealing element to effectively 'shrink' for passage and 'grow' for sealing.
3Reliability
If a deformable element is compressed radially outward to seal the annulus, then sealing engagement is achieved, but the element cannot accommodate variations in wellbore or casing diameter
Solution Approach 1:
The sealing element is segmented into multiple radially outward fins that can independently adjust their position and angle. This segmentation allows different portions of the sealing element to adapt to variations in casing diameter, maintaining reliable sealing engagement across a range of diameters while still achieving the necessary radial compression for sealing.
Solution Approach 2:
The sealing element incorporates dynamic adjustment capabilities where the fins can change their radial position and orientation in response to varying casing diameters. This dynamic adaptability allows the sealing element to maintain effective sealing engagement whether the casing diameter is smaller or larger than the nominal design size.
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 sealing element provides a versatile solution that effectively seals both smaller and larger diameter casings, ensuring fluid tightness and adaptability in various well operations by radially expanding to match the casing size, thus overcoming the limitations of prior sealing elements.
Implementation Method 1
A compressive force is generally applied to the deformable element, causing it to extrude radially outward
Data Source
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Figure 5
AI summary
Expansion sealing elements used to prevent fluid, flow through an annul us formed by tubing within the well and the wall of the wellbore or casing are provided. The expansion sealing elements are useful on downhole tools including those that need to be lowered through a first casing to be set in a second casing, which, has a larger diameter than the first casing.