Large-Gap Seal Assembly for High-Pressure Pipeline Isolation
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Solution Overview
Problem
Conventional elastomer packer seals for pipeline isolation face challenges such as elastomer creep and instability due to high extrusion gaps and pressure, leading to integrity issues and potential failure.
Innovation Solution
The large-gap-seal (LGS) assembly features multiple gap segments on the elastomer core's sidewalls and structural segments above them, which separate to expose the gap segments when activated, providing dynamic mechanical support and maintaining the elastomer core's integrity under high pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional seals use an adaptive spring to close the clearance gap, then the sealing capability is improved, but the elastomer core may protrude through spring coil openings causing elastomer creep and integrity loss
Solution Approach 1:
The seal assembly is divided into discrete gap segments (first gap segment, second gap segment, etc.) spaced apart along the elastomer core, rather than using a continuous spring structure. Each gap segment independently supports the elastomer core at specific locations, preventing protrusion through openings while maintaining sealing capability.
Solution Approach 2:
Gap segments are introduced as intermediary structures between the elastomer core and the pipeline wall, providing mechanical support and preventing direct contact between the elastomer core and potential escape paths, thereby eliminating elastomer creep while maintaining the sealing function.
2Ease of operation
If the extrusion gap is made large to allow smaller plugs, then the risk of plug getting stuck is reduced, but the spring becomes unstable and fails to support the elastomer core under high pressure
Solution Approach 1:
The continuous spring is segmented into multiple discrete gap segments spaced along the elastomer core. This segmentation provides distributed support points that maintain spring stability even when the overall extrusion gap is large, preventing plug accumulation while supporting the elastomer core under high pressure.
Solution Approach 2:
The support structure transitions from a one-dimensional continuous spring to a multi-point distributed support system along the longitudinal dimension of the elastomer core. This dimensional redistribution of support points enhances stability across large extrusion gaps by providing multiple stabilization locations.
3Reliability
If high pressure isolation is implemented, then the sealing effectiveness is improved, but the elastomer core integrity is compromised due to pressure-induced creep
Solution Approach 1:
Gap segments serve as intermediary mechanical supports between the high pressure environment and the elastomer core, distributing and bearing the pressure loads to prevent direct pressure-induced deformation and creep of the elastomer core, thereby maintaining integrity under high pressure isolation conditions.
Solution Approach 2:
The gap segments are positioned in advance along the elastomer core to provide preemptive mechanical support against pressure-induced deformation. This prior cushioning prevents elastomer creep before it can occur under high pressure isolation, maintaining both sealing effectiveness and material integrity.
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
This solution effectively prevents elastomer core escape, ensures a reliable seal, allows for higher pressure operations, and supports larger extrusion gaps, enabling the use of smaller plugs and broader pipeline size coverage while maintaining seal integrity.
Implementation Method 1
When the LGS assembly is activated and the elastomer core expands, causing adjoining structural segments to separate from one another
Implementation Method 2
pressurizing the elastomer core. This creates spaces between the opposing longitudinal edges of adjacent structural segments and exposes the gap segments
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A large-gap-seal ("LGS") assembly (30) and methods for its assembly and use are described. The LGS assembly (30) has an elastomer core (50) surrounded by adjoining structural segments (70). Non-adjoining gap segments (60) are located on the sidewall surfaces (55) of the elastomer core (50), with each gap segment (60) approximately centered beneath the edges of two adjoining structural segments (70). The gap segments (60) are exposed by the spaces that form between the structural segments (70) when the LGS assembly (30) is activated. Exposing the gap segments (60) rather than the elastomer core (50) protects the elastomer core (50) from damage and preserves the integrity of the seal between the isolation tool (20) and the inner wall of the pipeline.