Pipeline Isolation Seal Support for Large Extrusion Gaps
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Solution Overview
Problem
Conventional elastomer packer seals in pipeline isolation tools face challenges with seal creep and integrity issues due to pressure and temperature exposure, especially in applications with large extrusion gaps and high isolation pressures, where existing mechanical support structures are inadequate.
Innovation Solution
A segmented and wedge-based supporting system using overlapping metal segments with an inner ring and outer activation plate, which expands radially to form a fenced barrier around the elastomeric seal, preventing extrusion and maintaining seal integrity across a wider range of pipe diameters and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional elastomer packer seals are used in pipeline isolation tools, then the seal can be simple in structure and easy to manufacture, but the seal experiences creep and integrity loss under pressure and temperature, especially in large extrusion gaps
Solution Approach 1:
The mechanical support structure is divided into multiple segmented elements arranged circumferentially around the elastomer seal. These segments can independently expand and conform to the pipe wall, providing distributed support along the seal circumference. The segmentation allows the structure to adapt to large extrusion gaps while maintaining reliable support against seal creep under pressure and temperature conditions.
2Adaptability or versatility
If the extrusion gap between the plug and pipe wall is large (greater than 10% radial expansion), then the seal can accommodate larger pipe diameter variations, but the mechanical support structure becomes inadequate and springs become unstable
Solution Approach 1:
The mechanical support structure employs dynamic segmented elements that can expand and contract radially to accommodate varying pipe diameters. The segments are designed to flex and adapt their configuration based on the extrusion gap size, providing stable support in large gaps while maintaining adaptability across different pipe diameter ranges. This dynamic behavior allows the structure to remain effective from small to large extrusion gaps.
3Stress or pressure
If high isolation pressure (up to 102 bar or greater) is applied, then the seal can effectively isolate the pipeline, but the springs may become unstable and fail to support the elastomer core
Solution Approach 1:
The support structure is segmented into multiple independent elements distributed around the seal circumference. This segmentation distributes the high isolation pressure loads across multiple support points rather than relying on a single continuous spring structure. The segmented design provides enhanced stability under high pressure (up to 102 bar or greater) by preventing localized spring failure and maintaining elastomer core support through the distributed segment network.
4Ease of manufacture
If in-molded springs are used in the seal, then the manufacturing process can be simplified, but manufacturing errors cannot be visually detected
Solution Approach 1:
The mechanical support structure uses segmented elements that can be separately manufactured and then assembled around the elastomer seal. This segmentation enables visual inspection of each segment for manufacturing defects before final assembly, unlike in-molded springs where defects are hidden. The modular segmented design maintains ease of manufacture through standardized segment production while improving quality control through visible defect detection during assembly.
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 enables the seal to expand up to 20% more than traditional tools, withstand pressures up to 102 bar, and maintain integrity without seal creep, allowing for more versatile operations and cost-effective manufacturing.
Implementation Method 1
an elastomer core in the shape of a ring that is compressed to expand radially outward to the pipe from the tool or plug body
Implementation Method 2
Conventional seals use an adaptive or garter spring to close the clearance gap between the plug and the pipeline
Data Source
AI summary
Pipeline isolation tool for sealing extrusion gaps of up to about 20% or greater includes a pair of fenced barriers (60, 160) having overlapping segments (68/70, 168/170) for restraining a seal (40). The segments expand to a pipe wall before the seal to prevent transition of seal medium over the segments and form a support wall for the seal. The support wall may include a protection ring (200). Springs (80, 180) surround each fenced barrier for returning the support system to a relaxed position. Inner rings (90, 190) are provided on sealing element facing surfaces (64, 164) of the fenced barrier for supporting the segments. The inner rings define a smooth inner guiding surface (92, 192) for the seal. The guiding surface is tilted inwardly towards the seal for resisting the sealing element during expansion and for preventing an inside diameter of the seal from expanding outwardly when compressed.