Pressure Testable Tubing Connection for Downhole Sealing
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Solution Overview
Problem
Downhole connectors in hydrocarbon recovery face challenges in maintaining seal integrity due to harsh environments and issues with piston parting during pressure testing, leading to potential damage and costly repairs.
Innovation Solution
A pressure testable connector system that includes a primary seal, a test sleeve with multiple seals forming a pressure boundary, and a test port for integrity testing, allowing for pressure monitoring to detect leaks and ensuring reliable sealing of tubing to a device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a parting piston is used to contain pressure during testing, then pressure testing can be performed, but the piston may part early or fail to part due to machining tolerances, material variations, and fluid trapping
Solution Approach 1:
The invention extracts the pressure containment function from a complex parting piston mechanism and replaces it with a simple cap and plug system. The cap threads onto the valve body to contain pressure during testing, while the plug seals the test port. This eliminates machining tolerances, material variations, and fluid trapping issues associated with pistons, while maintaining the ability to perform pressure testing.
Solution Approach 2:
The invention segments the pressure testing system into separate functional components: a cap for pressure containment, a plug for port sealing, and a test port for fluid access. This segmentation allows each component to be optimized independently and eliminates the need for a complex integrated piston mechanism, thereby improving reliability while reducing device complexity.
2Reliability
If excessive overpressure is applied to part the piston, then the piston may be forced to part, but components may be damaged
Solution Approach 1:
The invention performs preliminary sealing actions using the cap and plug to contain pressure and isolate the test port before pressure testing begins. This preliminary setup eliminates the need for excessive overpressure to force parting, as the threaded cap and plug design allows for controlled pressure containment without risking component damage.
3Reliability
If debris from the piston or seals flows into the backcheck section, then the check dart may become lodged and fail to open or close
Solution Approach 1:
The invention extracts the potential debris-generating piston and seal mechanisms from the system and replaces them with a simpler cap and plug design. This extraction eliminates the source of debris that could contaminate the backcheck section and cause check dart malfunction, while still providing the necessary pressure containment and testing functionality.
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 system effectively tests the integrity of seals in a harsh downhole environment, preventing premature piston parting and potential damage, ensuring reliable operation and reducing maintenance costs by identifying and addressing seal issues before they cause damage.
Implementation Method 1
a first seal configured to seal the tubing to the device... a second seal... configured to seal the test sleeve to the device... a third seal disposed at the test sleeve and configured to seal the tubing to the test sleeve
Implementation Method 2
hydraulic pressure to move the parting mechanism from an initial position in which the parting mechanism seals the pressure boundary to a second position in which the fluid communication path is opened
Data Source
AI summary
An apparatus for sealing tubing to a device, the apparatus including: a first seal configured to seal the tubing to the device, the first seal having a device side in contact with the device and an interior side opposite the device side; a test sleeve configured to surround the first seal and to seal to the device using a second seal; a third seal disposed at the test sleeve and configured to seal the tubing to the test sleeve wherein the test sleeve, the second seal, and the third seal form a pressure boundary about the first seal; a test port disposed at the test sleeve, the test port being in communication with seals, wherein the test port is configured to connect to a seal test device to test the integrity of the seals in communication with the test port; and a plug configured to seal the test port.