Rotating Control Device Sealing Element with Reinforced Elastomeric Body
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Solution Overview
Problem
Existing sealing elements for rotating control devices in oil and gas well drilling are costly and inefficient to manufacture and refurbish, with conventional machining methods being time-consuming and expensive, and the process of removing damaged elastomeric sealing portions is expensive and inefficient.
Innovation Solution
A sealing element with a reinforced elastomeric body and a manufacturing process using additive manufacturing to create molds, reducing production costs and enabling cost-effective prototyping, and a design with a frame and pleated outer sidewall for enhanced columnar support and flexibility, along with a coupling structure for easy connection to rotating control devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to manufacture sealing elements, then manufacturing precision can be achieved, but production time and cost increase significantly
Solution Approach 1:
The patent replaces conventional mechanical machining methods with additive manufacturing (3D printing) technology. The sealing element is created by depositing material layer by layer according to digital models, eliminating the need for traditional CNC machining operations. This substitution reduces manufacturing time while maintaining precision through controlled material deposition and automated layer-by-layer construction.
Solution Approach 2:
The invention changes the fundamental manufacturing parameters from subtractive machining (removing material) to additive construction (depositing material). By using additive manufacturing parameters such as layer thickness, deposition rate, and heating/cooling cycles, the process achieves both high precision and reduced manufacturing time compared to conventional machining approaches.
2Manufacturing precision
If conventional machining methods are used to manufacture sealing elements, then manufacturing precision can be achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive conventional machining operations with additive manufacturing technology. The 3D printing process eliminates costly setup times, tooling changes, and manual machining operations while maintaining precision through automated digital control. This substitution significantly reduces manufacturing costs for sealing elements while preserving dimensional accuracy and surface quality.
Solution Approach 2:
The invention enables cost-effective production of sealing elements through additive manufacturing, making it economically viable to produce disposable or single-use sealing components. The reduced manufacturing cost allows for a business model where sealing elements can be replaced rather than refurbished, eliminating expensive refurbishment processes and associated labor costs.
3Reliability
If elastomeric sealing portions are removed for refurbishment, then reliability can be maintained, but the process becomes expensive and inefficient
Solution Approach 1:
The patent adopts a disposable sealing element approach where the entire sealing component is designed for single-use and replacement rather than refurbishment. The low-cost additive manufacturing process enables economical production of replacement sealing elements, making it more efficient to simply replace a worn seal rather than undergo expensive and time-consuming refurbishment procedures involving removal, inspection, and reinstallation.
Solution Approach 2:
The sealing element is designed as a separable component that can be easily removed and replaced independently from the main device structure. This segmentation allows for quick exchange of the sealing portion without affecting other components, improving productivity by enabling rapid replacement and eliminating the need for complex refurbishment processes.
4Adaptability or versatility
If the elastomeric body is made flexible for pipe passage, then adaptability is improved, but structural strength decreases
Solution Approach 1:
The patent employs composite construction combining elastomeric materials with reinforcing elements. The elastomeric body provides flexibility and sealing properties, while embedded reinforcement structures (such as fabric layers, mesh, or structural cores) provide the necessary structural strength. This composite approach allows the sealing element to simultaneously achieve the flexibility needed for pipe passage and the strength required to withstand operational pressures and mechanical loads.
Solution Approach 2:
The invention applies different material properties to different regions of the sealing element. The outer elastomeric layers provide flexibility and sealing contact, while strategically placed reinforcement zones provide localized strength where needed. This local differentiation of material quality allows the component to exhibit both flexibility for pipe passage and structural strength in critical areas without compromising either property.
Data Source
AI summary
A sealing element for a rotating control device is described. The sealing element includes an elastomeric body having a central bore for sealing against a pipe passing therethrough. The elastomeric body has an upper portion which is internally reinforced with a frame and a lower portion formed with a plurality of protrusions. The radial protrusions provide columnar support to the lower portion permitting the lower portion to resist centrifugal and frictional forces against the lower portion during drilling and other operations. The sealing element may be used to form an assembly with reusable parts for connecting the sealing element to a mandrel of a rotating control device.