Reinforced Swellable Elastomer Packer for Wellbore Sealing
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Solution Overview
Problem
Existing swellable elastomeric materials used in well packers degrade mechanically and deswell when exposed to hydrocarbons or water, limiting their durability and ability to maintain a seal over time.
Innovation Solution
Development of reinforced elastomeric compositions that swell and stiffen in response to triggering fluids, such as water or oil, using reactive fillers like cement and metal oxides, which maintain volume and mechanical strength even after the triggering fluid is removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If swellable elastomeric materials are used in well packers, then the packer can conform to irregular well surfaces and expand radially outward without complex mechanisms, but the materials degrade mechanically and deswell when exposed to hydrocarbons or water over time
Solution Approach 1:
The patent applies composite materials by combining swellable elastomeric materials with reactive fillers (such as cement, metal oxides, or other inorganic materials) to create a composite sealing element. This composite structure allows the material to maintain its swelling capability while the reactive filler provides mechanical reinforcement and structural stability, preventing degradation and deswelling over time. The reactive filler may also undergo chemical reactions with the triggering fluid to further enhance the sealing performance and durability.
2Volume of moving object
If the elastomeric material swells in response to triggering fluid, then the seal expands to form an annular barrier, but the material loses mechanical strength and deswells when the triggering fluid is removed
Solution Approach 1:
The reactive filler serves as a structural skeleton within the elastomeric matrix, maintaining the expanded volume and providing mechanical strength even after the triggering fluid is removed. The filler particles prevent the elastomer from collapsing back to its original state, effectively locking in the expanded configuration and maintaining both volume and strength simultaneously.
Solution Approach 2:
The patent utilizes parameter changes by selecting reactive fillers that undergo chemical reactions (such as hydration of cement or oxidation of metal oxides) when exposed to triggering fluids. These chemical reactions cause the filler to expand or harden, permanently altering the physical parameters of the composite material to maintain both volume increase and mechanical strength enhancement after the triggering fluid is removed.
3Reliability
If reactive fillers like cement and metal oxides are used to reinforce the elastomer, then the material maintains volume and mechanical strength after triggering, but the device complexity increases
Solution Approach 1:
The patent applies homogeneity by thoroughly mixing the reactive filler particles with the elastomeric material to create a uniform composite structure. This homogeneous distribution ensures consistent performance throughout the sealing element, where the reactive filler is evenly dispersed to provide uniform reinforcement and swelling response, simplifying the overall material behavior despite the complex composition.
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 reinforced elastomeric compositions provide a durable and long-lasting seal, maintaining mechanical strength and volume increase even in the absence of the triggering fluid, enhancing the sealing performance and durability of well packers.
Implementation Method 1
The mechanism of swelling is via a chemical reaction between the reactive filler and the triggering fluid
Implementation Method 2
when a particular fluid contacts and diffuses into the sealing material in the well
Data Source
AI summary
The subject disclosure relates to apparatus and methods that are particularly suited for creating a seal in a borehole annulus. More particularly, the subject disclosure relates to a seal with enhanced sealing capability. In one embodiment the subject disclosure relates to a reinforced and permanent swellable packer device.