Seal Wear Sensor for Drilling Pressure Containment
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Solution Overview
Problem
Existing sealing element wear monitoring systems in drilling operations are inadequate for accurately detecting wear in upper sealing elements and inner bore sealing areas, leading to potential uncontrolled pressure releases and safety hazards, as they rely on visual leak detection methods and pressure differentials, which are not proactive in replacing worn-out seals.
Innovation Solution
A seal assembly with an embedded wear sensor that emits an alert signal, such as a pressure or chemical signal, when the inner surface of the seal has worn by a preset amount, allowing for proactive replacement and preventing failure, comprising a tubular body with an electrical power supply and conductive probes or inductive proximity sensors to monitor wear and provide visual or audible warnings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual leak detection methods and pressure differential monitoring are used, then the system can detect seal failure, but the detection is not proactive and occurs only after wear has already compromised the seal
Solution Approach 1:
The wear sensor is embedded in the seal at a predetermined location to detect wear before the seal fails. The sensor protrudes into the sealed space and makes contact with the drill string or annular member when a predetermined amount of wear occurs, triggering an alert signal. This preliminary detection allows proactive replacement of the seal before complete failure and uncontrolled pressure release.
Solution Approach 2:
The patent replaces visual leak detection and pressure differential monitoring with an embedded wear sensor that provides direct mechanical contact detection. The sensor uses electrical conductivity or inductive proximity sensing to detect wear, substituting indirect monitoring methods with direct measurement at the wear interface.
2Device complexity
If no wear monitoring system is installed, then the system complexity is low, but uncontrolled pressure releases and safety hazards occur due to undetected seal wear
Solution Approach 1:
The wear sensor is embedded directly in the seal itself, making the seal self-monitoring. The seal detects its own wear condition through the embedded sensor and communicates this information via an alert signal. This self-service approach allows the seal to monitor its own health without requiring external monitoring systems.
Solution Approach 2:
The embedded wear sensor provides continuous feedback about the seal's wear condition to the drilling operation. When the sensor detects predetermined wear, it generates an alert signal that feeds back to operators, enabling them to replace the seal before failure. This feedback loop prevents the harmful effect of uncontrolled pressure release.
3Reliability
If embedded wear sensors are installed in seals, then proactive wear detection is enabled, but the device complexity and manufacturing cost increase
Solution Approach 1:
The embedded wear sensor serves multiple functions: it detects wear, provides structural support within the seal, and can be integrated with the seal's electrical or magnetic properties. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process despite the added capability.
Solution Approach 2:
The wear sensor is embedded within the seal structure itself, with the sensor nested inside the seal body. The sensor can be positioned in a cavity or channel within the seal, and its protruding portion extends into the sealed space. This nesting approach integrates the sensor into the seal rather than adding it as a separate external component.
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 enables proactive and safe replacement of sealing elements, reducing the risk of uncontrolled pressure releases and environmental hazards by accurately monitoring wear, ensuring continuous operation and enhancing workplace safety.
Implementation Method 1
The wear sensor is configured to emit an alert signal when the inner surface of the seal has been worn away by a first preset amount
Implementation Method 2
comprising a tubular body with an electrical power supply and conductive probes or inductive proximity sensors to monitor wear
Data Source
AI summary
A seal assembly for use in a pressure containment device for containing a fluid pressure in an annular space around a drill string whilst allowing the drill string to rotate in the pressure containment device. The seal assembly includes a seal with an inner surface and a tubular body, and a wear sensor embedded in the tubular body of the seal. The wear sensor emits an alert signal when the inner surface of the seal has been worn away by a first preset amount. The alert signal includes a pressure signal and/or a chemical signal.