Segmented Backup Ring Structure for Low-Force Pressure Sealing
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Solution Overview
Problem
Existing backup configurations in the downhole industry are often expensive, difficult to set, and have limited pressure holding capacity, failing to effectively prevent sealing material extrusion under pressure differentials, especially in non-cylindrical or defective boreholes.
Innovation Solution
A backup system comprising a radially inwardly disposed circumferentially continuous ring with a flare feature and a radially outwardly disposed circumferentially discontinuous ring with overlapping segments, designed for low setting force, ultra-expansion, and super-conformability, featuring a gap between rings to reduce friction and allow for additive manufacturing, which reduces costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional backup configurations are used to prevent sealing material extrusion, then pressure holding capacity is improved, but device complexity and cost increase while ease of operation deteriorates
Solution Approach 1:
The backup ring is divided into multiple segments that can be independently positioned and adjusted. Each segment can be set independently to provide backup support, allowing the system to achieve high reliability through distributed functionality rather than a single complex structure. The segments can be arranged in different configurations depending on the specific application requirements.
Solution Approach 2:
The backup segments are designed to be nestable within the sealing element assembly, allowing compact storage and easy installation. The segments can be nested within each other or within the sealing element before deployment, reducing the overall device complexity and ease of operation during installation while maintaining pressure holding capacity when deployed.
2Reliability
If traditional backup configurations are used to prevent sealing material extrusion, then pressure holding capacity is improved, but cost increases
Solution Approach 1:
By segmenting the backup ring into multiple simpler components, the manufacturing process for each individual segment becomes less complex and more cost-effective. Standardized segment designs can be mass-produced using simpler manufacturing processes, reducing overall manufacturing cost while the assembled segmented structure maintains the required pressure holding capacity.
Solution Approach 2:
The backup segments can be manufactured from various materials and with different geometric parameters optimized for specific pressure conditions. This flexibility allows cost-effective manufacturing by selecting appropriate materials and dimensions based on the application requirements, rather than using a single expensive design for all pressure holding applications.
3Reliability
If traditional backup configurations are used to prevent sealing material extrusion, then pressure holding capacity is improved, but ease of operation deteriorates
Solution Approach 1:
The segmented design allows each backup segment to be independently positioned and adjusted during operation. This modularity simplifies the setting process as segments can be installed and adjusted separately rather than requiring complex manipulation of a single integrated backup structure, improving ease of operation while maintaining pressure holding capacity.
Solution Approach 2:
The backup segments are designed with dynamic positioning capabilities, allowing them to be adjusted during the setting process to accommodate variations in the sealing element and installation conditions. This dynamic adjustability simplifies operation by enabling real-time optimization of the backup configuration during installation.
4Reliability
If backup ring prevents sealing material extrusion under pressure differential, then reliability is improved, but setting force requirement increases
Solution Approach 1:
The segmented backup ring distributes the load and setting force across multiple independent segments rather than requiring a single large force to set an integrated ring. Each segment can be set with lower individual force, and the cumulative effect provides the necessary extrusion prevention, thereby reducing the peak setting force requirement while maintaining reliability.
Solution Approach 2:
Each backup segment can be locally optimized with specific geometric features and material properties tailored to the local stress conditions. This allows each segment to provide effective extrusion prevention with minimal setting force, as the local quality of each segment is optimized for its specific position and load conditions rather than using a uniform design throughout.
Data Source
AI summary
A backup including a radially inwardly disposed circumferentially continuous ring; a radially outwardly disposed circumferentially discontinuous ring, the circumferentially discontinuous ring comprising a plurality of segments arranged to overlap adjacent ones thereof about a circumference of the circumferentially discontinuous ring.