Segmented Downhole Sealing Assembly for High-Pressure Wellbore Integrity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current sealing packers for subterranean wells are inadequate for high-temperature and high-pressure conditions, especially when the wellbore has irregular surfaces, leading to potential packer failure and risk of uncontrolled hydrocarbon flow.
Innovation Solution
A sealing assembly with moveable seal members that can expand to accommodate irregular wellbore surfaces, featuring a mandrel with pressure communication ports and valves to manage pressure differentials, allowing for adjustable sealing capability across multiple seal members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current packers are used to seal the wellbore, then the sealing capability is sufficient for normal conditions, but the packers cannot withstand high pressure differential at high temperatures and irregular wellbore surfaces
Solution Approach 1:
The packer is divided into multiple seal members (first seal member, second seal member, etc.) arranged in series along the mandrel. Each seal member independently contributes to the overall sealing capability, allowing the system to withstand higher pressure differentials than a single seal member could handle alone.
Solution Approach 2:
The seal members are designed with adjustable expansion characteristics to adapt to irregular wellbore surfaces. The seal members can be expanded to different degrees to accommodate washouts, oval shapes, and rough surfaces, optimizing the sealing interface under various wellbore conditions.
2Reliability
If the seal members are expanded to accommodate irregular wellbore surfaces, then the sealing contact is improved, but the outer expansion of the sealing element reduces the capability to withstand pressure differential
Solution Approach 1:
By segmenting the sealing function into multiple seal members, each seal member can be designed with optimized expansion characteristics. The cumulative sealing effect of multiple segments provides reliable sealing contact while each individual segment maintains sufficient strength to withstand pressure differential.
Solution Approach 2:
The sealing capability is enhanced by adding the dimensional aspect of multiple seal members arranged axially along the mandrel. This multi-dimensional sealing approach distributes the sealing load and pressure resistance across multiple elements rather than relying on a single expanded seal.
3Reliability
If multiple seal members are added to increase pressure differential capability, then the sealing reliability at high pressure and temperature is improved, but the device complexity increases
Solution Approach 1:
Each seal member is designed with universal characteristics to perform both sealing and pressure resistance functions. The seal members share common structural features and material properties, allowing them to be replicated in series without proportionally increasing overall system complexity.
Solution Approach 2:
The seal members utilize temperature-resistant materials and design parameters optimized for high-temperature operation. By standardizing the design parameters of each seal member for high-temperature and high-pressure conditions, the system achieves improved reliability without excessive complexity.
4Reliability
If the seal members are designed for high temperature operation, then the sealing capability at elevated temperatures is improved, but the material selection and manufacturing difficulty increase
Solution Approach 1:
The seal members utilize composite material construction combining temperature-resistant materials with sealing materials. This composite approach provides both the thermal stability required for high-temperature operation and the elastic properties needed for effective sealing, while maintaining manufacturability through standardized composite material selection.
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 sealing assembly effectively maintains a reliable seal across subterranean wells under high pressure and temperature conditions, reducing the risk of packer failure and enabling safe hydrocarbon development without the need for immediate casing.
Implementation Method 1
Two or more seal members circumscribe the mandrel. The seal members are moveable between a retracted position where the two or more seal members have a minimal outer diameter and an extended position where the two or more seal members have an expanded outer diameter.
Implementation Method 2
A pressure communication valve is associated with the pressure communication port. The pressure communication valve is operable to move between an open position where the pressure communication valve provides a path for flow of a fluid between the central passage and the exterior of the sealing tool between adjacent of the two or more seal members, and a closed position where the pressure communication valve prevents flow of the fluid through the pressure communication port.
Data Source
AI summary
A sealing assembly for forming a seal within a subterranean well includes a sealing tool having a mandrel. Two or more seal members circumscribe the mandrel. The seal members are moveable between a retracted position and an extended position. A seal actuator can move the seal members between the retracted position and the extended position. A pressure communication port is located between adjacent of the two or more seal members, the pressure communication port extending from the central passage of the mandrel to an exterior of the sealing tool. A pressure communication valve is associated with the pressure communication port, the pressure communication valve operable to move between an open position where the pressure communication valve provides a path for flow of a fluid between the central passage and the exterior of the sealing tool between adjacent of the two or more seal members, and a closed position.