Self-Inflating Downhole Seals for High Expansion Without Extrusion Gaps
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Solution Overview
Problem
Existing expanding and collapsing apparatuses in hydrocarbon exploration and production are limited by expansion ratios, leading to extrusion gaps and reduced surface area for contact, which limits maximum force and pressure rating, and are difficult to reliably move back to their collapsed configurations.
Innovation Solution
A sealing device with a load retention/equalization mechanism that includes an elastomer seal component, lower and upper support barriers, and a spool/inflation valve to direct fluid into an internal volume based on differential pressure, allowing for high expansion without extrusion gaps and maintaining seal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If discrete circumferential distribution of expanding structures is used, then anchoring force and pressure rating are improved, but expansion ratio is limited and extrusion gaps are created
Solution Approach 1:
The expanding structure is divided into multiple discrete circumferential elements that can expand independently, allowing each segment to maintain structural integrity while collectively providing high expansion ratio without creating extrusion gaps between segments
Solution Approach 2:
The expanding elements are nested within a common structure that allows them to expand radially outward while maintaining circumferential continuity, enabling high expansion ratio without creating gaps that would compromise seal integrity
2Area of stationary object
If high expansion ratio is achieved, then surface area for contact is increased, but device complexity and difficulty of collapsing back increase
Solution Approach 1:
The expanding structure employs dynamic elements that can transition between expanded and collapsed states through controlled movement, allowing high expansion ratio to be achieved while maintaining the ability to collapse back through reversible mechanical action
Solution Approach 2:
The collapse mechanism replaces complex mechanical linkages with a simpler system that uses differential pressure and elastic recovery to return the expanding elements to their collapsed state, reducing device complexity while maintaining high expansion capability
3Reliability
If high compressive loads are applied to maintain seal, then seal integrity is improved, but damage to sealing elements and difficulty of recovery increase
Solution Approach 1:
The seal energizing mechanism uses fluid pressure (pneumatics or hydraulics) to apply controlled force to the sealing element, maintaining seal integrity without requiring excessive compressive loads that would damage the sealing material or hinder recovery
Solution Approach 2:
The system changes the physical state or parameters of the sealing element (such as inflation pressure or material properties) to maintain seal integrity under varying conditions, allowing the seal to remain effective without applying damaging compressive loads
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
Enables high expansion seals with increased anchoring force and pressure rating without requiring high compressive loads, facilitating recovery and reducing damage to sealing elements.
Implementation Method 1
a spool/inflation valve to direct fluid into an internal volume based on a differential pressure between a first volume uphole relative to the downhole tool and a second volume downhole relative to the downhole tool
Implementation Method 2
a seal energizing spring to maintain an initial setting force of the elastomer seal component against the wellbore casing
Implementation Method 3
outwardly radially expanding an expansion device of the sealing device to compress an elastomer seal component of the sealing device against the wellbore casing
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 3
AI summary
Embodiments described herein provide a downhole tool (e.g., a retrievable bridge plug) that includes a sealing device and a load retention/equalization mechanism. The sealing device includes an elastomer seal component and an expansion device configured to radially expand outwardly to compress the elastomer seal component against a wellbore casing within which the downhole tool is located. The sealing device further includes lower and upper support barriersconfigured to radially expand outwardly against the wellbore. The sealing device also includes a seal energizing spring configured to maintain an initial setting force of the elastomer seal component against the wellbore casing. The load retention/equalization mechanism includes a spool/inflation valve configured to direct fluid into an internal volume to inflate the elastomer seal component radially outwardly based on a differential pressure between a first volume uphole relative to the downhole tool and a second volume downhole relative to the downhole tool.