Swellable Packer Seal Elements for Adjustable Pressure Sealing
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Solution Overview
Problem
Conventional swellable packers require varying the length of seal elements to achieve different differential pressure ratings, leading to increased manufacturing, inventory, and distribution costs due to the need for multiple configurations.
Innovation Solution
The solution involves varying the number of swellable seal elements with inclined faces and support rings to enhance sealing capability, allowing for adjustable differential pressure sealing without changing the length of the seal elements, thereby reducing the need for multiple configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the length of the seal element is varied to produce different differential pressure ratings, then the differential pressure sealing capability is improved, but the device complexity and manufacturing costs increase due to the need for multiple configurations
Solution Approach 1:
The seal element is divided into multiple segments or discrete components that can be combined in different quantities. Instead of manufacturing seal elements of different lengths, the patent uses multiple identical or standardized seal segments that can be assembled in series to achieve the required differential pressure rating, thereby reducing the need for multiple unique configurations
Solution Approach 2:
The patent changes the quantity parameter of seal elements rather than the dimensional parameter (length). By varying the number of identical seal elements in the assembly, different differential pressure ratings are achieved without requiring different physical dimensions, thus simplifying manufacturing and inventory management
2Reliability
If different length base pipes and seal elements are manufactured to achieve different differential pressure ratings, then the sealing capability is improved, but the manufacturing and distribution costs increase
Solution Approach 1:
A single standardized seal element design serves multiple functions and multiple differential pressure ratings by being used in different quantities. The same base pipe configuration can accommodate various numbers of identical seal elements, making the base pipe universal across different pressure rating applications and eliminating the need for multiple base pipe lengths
Solution Approach 2:
Instead of varying the size of individual components to achieve different performance levels, the patent inverts the approach by keeping components standardized and varying the quantity. This reversal of the design strategy simplifies manufacturing while achieving the same performance differentiation
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
This approach allows for customizable differential pressure sealing capabilities by selecting the appropriate number of seal elements, reducing production and distribution costs while maintaining effective sealing performance.
Implementation Method 1
The seal material forms a seal element... Each of the seal elements is swellable in a downhole environment
Implementation Method 2
Each of the seal elements is swellable in a downhole environment... the combined predetermined differential pressure sealing capabilities of the installed seal elements is at least as great as the desired differential pressure sealing capability
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~5A
AI summary
A swellable packer with enhanced sealing capability. A packer assembly includes multiple seal elements, each seal element being swellable downhole, each seal element having at least one face inclined relative to a longitudinal axis of the assembly, and the inclined faces of adjacent seal elements contacting each other. A method of constructing a packer assembly having a desired differential pressure sealing capability includes: providing a base pipe and multiple seal elements, each seal element being swellable in a downhole environment, and each seal element having a predetermined differential pressure sealing capability less than the desired sealing capability; and after the desired sealing capability is determined, installing a selected number of the seal elements on the base pipe, so that the combined predetermined differential pressure sealing capabilities of the installed seal elements is at least as great as the desired sealing capability.