Variable Bore Packer Protrusion for Extrusion Control
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Solution Overview
Problem
Variable bore packers in ram-type and annular BOPs face durability issues due to material extrusion and inadequate sealing caused by gaps between insert tips and pipes, leading to incomplete closure and low pressure sealing, especially when handling a range of pipe diameters.
Innovation Solution
Incorporating a protrusion with higher mechanical properties, such as fiberglass or carbon fiber, embedded within the elastomeric material to prevent extrusion through gaps between packer inserts and pipes, while maintaining a low Durometer for sealing versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If low Durometer elastomeric material is used for the packer, then sealing versatility across a range of pipe diameters is improved, but material support during loading deteriorates and extrusion through gaps occurs
Solution Approach 1:
The packer is constructed as a composite structure combining low Durometer elastomeric material with high strength support inserts (such as fiberglass or carbon fiber reinforced polymers). The elastomeric material provides the necessary flexibility and sealing versatility across different pipe diameters, while the support inserts provide structural strength and prevent material extrusion through gaps, resolving the contradiction between softness for sealing and strength for support.
2Strength
If high Durometer packer material is used, then material support and structural strength are improved, but sealing capability across varying pipe diameters deteriorates and incomplete closure occurs
Solution Approach 1:
The composite packer structure combines high strength support inserts with compliant elastomeric material. The support inserts provide the necessary structural strength to prevent collapse and maintain shape, while the compliant elastomeric outer layer adapts to varying pipe diameters and provides effective sealing, thereby resolving the contradiction between strength and sealing capability.
Solution Approach 2:
Different regions of the packer have different material properties: the support inserts provide localized structural strength where needed to prevent collapse and maintain shape, while the elastomeric material provides localized compliance and sealing capability. This local differentiation allows the packer to simultaneously achieve both strength and sealing versatility.
3Ease of operation
If gaps are left between insert tips and pipe, then ease of installation and adjustment for different diameters is improved, but material extrusion and seal integrity deteriorate under load
Solution Approach 1:
The support inserts act as intermediaries between the elastomeric packer material and the pipe. They provide structural support to prevent extrusion while allowing the elastomeric material to maintain gaps for ease of installation and adjustment. The inserts mediate between the need for seal integrity and the need for installation flexibility.
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
Enhances the durability and sealing effectiveness of variable bore packers by minimizing material extrusion and maintaining an adequate seal across a range of pipe diameters with reduced material deterioration.
Implementation Method 1
Incorporating a protrusion with higher mechanical properties, such as fiberglass or carbon fiber, embedded within the elastomeric material to prevent extrusion through gaps between packer inserts and pipes
Implementation Method 2
the packer material must be of a low enough Durometer to close against the pipe and provide enough pressure for a range of pipe diameters
Data Source
AI summary
A variable bore packer used in a blowout preventer to form a seal against different diameter tubular members for oil and gas drilling operations. The variable bore packer includes a packer member molded of elastomeric material with certain mechanical properties and including an inside curved surface. The packer also includes a plurality of packer inserts molded within the packer member to form an insert array. Additionally, the packer includes a protrusion extending from and bonded to the packer member inside curved surface, the protrusion including increased mechanical properties compared to the packer member. The packer member, the insert array, and the protrusion are molded into a unitary structure and sized to form a seal against the different diameter tubular members upon closure of the blowout preventer. Also, the insert array and the protrusion diminishing extrusion of the elastomeric material between the packer inserts and the tubular members.