High-Expansion Well Plug Seal With Low-Work Elastomer Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing radially expandable elastomer sealing elements for well plugs require substantial mechanical work for expansion and are limited in the types of elastomers that can be used, necessitating a need for a plug capable of large radial expansion with reduced mechanical work and a wider range of elastomeric materials.
Innovation Solution
A plugging tool with a tool mandrel and longitudinally spaced apart extrusion barriers that urge elastomer sealing elements, such as cords or discrete bodies, to radially expand, reducing the mechanical work required for sealing by using elastomer cords or discrete bodies with or without a retaining sleeve, and potentially filled with volume fill materials like potting compound or sand and clay mixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If radially expandable elastomer sealing elements are used to close wells, then hydraulic closure is achieved, but substantial mechanical work is required for expansion
Solution Approach 1:
The elastomer seal is divided into multiple discrete bodies (spheres, shreds, or cord segments) rather than a single continuous element. This segmentation allows each piece to expand independently with less resistance, reducing the total mechanical work required while maintaining the hydraulic closure function
Solution Approach 2:
The elastomer bodies are expanded radially outward from the wellbore center rather than elongating axially. This dimensional change from longitudinal to radial expansion reduces the mechanical work required by utilizing the natural elasticity of the elastomer in a more efficient direction
2Reliability
If radially expandable elastomer sealing elements are used, then well closure is achieved, but the types and compositions of elastomers are limited
Solution Approach 1:
The patent changes the physical state and configuration parameters of the elastomer from continuous to discrete segmented forms. This parameter change allows a wider range of elastomeric materials to be used, including those with varying durometers, compositions, and elastic properties, since each discrete body can be independently selected to match specific well conditions
Solution Approach 2:
The elastomer bodies are designed to dynamically transform from a compact configuration during insertion to an expanded configuration during sealing. This dynamic behavior allows different elastomer compositions to be used, as each material's unique elastic recovery characteristics can be exploited during the expansion phase to achieve reliable well closure
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 solution reduces the mechanical work needed for sealing, allowing a wider range of elastomeric materials and efficient sealing in wellbores or tubulars, facilitating deployment in complex well geometries.
Implementation Method 1
The elastomer is deformed as a result of radial expansion
Data Source
AI summary
A plugging tool, comprises a tool mandrel adapted to traverse an interior of a wellbore or well tubular. The mandrel has a seal section thereon, the seal section comprising longitudinally spaced apart extrusion barriers. The seal section comprises a mechanism to urge the extrusion barriers toward each other. At least one elastomer sealing element is disposed between the extrusion barriers and arranged to radially expand when the extrusion barriers are urged toward each other.