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<p>Sealing failure in packer rubber elements poses critical safety risks in oil/gas well operations. This study investigates leakage mechanisms in Y344-142 compression packers through an integrated computational-experimental approach. A novel bidirectional fluid-structure interaction (FSI) model was developed using the immersed boundary method, uniquely capturing dynamic leakage processes at fluid-rubber interfaces. Experimental validation under extreme conditions (180&#xa0;°C,113.12&#xa0;MPa) confirmed model accuracy with &lt; 15% deviation from pressure test data. Key findings reveal: (1) Maximum sustainable sealing pressure differential of 113.12&#xa0;MPa in field tests, correlating with 122.62&#xa0;MPa penetration pressure in simulations; (2) Parametric optimization showing dual-seal configurations increase leakage resistance by 38% versus single-element designs, while tripling elements only yield 12% additional gain at more cost escalation; (3) Critical length threshold of 92.4&#xa0;mm (vs. standard 84&#xa0;mm) enhancing sealing performance by 22% without compromising structural integrity. These quantitative insights establish design guidelines for next-generation packers, demonstrating 45% longer service life in validation trials compared to conventional configurations.</p>

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Study on seal leakage test and simulation analysis of packer at high temperature and high pressure

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年10月21日

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  • Gensheng Fei,
  • Xu Zheng,
  • Changqing Zhao

摘要

Sealing failure in packer rubber elements poses critical safety risks in oil/gas well operations. This study investigates leakage mechanisms in Y344-142 compression packers through an integrated computational-experimental approach. A novel bidirectional fluid-structure interaction (FSI) model was developed using the immersed boundary method, uniquely capturing dynamic leakage processes at fluid-rubber interfaces. Experimental validation under extreme conditions (180 °C,113.12 MPa) confirmed model accuracy with < 15% deviation from pressure test data. Key findings reveal: (1) Maximum sustainable sealing pressure differential of 113.12 MPa in field tests, correlating with 122.62 MPa penetration pressure in simulations; (2) Parametric optimization showing dual-seal configurations increase leakage resistance by 38% versus single-element designs, while tripling elements only yield 12% additional gain at more cost escalation; (3) Critical length threshold of 92.4 mm (vs. standard 84 mm) enhancing sealing performance by 22% without compromising structural integrity. These quantitative insights establish design guidelines for next-generation packers, demonstrating 45% longer service life in validation trials compared to conventional configurations.