Improvement of leak tightness for swellable elastomeric seals through the shape optimization

Swellable packers have been widely employed in various oil & gas applications. Downhole conditions are difficult to reproduce using physical testing environments, but can be simulated in a virtual environment using CAE software. A better understanding of packers’ mechanical behaviour in downhole conditions would provide a higher confidence and improvement in existing engineering design practices for the manufacturing of packers. The numerical simulation can be incorporated into optimisation procedures searching for an optimal shape of packers aiming to minimise the time to seal the borehole and maximise the contact pressure between the seal and borehole. Such an optimisation would facilitate the development of a packer with various designs optimised for different downhole conditions. The objective of this work is to develop a design tool integrated into Abaqus/CAE to implement parametric numerical studies using implicit and explicit FE-simulations. However, development of such a CAE plugin is associated with a number of technical challenges specific to this class of multiphysics problems, which are addressed in this research and discussed in the paper.