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

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.