The present application is a U.S. National Stage patent application of International Patent Application No. PCT/US2015/031402, filed on May 18, 2015, the benefit of which is claimed and the disclosure of which is incorporated herein by reference in its entirety.
The present disclosure relates generally to operations performed and equipment used in conjunction with a subterranean well, such as a well for recovery of oil, gas, or minerals. More particularly, the disclosure relates to reusable expandable seals for downhole applications.
In the course of drilling, completing, or servicing a subterranean well for hydrocarbon production, one or more seals, or packers, may be installed in the wellbore to isolate one zone from another. A seal may be run into a wellbore via wireline, slick line, coiled tubing, drill string, or another conveyance, and then radially expanded into sealing engagement with the interior surface of a casing, liner, or other tubular member.
Expandable seals must be able to operate against increasingly higher pressures and axial forces. Differential pressures across a seal may reach up to 15,000 psi.
Resilient materials such as rubber, which can readily be axially compressed to cause their diameters to expand, tend to have very low pressure holding capabilities due to the tendency of the resilient material to axially extrude into an extrusion gap under a differential pressure. These types of sealing mechanisms usually require structural extrusion limiters to reduce the extrusion gap. Moreover, resusable resilient seals may become subject to damaged sealing surfaces, referred to as nibbling, in which small edge portions of the sealing element become detached over repeated uses.
Recently, dissolving frac plugs have been commercialized. Currently dissolving elastomeric elements used on dissolving frac plugs tend to dissolve too slowly at temperatures below 200 F. Metallic dissolving materials dissolve more quickly below 200 F. In dissolving frac plug applications, the use of metallic seal made from the dissolving metal alloys may improve full dissolution of the frac plug below 200 F. The dissolving metallic alloys also dissolve into solution and do not reform at cooler temperatures. Currently dissolving rubber or rubber-like elements do not completely dissolve into solution; rather they flake apart into particles and chunks. Certain types may also break down to consistency of low torque grease or syrup, and in some cases these types of materials can reform as solids at the cooler temperatures that occur near the surface of the wellbore. Particles, chunks, low torque grease, syrup, or reformed solid chunks flowing through wellhead or surface equipment may create restrictions and clogs. The dissolving metallic alloys reduce this risk, because they dissolve more fully into solution.
A metallic circular seal may also be radially expanded to form a seal, which may be operable under a higher differential pressure than a resilient member and less prone to nibbling effects. However, the expansion process to a larger diameter introduces internal stresses in the sealing element. The outer diameter fibers of the seal will require a growth in length, which creates geometry and stress challenges when using metallic materials. Such stresses may cause a metallic seal to become plastically deformed and therefore not able to retract when desired. Accordingly, when designing a seal, materials and/or geometries that allow high expansion with acceptable stresses tend to sacrifice the strength and pressure holding capabilities.
For many oil and gas applications, a perfect seal is not required. A metallic circular seal that is radially expanded may prevent majority of flow and meet the application needs. In many applications, the fluid media itself may bridge seal imperfections, and in doing so, provide a full seal. For example, many hydraulic fracturing applications include sand in the fluid media. Sand and gel-like fluids used in the hydraulic fracturing media are known to bridge and block seal imperfections.
Embodiments are described in detail hereinafter with reference to the accompanying figures, in which:
The present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” “uphole,” “downhole,” “upstream,” “downstream,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the apparatus in use or operation in addition to the orientation depicted in the figures.
Wireline tool 12 may have a protective shell or housing which may be fluid tight and pressure resistant to enable the equipment within the interior to be supported and protected during deployment. Wireline tool 12 may enclose one or more sealing tools 100, as described hereinafter. However, other types of tools, including logging tools, fishing tools, perforating tools, coring tools, and testing tools may be also used.
Wireline tool 12 may also enclose a power supply 15 and a computer or processor system 16. Output data streams of one or more detectors may be provided to a communications module 17 having an uplink communication device, a downlink communication device, a data transmitter, and a data receiver, for example.
One or more electrical wires in wireline cable 11 may be connected with surface-located equipment, which may include a power source 27 to provide power to tool power supply 15, a surface communication module 28 having an uplink communication device, a downlink communication device, a data transmitter and also a data receiver, a surface computer 29, a display 31, and one or more recording devices 32. Sheave 25 may be connected by a suitable sensor to an input of surface computer 29 to provide depth measuring information.
One or more pumps 48 may be used to pump drilling fluid 46 from fluid reservoir or pit 30 via conduit 34 to the uphole end of drill string 32 extending from well head 24. Annulus 66 is formed between the exterior of drill string 32 and the inside diameter of wellbore 13. The downhole end of drill string 32 may carry one or more downhole tools 90, which may include one or more sealing tools 100, as described hereinafter. Further, a bottom hole assembly, mud motor, drill bit, perforating gun, fishing tool, sampler, sub, stabilizer, drill collar, tractor, telemetry device, logging device, or any other suitable tool(s) (not expressly illustrated) may be carried by drill string 32. Drilling fluid 46 may flow through a longitudinal bore (not expressly shown) of drill string 32 and exit into wellbore annulus 66 via one or more ports. Conduit 36 may be used to return drilling fluid, reservoir fluids, formation cuttings and/or downhole debris from wellbore annulus 66 to fluid reservoir or pit 30. Various types of screens, filters and/or centrifuges (not expressly shown) may be provided to remove formation cuttings and other downhole debris prior to returning drilling fluid to pit 30.
Referring to
In one or more embodiments, ring assembly 130 is coaxially carried about a base 102. Base 102 may have a region 103 of a reduced outer diameter that is slightly smaller than the inner diameter ring assembly 130. Base 102 may also include a region 104 of greater outer diameter. The intersection of regions 103 and 104 may either define uphole shoulder 110 or downhole shoulder 112. A sleeve 108 may also be coaxially carried about a portion of base 102. Sleeve 108 is arranged to be axially movable with respect to base 102. Sleeve 108 may either define uphole shoulder 110 or downhole shoulder 112, whichever is not defined by base 102. In
An actuator assembly 115 may be provided to axially move sleeve 108 with respect to base 102, thereby selectively controlling the distance between uphole shoulder 110 and downhole shoulder 112. In one or more embodiments, sleeve 108 may act as a piston that slides within a cylinder 116 formed within actuator assembly 115. A volume of hydraulic fluid within cylinder 116 may be selectively controlled by actuator assembly 115 to move sleeve 108 and thereby axially compress ring assembly 130. Though a hydraulic actuator assembly 115 is illustrated and described herein, a routineer may recognize that any suitable actuator assembly may be used, including lead screw actuators, rack and pinion actuators, solenoids, and the like. Moreover, sleeve 108 may remain stationary with respect to actuator assembly 115, and actuator assembly 115 may be operable to move base 102 with respect to sleeve 108.
According to one or more embodiments, ring 132 may include a first plurality of slits 170 radially formed through ring 132 about outer surface 150. Ring 132 may also include a second plurality of slits 172 formed through ring 132 about outer surface 150. Slits 172 may be circumferentially intervaled, or alternated, with slits 170. More particularly, the first plurality of slits 170 may be positioned toward uphole end 160 of ring 132, and the second plurality of slits 172 may be positioned toward downhole end 162 of ring 132. Even more particularly still, the first plurality of slits 170 may be positioned at least partially between convexity 151 and uphole end 160, and the second plurality of slits 172 may be positioned at least partially between convexity 151 and downhole end 162. Slits 170, 172 may extend beyond convexity 151.
Ring 132 may be made of steel, spring steel, titanium, or any other suitable metal. Gasket 134 may be made of an elastomeric material such as rubber, a polymer, or any other suitable gasket material. Ring 132 and gasket 134 may be separately formed, and gasket 134 may thereafter be inserted into inner surface 152 (i.e., concavity 153) of ring 132. Alternatively, gasket 134 may be directly molded into inner surface 152 (i.e., concavity 153) of ring 132. Slits 170, 172 may, but need not be, filled with a resilient material, such as rubber. The force generated during axial compression and radial expansion of gasket 134 during sealing operations may potentially fill Slits 170, 172 with gasket material.
Slits 170, 172 formed within metallic ring 132 enable diameter expansion (i.e., outer diameter fiber elongation) while minimizing stresses. In particular, because the widths of slits 170, 172 increase during radial expansion of ring 132, slits 170, 172 provide a scheme to reduce expansion stresses, thereby enabling the outer metallic fibers of ring 132 elongate without plastic deformation. Alternating slits 170 and 172 may reduce the tendency for gasket 134 material to extrude into slits 170, 172 during radial expansion.
Ring 132 may have any suitable unexpanded outer diameter for sealing against interior 120 of tubular member 119 (
To provide a numeric example, metallic ring 132 may have a retracted outer diameter of 3.45 inches and an expanded outer diameter of 3.70 inches. The circumference of ring 132 is 10.83 inches when unexpanded and 11.62 inches. when expanded. Thus, the outer fiber material length of ring 132 will increase by 0.79 inches during expansion. If first and second alternating pluralities of slits 170, 172 are provided, each with sixteen slits, there will be thirty-two slits in the outer most fibers. Accordingly, each slit width will increase at the outer fibers by 0.024 inches. If the widths of slits 170, 172 are 0.015 inches in the unexpanded state, in the expanded state the widths will be 0.039 inches.
In one or more embodiments, metallic ring 132 may provide a metal-to-metal seal against interior surface 120 of tubular member 119 (
As best seen in
Stiffener 180 may be made of steel, titanium, or a another suitable metal. Because stiffener replaces a volume of resilient gasket 134′ with rigid material, stiffener 180 provides greater support of ring assembly 130′ in the expanded diameter state. Stiffener 180 provides more structure and support, which aids in supporting gasket 134′ and thereby enables sealing against higher pressure loads. Metal stiffener 180 also aids in supporting tensile loads created when a seal is formed and pressure is applied, may promote radial retraction of ring 132 and gasket 134′ to original diameters, and may facilitate multiple reuse of ring 132 without redressing.
As described hereinabove, sealing method 200 and sealing apparatus 100 with ring assembly 130, 130′ allows for repeated sealing and unsealing operations under high differential pressures. Because ring 132 is metallic, sealing apparatus 100 is not prone to extrusion failure or nibbling. No extrusion limiter is required. Internal stresses within ring 132 are minimized by slits 170, 172, thereby preventing plastic deformation and enabling retraction and reuse.
In summary, an apparatus and method for sealing against an interior surface of a cylindrical tubular member have been described. Embodiments of an apparatus for sealing against an interior surface of a cylindrical tubular member may generally have: A metallic ring defining an axis, an uphole end, a downhole end, an inner circumferential surface, and an outer circumferential surface, the ring characterized by a uniform axial cross-sectional profile having an outward-facing convexity and an inward-facing concavity; a first plurality of slits radially formed through the ring about the outer surface; a circular resilient gasket at least partially coaxially disposed within the concavity; an uphole shoulder abutting the uphole end of the ring; and a downhole shoulder abutting the downhole end of the ring and axially movable with respect to the uphole shoulder so as to selectively axially compress and radially expand the ring. Embodiments of a method for sealing against an interior surface of a cylindrical tubular member may generally include: Providing an apparatus including a metallic ring characterized by a uniform axial cross-sectional profile with an outward-facing convexity and an inward-facing concavity, a first plurality of slits radially formed through the ring about an outer surface of the ring, and a circular resilient gasket at least partially coaxially disposed within the concavity; disposing the apparatus within the tubular member; and selectively axially compressing an uphole end of the ring with respect to a downhole end of the ring so as to radially expand the ring into sealing engagement with the interior surface of the tubular member.
Any of the foregoing embodiments may include any one of the following elements or characteristics, alone or in combination with each other: The first plurality of slits radially formed through the ring about the outer surface at least partially between the convexity and the uphole end; a second plurality of slits radially formed through the ring about the outer surface at least partially between the convexity and the downhole end; the second plurality of slits is circumferentially alternated between the first plurality of slits; a base coaxially disposed within the ring and forming one of the uphole shoulder and the downhole shoulder; a sleeve coaxially and axially movably carried by the base and forming the other of the uphole shoulder and the downhole shoulder; an actuator coupled between the uphole shoulder and the downhole shoulder; a circular stiffener at least partially coaxially disposed within the concavity, the resilient gasket sandwiched between the ring and the stiffener; the stiffener is characterized by a generally triangular axial cross-sectional profile; a resilient material filling the first plurality of slits; a resilient material filling the first and second pluralities of slits; a coating of resilient material formed about the outer surface; reducing stress within the ring during radial expansion of the ring by the first plurality of slits; radially forming the first plurality of slits through the ring about the outer surface at least partially between the convexity and the uphole end; radially forming a second plurality of slits through the ring about the outer surface at least partially between the convexity and the downhole end; circumferentially alternating the second plurality of slits between the first plurality of slits to reduce expansion of the circular gasket into the first and second pluralities of slits during radial expansion of the ring; coaxially carrying the ring about a base, the base forming one of an uphole shoulder disposed adjacent the uphole end of the ring and a downhole shoulder disposed adjacent the downhole end of the ring; coaxially carrying a sleeve about the base, the sleeve forming the other of the uphole shoulder and the downhole shoulder; selectively axially moving the sleeve with respect to the base to axially compress and radially expand the ring; selectively operating an actuator to axially compress and radially expand the ring; supporting the resilient gasket by a circular stiffener at least partially coaxially disposed within the concavity, the resilient gasket sandwiched between the ring and the stiffener; filling the first plurality of slits with a resilient material; coating the outer surface of the ring with a resilient material; and radially expand the ring to bring the resilient material into sealing engagement with the interior surface of the tubular member.
While various embodiments have been illustrated in detail, the disclosure is not limited to the embodiments shown. Modifications and adaptations of the above embodiments may occur to those skilled in the art. Such modifications and adaptations are in the spirit and scope of the disclosure.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/US2015/031402 | 5/18/2015 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2016/186643 | 11/24/2016 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
4444403 | Morris | Apr 1984 | A |
4482086 | Wagner | Nov 1984 | A |
4448740 | Baugh et al. | Dec 1984 | A |
5180008 | Aldridge | Jan 1993 | A |
5226492 | Solaeche | Jul 1993 | A |
5775429 | Arizmendi et al. | Jul 1998 | A |
5819846 | Bolt, Jr. | Oct 1998 | A |
5904354 | Collins | May 1999 | A |
6640893 | Rummel | Nov 2003 | B1 |
7497443 | Steinetz | Mar 2009 | B1 |
8113276 | Greenlee et al. | Feb 2012 | B2 |
8191625 | Porter et al. | Jun 2012 | B2 |
8336635 | Greenlee et al. | Dec 2012 | B2 |
8469087 | Gray | Jun 2013 | B2 |
8695695 | Moeller et al. | Apr 2014 | B2 |
8967301 | Curry | Mar 2015 | B2 |
9145755 | Farquhar | Sep 2015 | B2 |
20040031605 | Mickey | Feb 2004 | A1 |
20050217869 | Doane | Oct 2005 | A1 |
20050263296 | Moyes | Dec 2005 | A1 |
20060260820 | Whitsitt et al. | Nov 2006 | A1 |
20090242211 | Fagley, IV et al. | Oct 2009 | A1 |
20100019426 | Kunz | Jan 2010 | A1 |
20100148446 | Gaudette | Jun 2010 | A1 |
20100200218 | Palidwar et al. | Aug 2010 | A1 |
20100206571 | Tunc et al. | Aug 2010 | A1 |
20100276137 | Nutley et al. | Nov 2010 | A1 |
20110193291 | Schilte | Aug 2011 | A1 |
20130087334 | Buytaert et al. | Apr 2013 | A1 |
20130147121 | Xu | Jun 2013 | A1 |
20140202708 | Jacob et al. | Jul 2014 | A1 |
20160208577 | Byberg | Jul 2016 | A1 |
Number | Date | Country |
---|---|---|
2357098 | Jun 2001 | GB |
2426022 | Nov 2006 | GB |
2472287 | Feb 2011 | GB |
2474599 | Apr 2011 | GB |
WO 2007131134 | Nov 2007 | WO |
Entry |
---|
Intellectual Property Office of Singapore, Application No. 11201708385U, Search Report and Written Opinion, dated Nov. 21, 2018, 9 pages Singapore. |
Office Action and Search Report issued for Danish Patent Application No. PA201770779 dated May 9, 2018, 8, pages. |
International Search Report and the Written Opinion of the International Search Authority, or the Declaration, dated Feb. 4, 2016, PCT/US2015/031402, 15 pages, ISA/KR. |
Number | Date | Country | |
---|---|---|---|
20180073323 A1 | Mar 2018 | US |