The present disclosure relates to a packer apparatus for engaging a surface of a wellbore or wellbore casing to create an annular seal or deform the wellbore casing, and relates particularly, but not exclusively to a workstring comprising a packer apparatus.
In hydrocarbon production, packer apparatuses are used to create annular seals in open wellbores or wellbore casing to isolate sections of the wellbore. This can be particularly useful in hydraulic fracturing operations where compartmentalised zones of a wellbore are individually stimulated to produce hydrocarbons.
The use of packers to isolate sections of wellbore can also be useful for example when abandoning wellbores to ensure that the sections of the wellbore are sealed to prevent leakage of hydrocarbons and other chemicals. However, in some wellbore environments, a combination of dissolved corrosive chemicals such as carbon dioxide, hydrogen sulphide and oxygen as well as high temperatures can corrode and damage packer elements leading to seal failures.
Preferred embodiments of the present disclosure seek to overcome the above disadvantages of the prior art.
According to an aspect of the present disclosure, there is provided a packer apparatus for engaging a surface of a wellbore or wellbore casing to create an annular seal or deform the wellbore casing, the apparatus comprising:
a body configured to be disposed in a wellbore;
a deformable packer element disposed on the body, the deformable packer element comprising a deformable metallic outer cover; and
actuation apparatus configured to move relative to the body to deform said deformable packer element outwardly from the body to cause said deformable metallic outer cover to contact the surface of the wellbore or casing in which the apparatus is located;
wherein deactivation of the actuation apparatus causes the deformable packer element and deformable metallic outer cover to return to a retracted condition.
By providing a deformable packer element comprising a deformable metallic outer cover, this provides the advantage that the element that is used to create a seal in the wellbore is resistant to corrosion from dissolved chemicals such as carbon dioxide and hydrogen sulphide, particularly when operating in high temperature wellbore environments.
This also provides the advantage that the deformable metallic outer cover has been found to be effective in deforming wellbore casing if the deforming force is sufficient, whereas elastomeric elements due to their elasticity are less effective in such circumstances.
The feature that deactivation of the actuation apparatus causes the deformable packer element to return to a retracted condition provides the advantage that the packer can be reused multiple times and moved along the wellbore to seal at different points or deform casing at different points.
Said deformable packer element may comprise a chamber configured to contain fluid, such that when the actuation apparatus is activated, said fluid is pressurised to deform said deformable metallic outer cover outwardly.
This provides the advantage that the fluid conforms to the inner shape of the deformable metallic outer cover to efficiently transfer force from the actuation apparatus to the deformable metallic outer cover during deployment of the deformable packer element.
The apparatus may further comprise at least one floating piston disposed at an end of said chamber, wherein said actuation apparatus is configured to move said floating piston to pressurise said fluid disposed in the chamber.
This provides the advantage of a means of sealing the deformable packer element to prevent ingress of contaminants from the wellbore environment.
Said fluid may be compressible such that such that when the actuation apparatus is deactivated, said fluid expands to return the deformable packer element to a retracted condition.
This provides the advantage of a means for ensuring that the deformable packer element returns to a retracted condition subsequent to deactivation of the actuation apparatus.
Said fluid may be incompressible and said deformable packer element may further comprise a return spring or elastomeric element disposed in said chamber such that deactivation of the actuation apparatus causes the return spring or elastomeric element to expand to return the deformable packer element to a retracted condition.
This provides the advantage of a means for ensuring that the deformable packer element returns to a retracted condition subsequent to deactivation of the actuation apparatus.
Said deformable packer element further comprises an elastomeric element such that when the actuation apparatus is activated, said elastomeric deforms said deformable metallic outer cover outwardly, and when said actuation apparatus is deactivated, said elastomeric element expands to return the deformable packer element to a retracted condition.
This provides the advantage of a means for ensuring that the deformable packer element returns to a retracted condition subsequent to deactivation of the actuation apparatus.
Said elastomeric element may be disposed in a chamber having a floating piston disposed at an end of said chamber, and wherein said actuation apparatus is configured to move said floating piston to compress said elastomeric element disposed in the chamber.
This provides the advantage of a means of sealing the deformable packer element to prevent ingress of contaminants from the wellbore environment.
The apparatus may further comprise fluid disposed in said chamber.
In a preferred embodiment, the deformable packer element is rotatably mounted on said body.
This provides the advantage of preventing the workstring becoming stuck in the wellbore. It is generally easier to move a workstring in a wellbore when the workstring is rotating. However, packer elements whether deployed or retracted can engage the wellbore inadvertently (or the casing) to cause drag. By therefore mounting the deformable packer elements rotatably on the body, this reduces the friction during the workstring movement.
In a preferred embodiment, said actuation apparatus comprises a plurality of hydraulic cylinders configured to compress said deformable packer element in response to an increase in fluid pressure in each of said hydraulic cylinders.
This provides the advantage of a modular assembly which enables an operator to choose the amount of hydraulic pressure available to suit particular wellbore conditions and therefore the force that can be applied by the deformable packer elements to form a seal or cause casing expansion. By increasing the number of hydraulic cylinders in the apparatus, the force available can be correspondingly increased.
In a preferred embodiment, said actuation apparatus further comprises at least one mandrel element at least partially defining a longitudinal bore of the apparatus, said at least one hydraulic cylinder slidably disposed on said at least one mandrel element and being in fluid communication with said longitudinal bore.
This provides the advantage of a compact configuration which enables multiple hydraulic cylinders to be assembled in the apparatus.
The apparatus may further comprise a locking apparatus configured to prevent said at least one hydraulic cylinder moving relative to said at least one mandrel element, the locking apparatus comprising:
at least one shear pin configured to prevent relative movement between said at least one hydraulic cylinder and said at least one mandrel element; and
a restriction disposed in said longitudinal bore for engaging a ball or dart dropped into the longitudinal bore to block the longitudinal bore to enable fluid pressure to increase to shear said at least one shear pin and enable relative movement between said at least one hydraulic cylinder and said at least one mandrel element.
This provides the advantage that the apparatus can be incorporated into a workstring having secondary functions. For example, a hydraulically operated perforating tool might be incorporated into the workstring to enable casing to be perforated to conduct hydraulic fracturing. However, a situation is to be avoided whereby an increase in fluid pressure operates the deformable packer elements at the same time as the perforating tool. By therefore providing a locking apparatus comprising a restriction that is blocked by either a ball or a dart, the packer apparatus can be prevented from deploying until such time as the ball or dart is dropped.
Said body portion may at least partially define a longitudinal bore of the apparatus, and wherein the apparatus further comprises at least one valve assembly disposed in said longitudinal bore, said at least one valve assembly configured to permit fluid to enter said longitudinal bore when the apparatus is moved into a wellbore containing fluid.
In some circumstances, it is desirable to have the deformable packer elements in very close tolerance with the surface of the wellbore or the casing in which the apparatus is operating. However, this creates a problem during workstring deployment because the wellbore is likely to be full of fluid. This fluid therefore requires a path to be displaced when the workstring moves into the fluid which is advantageously provided by enabling the wellbore fluid to pass through the longitudinal bore of the apparatus. The valve assembly therefore ensures that the wellbore can be sealed to enable a pressure increase to deploy the deformable packer elements when the workstring is in place.
Said at least one valve assembly may be configured to close when fluid is pumped into the longitudinal bore to enable fluid pressure to increase in the apparatus.
This provides the advantage of enabling fluid pressure to increase in the apparatus after deployment of the workstring.
According to another aspect of the present disclosure, there is provided a workstring comprising:
a first packer apparatus according to any one of the preceding claims;
a second packer apparatus according to any one of the preceding claims; and
a ported sub comprising ports, the ported sub connected between said first and second packer apparatuses.
This provides the advantage of a straddle packer assembly with a ported sub between packers to create a pressure differential to actuate the packers and isolate a section of wellbore to enable fluid to fracture the formation.
Preferred embodiments of the present disclosure will now be described, by way of example only and not in any limitative sense, with reference to the accompanying drawings in which:
Referring to
An actuation apparatus 10 is configured to move relative to the body 4 to deform said deformable packer element 6 outwardly from the body 4 (
Depending on the alloy used to form the deformable metallic outer cover 8, after deactivation of the actuation means, the deformable metallic outer cover might not completely return to the undeformed state of
The actuation apparatus 10 comprises a plurality of hydraulic cylinders 12 disposed on mandrel elements 14 which define a longitudinal bore 16 of the packer apparatus 2. A plurality of internal ports 18 enables fluid communication between the longitudinal bore 16 and the hydraulic cylinders 12. Each hydraulic cylinder 12 comprises a piston element 20, a housing portion 22 and an annular port 24 on one side of the piston element 20 opposite to the hydraulic cylinder to provide fluid communication with the outside of the packer apparatus 2. When hydraulic fluid pressure increases in longitudinal bore 16, fluid pressure is communication through internal ports 18 to hydraulic chambers 12 to increase fluid pressure in the hydraulic chambers 12. This creates a pressure differential to the volume on the opposite side of piston elements 20 which if sufficient pushes actuation apparatus 10 and causes annular fluid to vent through annular ports 24 to enable the actuation apparatus 10 to move to compress the deformable packer element 6.
Deformable packer element 6 comprises a deformable metallic outer cover 8 defining a chamber 30. A floating piston 32 closes off chamber 30 which is filled with fluid which might for example be oil or water. Movement of actuation apparatus 10 from the position of
The deformable packer element 6 is rotatably mounted on body 4 by means of ball bearings 36. Referring to
A return spring 34 is mounted in the chamber 30 such that when the actuation apparatus is deactivated, the deformable packer element 6 is returned to a retracted condition. Deactivation of the actuation apparatus 10 is accomplished by the operator reducing fluid pressure in longitudinal bore 16 to equalise with the outside annulus such that there is no pressure differential between hydraulic chambers 12 and the annulus outside of the apparatus 2.
Instead of a return spring 34, another biasing means such as an elastomeric element could be used. If the fluid in chamber 30 is an incompressible fluid such as water or an incompressible oil, the return spring 34 (or other biasing means) is required to ensure that the deformable packer element returns to a retracted condition after use. However, if the chamber 30 is filled with a compressible fluid such as a compressible oil, the natural resilience of the compressible fluid will be sufficient to expand after the actuation apparatus 10 is deactivated to return the deformable packer element to a retracted condition after use for redeployment at a different position along the wellbore. It should also be noted that the packer apparatus 2 will generally be operated in a workstring by locating the packer apparatus at the farthest point along a wellbore from the surface for an initial sealing operation. Once that sealing operation has been completed, the workstring is pulled to the next point along the wellbore for sealing. The action of pulling the packer apparatus also aids in returning the deformable packer element 106 and therefore the deformable metallic outer cover to a retracted condition.
In some circumstances, it is desirable to have the deformable packer element 6 very close to the surface of the casing or the wellbore on which the apparatus 2 is disposed. However, this creates a problem that the fluid already in the wellbore or casing must be displaced to enable the workstring containing the packer apparatus 2 to be moved into the wellbore. Moving a close tolerance workstring into a fluid filled wellbore can cause a fluid surge leading to an uncontrolled release of fluid at the surface. For this reason, a first valve 40 comprising a spring-loaded ball 42 is mounted in longitudinal bore 16. When the apparatus 2 is moved into a wellbore containing fluid, the fluid pushes ball 42 against spring 44 to enable a fluid path up through longitudinal bore 16.
A second valve assembly 50 comprises a spring-loaded sleeve 52 having internal ports 54 configured to align with external ports 56 formed through the body portion 4 when ball 58 pushes the sleeve 52 against the force of spring 60. This creates a second fluid path to allow wellbore fluid to move. When the operator wishes to pressure up the apparatus 2 to deploy the deformable packer elements 6, fluid pumped from the surface pushes the balls 42 and 58 back to the positions shown in
Operation of the packer apparatus 2 to form a seal in a wellbore or wellbore casing will now be described. Referring to
When the seal formed by expanded deformable metallic outer cover 8 is no longer required, fluid pressure is reduced in the longitudinal bore 16 which enables return spring 34 to push the floating piston 32 and actuation apparatus 10 back along the tool to the condition of
Referring to
When a portion of the formation through which the wellbore is drilled is to be stimulated in hydraulic fracturing by pumping fracturing fluid into the formation, the operator increases the fluid pressure in longitudinal bore 16 to deploy the deformable packer elements and deformable metallic outer covers 8 to form two annular seals which creates an isolated section of wellbore containing the ported sub 60. This enables fluid being pumped through ports 62 to be contained in a volume between the seals formed by the deformable metallic outer covers 8 to increase pressure sufficiently to cause hydraulic fracturing.
An alternative use for the packer apparatus 2 will be described in reference to
Packer apparatus 2 is located at a position at which such an annular seal is required. An elastomeric sleeve 76 has been mounted on the casing 72 but this is not always required, and the following procedure can be also conducted on steel casing 72 without any form of elastomeric or other sleeve. The actuation apparatus 10 is then operated in the manner described above to pressurise hydraulic chambers 12 and compress the deformable packer element 6 to push the deformable metallic outer cover 8 against the casing 72. If sufficient force is applied, steel casing 72 deforms past its elastic limit to form a permanent deformed portion of casing and therefore a seal 78 compressing the elastomeric sleeve 76 against the surface of wellbore 70. The packer apparatus can then be deactivated leaving the seal 78 in place and the packer apparatus to move to a different point in the casing 72 to form another seal.
Referring to
If a packer apparatus 2 is mounted in such a workstring, it is desirable to prevent the deformable packer element 6 from deploying to create unwanted seals. A locking mechanism 80 is therefore provided to hold the actuation apparatus 10 static when the pressure is changed in longitudinal bore 16. Locking mechanism 80 comprises at least one sheer pin 82 which projects through the body into an internal sleeve 84 which comprises a restriction 86 for catching a deformable ball 92 or a dart. A recessed portion 88 is formed in sleeve 84 for holding keys 90. Keys 90 increase the force required to release the locking mechanism 80.
In the configuration of
A packer apparatus 102 of a second embodiment of the invention is shown in
Packer apparatus 102 comprises actuation apparatus 110 and hydraulic cylinders 112 and other pressure operated components that operate in exactly the same way as the embodiment of
Once the actuation apparatus 110 is deactivated, the resilience of the deformable elastomeric element 109 pushes back against the actuation apparatus 110 to return the deformable packer elements 106 and therefore deformable metallic outer cover 108 to a retracted.
A packer apparatus 202 of a third embodiment of the invention is shown in
In this embodiment, packer apparatus 202 comprises a deformable packer element 206 having a deformable metallic cover 208 under which deformable elastomeric element 209 is disposed in common with the embodiment of
The difference between the embodiment of
In all embodiments, the deformable metallic outer cover 8, 108 and 208 has been found to effectively form seals and be able to deform wellbore casing in corrosive environments whilst prevent corrosion and protecting other components of the packer apparatus.
It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the invention as defined by the appended claims.
Number | Date | Country | Kind |
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2103681.9 | Mar 2021 | GB | national |