The present invention relates to an apparatus for sealing a well bore, particularly, but not exclusively, the present invention relates to a high temperature and/or expansion sealing apparatus.
In many downhole environments, packers or similar sealing devices are used to seal sections of the well bore so that, for example, hydrocarbons can be extracted from a well bore section into the production tube without leakage up or down the annulus between the well bore surface and the production tube.
Elastomeric seal elements are widely used in conventional packers as they are relatively easy to manipulate and have good sealing properties once engaged with a well bore surface. A conventional packer is also often provided with one or more seal back-ups to prevent extrusion of the elastomeric sealing element in the annulus when the sealing apparatus is under pressure.
However, the mechanical properties of elastomers can deteriorate as pressure and/or temperature increases. The performance of these conventional packers are also affected when, in addition to the high pressure and/or high temperature environment, the seal has to seal across a large annulus. These high expansion seals are particularly vulnerable in the aggressive environments described.
There is a desire within the oil industry to operate in high temperature and high pressure environments, and there is need for a sealing apparatus which can operate successfully in these environments, particularly a high expansion sealing apparatus.
According to a first aspect of the present invention there is provided a sealing apparatus for sealing a well bore, the sealing apparatus comprising:
a sealing element adapted to be moved from a run-in configuration to a set configuration;
a first back-up layer; and
at least one second back-up layer sandwiched between the sealing element and the first back-up layer, the first back-up layer and the at least one second back-up layer being adapted to be moved from the run-in configuration to the set configuration under the action of the sealing element;
wherein the at least one second back-up layer comprises a thinner material than the first back-up layer.
In one embodiment, providing a second back-up layer of a thinner material than the first back-up layer facilitates the expansion of the back-up system as the sealing element moves from the run-in configuration to the set configuration. This is of particular importance in environments in which sealing apparatus has to seal across a large annular gap. Furthermore, use of a thinner material which is easier to bend will result in a reduced level of stress being built up in the sealing element during deployment. This is advantageous because stress can have a detrimental effect on the mechanical properties of the element.
Preferably, the first and second back-up layers are annular.
Preferably, the first back-up layer comprises a slotted portion.
Preferably, the first back-up layer is slotted to form discrete petals. A back-up layer which is slotted to form “petals” can expand greater distances than a non-slotted layer and permits the material to expand without elongation. Furthermore, a slotted first back-up layer will expand more easily than a continuous layer resulting in lower stress levels in the sealing element. The second layer of the thinner material has further advantages with a slotted first back-up layer. As the first back-up layer expands, the slots open up and a thinner second back-up layer can form into the gaps between the first back-up layer petals to remove any clearances between the first and second back-up layers and any curvature mismatches between the first back-up layer and the bore wall. Removal of these clearances and mismatches is important, since the properties of some sealing elements, for example rubber elements, are very poor at very high temperatures, i.e. around 200° C. At this temperature, rubber can extrude through any clearances in the back-up layers or between the apparatus and the bore wall. The first back-up layer is the primary structural layer supporting the sealing element. The second back-up layer is provided to fill the gaps inbetween the petals of the first back-up layer and to resist extrusion of the sealing element, in use, between the apparatus and the well bore.
Preferably, the first back-up layer comprises a non-slotted portion.
Preferably, the first back-up layer comprises a deformable material.
In one embodiment the deformable material is ductile.
Preferably, in use, the first back-up layer, in the run-in configuration, is adapted to engage the bore wall. This permits the first back-up layer, in use, to be pinned to the well bore surface by friction once the sealing apparatus is set. This method of constraint removes any shear loading applied to the first back-up layer, which in turn allows for a thinner section to be used. A thinner section reduces the stress imparted into the sealing element as the sealing element moves into the set configuration, and once fully deployed.
Preferably, the first back-up layer comprises a bore engaging surface.
Preferably, in use, more than 50% of the bore engaging surface is, in use, engaged with the bore surface in the set configuration. Such an arrangement ensures that the axial load applied to the sealing element, in use, is not sufficient to overcome the radial load maintaining the sealing apparatus in contact with the bore wall.
Preferably, in use, more than 50% of the slotted portion surface is, in use, engaged with the bore surface in the set configuration.
Preferably, the bore engaging surface comprises relatively high friction co-efficient.
Preferably, the bore engaging surface defines a relatively high friction co-efficient surface profile.
Alternatively or additionally, the bore engaging surface comprises a coating of a relatively high friction coefficient material.
Preferably, the/each second back-up layer is a ductile material. Providing a ductile layer, which can form and adapt in shape, minimises the stress imparted to the seal element as the seal apparatus sets and is adapted to mould, when used with a slotted first back-up layer, into gaps between adjacent first back-up layer petals.
Preferably, the ductile material is stainless steel.
In one embodiment, the/each second back-up layer comprises a plurality of back-up layers.
Preferably, the first back-up layer has an upper edge.
Preferably, the first back-up layer upper edge is chamfered.
Preferably, the upper edge, in use, is chamfered towards the bore wall. A chamfered edge will more easily deform into a close engagement with the bore wall reducing the possibility of clearances between the first back-up layer and the bore wall opening up.
Preferably, where the first back-up layer defines discrete petals, each petal has side edges. By side edges it is meant edges which lie in a direction parallel to the longitudinal axis of the sealing apparatus.
Preferably, the side edges are chamfered.
Preferably, the side edges are, in use, chamfered towards the bore wall.
Preferably, the at least one second back-up layer has an upper edge.
Preferably, the at least one second back-up layer upper edge is chamfered.
Preferably, the at least one second back-up layer upper edge extends above the first back-up layer upper edge. As the second back-up layer is of a thinner material to the first back-up layer, the/each second back-up layer will more easily deform into engagement with the well bore surface, in use, closing any clearances between the apparatus and the well bore and to remove any mismatches between the apparatus and the bore internal diameter. The removal of clearances is important as, at high temperatures, sealing elements made of elastomeric materials can extrude through the clearances.
In an alternative embodiment, the first back-up layer upper edge extends above the at least one second back-up layer upper edge. As the side edges are less exposed than the upper edge, it is possible to make the edge of the side edge chamfers sharper as they are not as exposed as the upper edge. A sharp edge can form a tighter fit with the at least one second back-up layer minimising the possibility of clearances between the first back-up layer and the bore wall opening up.
Preferably, each of the plurality of second back-up layers comprises a slotted portion. Having slotted second back-up layers also provides for additional expansion. If the back-up layers are slotted, the provision of multiple second layer will ensure that gaps between the adjacent petals of the first back-up layer are filled.
In one embodiment, each of the second back-up layers comprises fewer slots than the first back-up layer.
Preferably, at least one second back-up layer has a sealing element engaging surface.
Preferably the/each sealing element engaging surface comprises a low friction coating. A low friction coating reduces the stresses imparted into the element material during deployment and under pressure.
Preferably, the first and second back-up layers deform under the action of the sealing element.
In one embodiment, the back-up layers plastically deform. Plastic deformation reduces the stresses imparted to the sealing element by the back-up layers once the sealing apparatus is set.
In an alternative embodiment, the back-up layers elastically deform. Elastic deformation allows the back-up layers to at least partially recover to the run-in configuration when it is desired to retrieve the sealing apparatus.
In one embodiment a first back-up layer upper portion is bent inwards towards a sealing apparatus longitudinal axis. Having the upper portion of the first back-up layer facing radially inwards, biases the first back-up layer to a run in configuration such that the first back-up layer at least partially recovers to the run-in configuration when it is desired to retrieve the sealing apparatus. Such an arrangement is most effective in an apparatus in which the first back-up layer upper edge extends above the at least one second back-up layer upper edges.
Preferably, the sealing apparatus further comprises a ring member.
Preferably, the ring member is attached to a lower portion of the first back-up layer. A ring member is provided to withstand the hoop stress imparted to the back-up layers by the differential pressure held by the sealing element.
Preferably, the ring member is separate to the first and second back-up layers. The use of a separate ring member to the first and second back-up layers means that the back-up layers can be of substantially constant cross-sections. The use of a constant cross-section material, particularly for the first back-up layer, helps reduce stress concentrations in the first back-up layer and enables a relatively thin section to be used. A thin section will bend more easily and will reduce the stress imparted into the sealing element.
Preferably, the first back-up layer lower portion is received within the ring member.
Preferably, the ring member is attached to the non-slotted portion of the first back-up layer.
Preferably, the interface between the slotted and non-slotted portions of the first back-up layer is received within the ring member.
Preferably, the ring member is connected to an external surface of the first back-up layer lower portion.
Preferably, the/each second back-up layer is connected to the ring member.
Preferably, the ring member defines a profiled surface.
Preferably, as the sealing apparatus moves from the run-in configuration to the set configuration, the first back-up layer bends around at least a portion of the profiled surface.
In one embodiment, at least a portion of the first back-up layer, in the run-in configuration is displaced from the ring member profiled surface.
Preferably, in this embodiment, the ring member profiled surface tapers axially away from the first back-up layer in the run-in configuration.
In one embodiment the first back-up layer comprises spring steel. Spring steel can be used to assist in returning the sealing apparatus to the run-in configuration when it is desired to recover the sealing apparatus from downhole.
The sealing element may comprise a packing element, a cup, an expandable element, a swellable element, an inflatable element or any suitable style of element.
Preferably, in the run-in configuration, the maximum diameter defined by the back-up layers is no more than the maximum diameter defined by the ring member.
Preferably, the sealing apparatus further comprises an intermediate layer between the first back-up layer and the/each second back-up layer.
Preferably the intermediate layer extends above and below a first back-up layer upper edge.
Preferably the intermediate layer comprises a strong flexible material.
Most preferably the intermediate layer comprises a woven steel mesh. Using a flexible layer such as a woven steel mesh further minimises the existence of gaps between the first and second back-up layers in the set configuration. The flexible material fills up any gaps which may exist between the first and second back up layers.
Preferably the intermediate layer is thinner than either or any of the first and second back-up layers.
In one embodiment the intermediate layer wraps over an upper edge of the/each second back-up layer.
In an alternative embodiment the intermediate layer wraps over the upper edge of the first back up layer.
According to a second aspect of the present invention, there is a sealing apparatus for sealing a well bore, the sealing apparatus comprising:
a seal element adapted to move from a run-in configuration to a set configuration;
at least one back-up layer, the/each back-up layer being adapted to be moved from the run-in configuration to the set configuration under the action of the sealing element; and
a ring member;
wherein a portion of the/each back-up layer is received inside the ring member, the ring member and/each back-up layer being separate components.
Preferably, at least one of said back-up layers is of substantially constant cross-section.
According to a third aspect of the present invention, there is provided a sealing apparatus for sealing a well bore, the sealing apparatus comprising:
a seal element adapted to be moved from a run-in configuration to a set configuration; and
at least one back-up layer, the/each back-up layer being adapted to be moved from the run-in configuration to the set configuration under the action of the sealing element;
wherein at least one of said back-up layers comprises a resilient material, said resilient material being biased to the run-in configuration.
According to a fourth aspect of the present invention there is provided a sealing apparatus for sealing a well bore, the sealing apparatus comprising:
a sealing element adapted to be moved from a run in configuration to a set configuration;
a first back-up layer;
at least one second back-up layer located between the sealing element and the first back-up layer, and
an intermediate layer sandwiched between the first back-up layer and the at least one second back-up layer, the first back-up layer, the intermediate layer and at least one second back-up layer being adapted to be moved from the run-in configuration to the set configuration under the action of the sealing element.
It will be understood that features of one aspect may be equally applicable to the other aspects and are not listed for brevity.
Embodiments of the present invention will now be described with reference to the accompanying drawings in which:
Reference is firstly made to
The sealing apparatus 10 comprises a sealing element 12 (only shown in
The second back-up layer 16 is pressed from annealed stainless steel sheet and is 0.5 mm thick. This is considerably thinner than the first back-up layer 14 which is machined from solid bar to a wall thickness of 2 mm. The thinness of the second back-up layer 16 facilitates the expansion of the back-up layers 14,16 as the sealing element 12 moves from the run-in configuration to the set configuration.
As can be seen from
Referring particularly to
As can be seen from
The ring member 20 is provided as a separate component to the back-up layers 14,16. During assembly the back-up layers 14,16 are slid inside the ring member 20. The seal element 12 is bonded to the ring member 20, trapping the back-up layers between the sealing element 12 and the ring member 20.
The ring member 20 defines a profiled surface 40 which the back-up layers 14,16 bend around under the action of the sealing element 12 as the sealing apparatus 10 moves from the set configuration to the run-in configuration. As will be clear from
Referring now to
As can be seen from
Reference is now made to
In the second embodiment, the sealing apparatus 110 comprises two back-up layers 116a,116b. Each second back-up layer 116a,116b is pressed from annealed stainless steel sheet. In this embodiment, two back-up layers 116 are required to fill the significant increase in the number of narrower gaps between adjacent petals 124 as the first back-up layer 114 expands. The second back-up layers 116 of this embodiment are thinner than the second back-up layer 16 of the first embodiment to compensate for the additional stiffness which arises by using wider petals 134.
Referring now to
The sealing apparatus 210 is a retrievable apparatus and the first back-up layer 214 is manufactured from spring steel. The first back-up layer 214 is biased towards the run-in configuration shown in
In addition, the first back-up layer petal tips 242, in the run-in configuration, are bent slightly radially inwards to facilitate recovery to the run-in configuration.
Reference is now made to
The sealing apparatus 310 comprises a sealing element 312, the sealing element 312 adapted to moved from the run-in configuration shown in
Other features of note in this embodiment is the upper portion 322 of the first back-up layer 314 which includes a radially inward facing portion 360. This radially inward facing portion 360 facilitates recovery of the first back up layer 314 from the extended configuration in which the first back-up layer 314 and the sealing element 312 are in contact with the conduit wall to the run-in configuration shown in
It will also be noted that the first back-up layer 314 extends above an upper edge 364 of the second back-up layer 316. To ensure tight fit between the first and second back-up layers 314, 316 and to eliminate any extrusion gaps, the side edges 366 (
Referring finally to
The intermediate layer 470 is a woven steel mesh and is made from a sheet which is formed into a sleeve and spot welded to the first back-up layer 414. As the sealing apparatus 410 expands from the run-in configuration (not shown) to the set configuration (shown in
Various modifications and improvements can be made to the above described embodiment without departing from the scope of the present invention. For example, for low expansion environments it is not necessary to have the first and/or second back-up layers slotted, continuous banded material could be used. In an alternative embodiment, where there are two second back-up layers used, the tips of the inner back-up layer could extend above the tips of the outer back-up layer, which in turn extend above the tips of the first back-up layer. This further facilitates the closing of any gaps or clearances between the apparatus and the well bore surface.
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0724122.7 | Dec 2007 | GB | national |
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PCT/GB2008/004059 | 12/10/2008 | WO | 00 | 12/30/2010 |
Publishing Document | Publishing Date | Country | Kind |
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WO2009/074785 | 6/18/2009 | WO | A |
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