Wellbores are drilled into the earth for a variety of purposes including accessing hydrocarbon bearing formations. A variety of downhole tools may be used within a wellbore in connection with accessing and extracting such hydrocarbons. Throughout the process, it may become necessary to isolate sections of the wellbore in order to create pressure zones. Downhole tools, such as hydraulic fracturing (“frac”) plugs, bridge plugs, packers, and other suitable tools, may be used to isolate wellbore sections.
Downhole tools, such as frac plugs, are commonly run into the wellbore on a conveyance such as a wireline, work string or production tubing. Such tools typically have either an internal or external setting tool, which is used to set the downhole tool within the wellbore and hold the tool in place. Once in place, the downhole tools allow fluid communication between sections of the wellbore above the plug and below the plug until another downhole tool, such as a ball, is pumped down to seat in the plug and interrupt fluid communication through the plug and a sealing assembly, which can be made of rubber and extends outwards to seal off the flow of liquid around the downhole tool.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms.
Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.
Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” “downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis. Unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.
Sealing elements are traditionally a critical part of a sealing assembly. The present disclosure, however, has recognized that sealing elements tend to have difficulties when the expansion ratio (e.g., the distance the sealing elements must move from their radially retracted state to their radially expanded state to engage with a bore, such as a wellbore, tubular, casing, etc.) is large. Specifically, the present disclosure has recognized that such sealing elements often experience challenges in open-hole conditions that require significant expansion ratios. For example, due to the large extrusion gap in certain conditions, when the sealing element expands, it will often lose its axial stiffness and escape the desired load path.
Given the foregoing recognitions, the present disclosure proposes inserting a cylindrical extrusion limiter radially about the sealing element. The cylindrical extrusion limiter, in accordance with this embodiment, is configured to break (e.g., break to form first and second separate extrusion limiting rings) to deploy from an undeployed state to a deployed state as the sealing element moves from a radially retracted state to a radially expanded state. In at least one embodiment, the cylindrical extrusion limiter is located radially about a centerpoint of the sealing element. In at least one other embodiment, the cylindrical extrusion limiter is located radially about at least 60 percent of the sealing element, if not at least 80 percent, if not at least 90 percent, if not at least 95 percent. In yet another embodiment, the cylindrical extrusion limiter is located radially about an entirety of the sealing element.
In even yet another embodiment, the extrusion limiter is located radially about a centerpoint of the sealing element, but not located about an entirety of the sealing element. In accordance with this embodiment, separate uphole and downhole retaining rings may overlap radially outside of the extrusion limiter, thus creating a three-piece design.
The cylindrical extrusion limiter, in at least one embodiment, includes an extrusion limiter body having a weakened region proximate a midpoint thereof. The weakened region, in at least one embodiment, is a circumferential notch located around an inside radial surface of the extrusion limiter body. The weakened region, in at least one other embodiment, is a circumferential notch located around an outside radial surface of the extrusion limiter body. The weakened region, in at least another embodiment, is a series of holes extending entirely through a thickness of the extrusion limiter body. In at least one embodiment, the series of holes are a series of slots extending entirely through the thickness of the extrusion limiter body. The weakened region, in at least one embodiment, is configured to remain intact prior to setting the sealing element, but once enough axial compression is imparted upon the sealing element break resulting in first and second separate extrusion limiting rings.
Turning to
The wellbore sealing system 135 in at least one embodiment includes a sealing assembly 150, shown in
The setting tool 140, in one embodiment, includes an actuatable element, such as a sleeve 145, for applying a large axial setting force (e.g., hydraulically) to set the sealing assembly 150, for example once the sealing assembly 150 is positioned at a desired location within the wellbore 110. Setting the sealing assembly 150 squeezes the components (e.g., collar sleeves, scaling element(s), etc.) of the sealing assembly 150 together axially, which may both anchor the sealing assembly 150 in the casing 120 and seal against the casing 120. For instance, the scaling assembly 150 may be set in the axial position shown to sealingly isolate an uphole portion of the wellbore 110 from a downhole portion of the wellbore 110. In some examples, the scaling assembly 150 may be a hydraulic fracturing plug (i.e., frac plug) used to plug the wellbore 110 prior to performing a hydraulic fracturing operation in the uphole portion of the wellbore 110. In yet another embodiment, the sealing assembly 150 is a packer. The various configurations discussed below may allow the sealing assembly 150 to be set within a larger diameter and/or within a larger range of diameters than might ordinarily be practicable for a conventional tool.
In the illustrated embodiment, the sealing system 150 includes a cylindrical extrusion limiter 155, for example positioned radially about a sealing element. As will be discussed in detail below, the cylindrical extrusion limiter 155 is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
Turning now to
In the illustrated embodiment, a sealing element 220 is positioned about the mandrel 210. While a single sealing element 220 is illustrated in
In the illustrated embodiment, a first collar sleeve 230 is coupled proximate a first end 225a of the sealing element 220, and a second collar sleeve 235 is coupled proximate a second end 225b of the sealing element 220. In at least one embodiment, the first and second collar sleeves 230, 235 are configured to axially translate relative to one another along the mandrel 210 to move the sealing element 220 between a radially retracted state (e.g., that shown in
The sealing assembly 200, in the illustrated embodiment, may additionally include a cylindrical extrusion limiter 240 positioned radially about a centerpoint of the sealing element 220. In accordance with one or more embodiments, the cylindrical extrusion limiter 240 is configured to break to deploy from an undeployed state to a deployed state (e.g., break to form first and second separate extrusion limiting rings 240a, 240b) as the sealing element 220 moves from the radially retracted state to the radially expanded state.
In at least one embodiment, the cylindrical extrusion limiter 240 includes an extrusion limiter body 242 having a weakened region 244. In one or more embodiments, the weakened region 244 is located substantially proximate a midpoint of the extrusion limiter body 242. The phrase “substantially proximate,” as used herein with reference to the midpoint of the extrusion limiter body 242, means that the weakened region 244 is located within 20 percent of the midpoint of the extrusion limiter body 242. In yet another embodiment, the weakened region 244 is located ideally proximate a midpoint thereof, wherein the phrase “ideally proximate” means that the weakened region 244 is located within 5 percent of the midpoint of the extrusion limiter body 242. In yet another embodiment, the weakened region 244 is located at exactly the midpoint, which means that the weakened region 244 is located within 1 percent of the midpoint of the extrusion limiter body 242.
The weakened region 244 may take on many different sizes, shapes and/or styles and remain within the scope of the present disclosure. In the illustrated embodiment of
The cylindrical extrusion limiter 240 may comprise many different materials and remain within the scope of the disclosure. In at least one embodiment, however, the cylindrical extrusion limiter 240 comprises a deployable ductile metal, such as AISI 1018 steel or SAE 316L grade stainless steel. In yet another embodiment, the cylindrical extrusion limiter 240 comprises a dissolvable or corrodible material. In even yet another embodiment, the cylindrical extrusion limiter 240 comprises a deployable plastic, polymer or composite. For example, in at least one embodiment, at least a portion of the cylindrical extrusion limiter 240 comprises a material having a yield strength of 40 ksi or less, if not 30 ksi or less.
The cylindrical extrusion limiter 240, depending on the design of the sealing assembly 200, may cover varying amounts of the sealing element 220. For example, in at least one embodiment, the cylindrical extrusion limiter 240 is located radially about at least 60 percent of the sealing element 220. In yet another embodiment, the cylindrical extrusion limiter 240 is located radially about at least 80 percent of the sealing element 220, if not at least 90 percent, if not at least 95 percent. In yet another embodiment, the cylindrical extrusion limiter 240 is located radially about an entirety of the sealing element, such as is shown in
The sealing assembly 200, in the illustrated embodiment, may additionally include one or more anchoring systems 250. In the illustrated embodiment, a first anchoring system 250a and a second anchoring system 250b are included with the sealing assembly 200 to secure the sealing assembly 200 downhole. In the illustrated embodiment, the first anchoring system 250a is engaged with an outer taper face 230a of the first collar sleeve 230, and the second anchoring system 250b is engaged with an outer taper face 235a of the second collar sleeve 235. Thus, the same axial setting force provided by a setting tool to deploy the sealing element 220 into sealing engagement with the bore may also be used to deploy the first and second anchoring systems 250a, 250b into sealing engagement with the bore.
In one or more embodiments, a lower end of the sealing assembly 200 also includes a muleshoe 260 that protects certain other features of the sealing assembly 200 as it is run-in-hole. The muleshoe 260 also allows the sealing assembly 200 to pass through other tools, casing joints, or anything with an upset that may otherwise cause the sealing assembly 200 to get stuck.
Turning to
Turning now to
Turning now to
Turning now to
A. A sealing assembly, the sealing assembly including: 1) a mandrel; 2) a scaling element positioned about the mandrel; 3) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; 4) a first collar sleeve coupled proximate a first end of the sealing element; and 5) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
B. A well system, the well system including: 1) a wellbore located in a subterranean formation; and 2) a sealing assembly positioned in the wellbore, the sealing assembly including: a) a mandrel; b) a sealing element positioned about the mandrel; c) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; d) a first collar sleeve coupled proximate a first end of the sealing element; and 3) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
C. A method, the method including: 1) positioning a sealing assembly within a wellbore located in a subterranean formation, the sealing assembly including: a) a mandrel; b) a sealing element positioned about the mandrel; c) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; d) a first collar sleeve coupled proximate a first end of the sealing element; and 3) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.; and 2) moving the sealing element from the radially retracted state to the radially expanded state, the moving causing the cylindrical extrusion limiter to break deploy from the undeployed state to the deployed state.
Aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region substantially proximate a midpoint thereof. Element 2: wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region ideally proximate a midpoint thereof. Element 3: wherein the weakened region is a circumferential notch located around an inside radial surface of the extrusion limiter body. Element 4: wherein the weakened region is a circumferential notch located around an outside radial surface of the extrusion limiter body. Element 5: wherein the weakened region is a series of holes extending entirely through a thickness of the extrusion limiter body. Element 6: wherein the weakened region is a series of slots extending entirely through a thickness of the extrusion limiter body. Element 7: wherein the cylindrical extrusion limiter is located radially about an entirety of the sealing element. Element 8: wherein the cylindrical extrusion limiter is located radially about at least 60 percent of the sealing element. Element 9: wherein the cylindrical extrusion limiter is a three-piece cylindrical extrusion limiter located radially about a centerpoint of the sealing element, the three-piece cylindrical extrusion limiter including a central cylindrical extrusion limiter, and separate uphole and downhole retaining rings overlapping radially outside of the central cylindrical extrusion limiter.
Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.
This application claims the benefit of U.S. Provisional Application Ser. No. 63/516,951, filed on Aug. 1, 2023, entitled “SEALING ASSEMBLY EMPLOYING A CYLINDRICAL EXTRUSION LIMITER,” commonly assigned with this application and incorporated herein by reference in its entirety.
Number | Date | Country | |
---|---|---|---|
63516951 | Aug 2023 | US |