SEALING ASSEMBLY EMPLOYING A DEPLOYABLE CONTROL BAND

BACKGROUND

A typical scaling tool (e.g., packer, bridge plug, frac plug, etc.) generally has one or more sealing elements or “rubbers” that are employed to provide a fluid-tight seal radially between a mandrel of the sealing tool, and the casing or wellbore into which the sealing tool is disposed. Such a sealing tool is commonly conveyed into a subterranean wellbore suspended from tubing extending to the earth's surface.

To prevent damage to the elements of the sealing tool while the sealing tool is being conveyed into the wellbore, the sealing elements may be carried on the mandrel in a retracted or uncompressed state, in which they are radially inwardly spaced apart from the casing. When the sealing tool is set, the sealing elements radially expand, thereby sealing against the mandrel and the casing and/or wellbore. In certain embodiments, the sealing elements are axially compressed between element retainers that straddle them, which in turn radially expand the sealing elements.

BRIEF DESCRIPTION

Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates a schematic view of a well system designed, manufactured and operated according to one or more embodiments disclosed herein;

FIGS. 2A through 2F illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more embodiments of the disclosure;

FIGS. 2G through 2H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more embodiments of the disclosure;

FIGS. 3A through 3F illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure;

FIGS. 4A through 4F illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure;

FIGS. 5A through 5F illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure;

FIGS. 6A through 6H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure;

FIGS. 7A through 7H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure; and

FIGS. 8A through 8F illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure.

DETAILED DESCRIPTION

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 with significant expansion gaps. For example, due to the large extrusion gap in open-hole conditions, when the sealing element buckles, it will often lose much of its axial stiffness and escape the desired load path. As a result, the sealing element will not effectively transfer the load to the backup shoes, and often tends to extrude over the backup shoe, which in turn can result in an insufficient deployment. In the case of multi-piece sealing element designs, the sealing elements may also tend to climb up over each other in an uncontrolled and chaotic manner, resulting in insufficient deployment of the backup shoe, and thus a poor seal from the sealing elements.

The present disclosure further recognizes that the above problem is less of a challenge when the sealing assembly is employed within a fixed ID casing with small to moderate expansion gaps, for example because when the sealing element buckles the casing imposes an effective lateral confinement to the sealing elements. Accordingly, effective lateral confinement prevents total loss of the sealing element's axial stiffness, such that the backup shoe may continue to deploy following the buckling of the sealing element.

Given the foregoing, recognitions, the present disclosure proposes inserting a novel deployable spacer between ones of the sealing elements. The deployable spacer, in one example, improves the axial stiffness of the sealing elements and load transfer mechanism by controlling the deployment of the sealing elements. Accordingly, the use of the deployable spacer may ensure full deployment of the backup shoe with little to no risk of sealing element extrusion.

FIG. 1 is a schematic view of a well system 100 designed, manufactured and operated according to one or more embodiments disclosed herein. The well system 100 includes a platform 120 positioned over a subterranean formation 110 located below the earth's surface 115. The platform 120, in at least one embodiment, has a hoisting apparatus 125 and a derrick 130 for raising and lowering one or more downhole tools including pipe strings, such as a drill string 140. Although a land-based oil and gas platform 120 is illustrated in FIG. 1, the scope of this disclosure is not thereby limited, and thus could potentially apply to offshore applications. The teachings of this disclosure may also be applied to other land-based well systems different from that illustrated.

As shown, a main wellbore 150 has been drilled through the various earth strata, including the subterranean formation 110. The term “main” wellbore is used herein to designate a wellbore from which another wellbore is drilled. It is to be noted, however, that a main wellbore 150 does not necessarily extend directly to the earth's surface, but could instead be a branch of yet another wellbore. A casing string 160 may be at least partially cemented within the main wellbore 150. The term “casing” is used herein to designate a tubular string used to line a wellbore. Casing may actually be of the type known to those skilled in the art as a “liner” and may be made of any material, such as steel or composite material and may be segmented or continuous, such as coiled tubing. The term “lateral” wellbore is used herein to designate a wellbore that is drilled outwardly from its intersection with another wellbore, such as a main wellbore. Moreover, a lateral wellbore may have another lateral wellbore drilled outwardly therefrom.

In the embodiment of FIG. 1, a whipstock assembly 170 according to one or more embodiments of the present disclosure is positioned at a location in the main wellbore 150. Specifically, the whipstock assembly 170 could be placed at a location in the main wellbore 150 where it is desirable for a lateral wellbore 190 to exit. Accordingly, the whipstock assembly 170 may be used to support a milling tool used to penetrate a window in the main wellbore 150, and once the window has been milled and a lateral wellbore 190 formed, in some embodiments, the whipstock assembly 170 may be retrieved and returned uphole by a retrieval tool.

The whipstock assembly 170, in at least one embodiment, includes a whipstock element section 175, as well as a sealing/anchoring assembly 180 coupled to a downhole end thereof. The sealing/anchoring assembly 180, in one or more embodiments, includes an orienting receptacle tool assembly 182, a sealing assembly 184, and an anchoring assembly 186. In at least one embodiment, the anchoring assembly 186 axially, and optionally rotationally, fixes the whipstock assembly 170 within the casing string 160. The sealing assembly 184, in at least one embodiment, seals (e.g., provides a pressure tight seal) an annulus between the whipstock assembly 170 and the casing string 160. The orienting receptacle tool assembly 182, in one or more embodiments, along with a collet and one or more orienting keys, may be used to land and positioned a guided milling assembly and/or the whipstock element section 175 within the casing string 160.

The elements of the whipstock assembly 170 may be positioned within the main wellbore 150 in one or more separate steps. For example, in at least one embodiment, the sealing/anchoring assembly 180, including the orienting receptacle tool assembly 182, scaling assembly 184 and the anchoring assembly 186 are run in hole first, and then set within the casing string 160. In the illustrated embodiment, the sealing assembly 184 is located within an open-hole section of the wellbore 150. In other embodiments, however, the sealing assembly 184 could be located within the casing 160. Thereafter, the sealing assembly 184 may be pressure tested. Thereafter, the whipstock element section 175 may be run in hole and coupled to the scaling assembly 180, for example using the orienting receptacle tool assembly 182. What may result is the whipstock assembly 170 illustrated in FIG. 1.

Turning now to FIGS. 2A through 2F, illustrated are different cross-sectional views of various deployment states of a sealing assembly 200 designed, manufactured and/or operated according to one or more embodiments of the disclosure. The sealing assembly 200, in the illustrated embodiment of FIGS. 2A through 2F, includes a mandrel 210. The mandrel 210, in the illustrated embodiment, may be centered about a centerline (CL). The sealing assembly 200, in at least the embodiment of FIGS. 2A through 2F, additionally includes a bore 290 positioned around the mandrel 210. The bore 290, in at least one embodiment, is a wellbore, such as an open-hole wellbore. The bore 290, in at least one other embodiment, is a tubular positioned within a wellbore, such as a casing, production tubing, etc. In accordance with one aspect of the disclosure, the mandrel 210 and the bore 290 form an annulus 280.

In accordance with one embodiment of the disclosure, the sealing assembly 200 includes a sealing element 220 (e.g., an elastomeric sealing element). The sealing element 220, in accordance with at least one embodiment, includes a first sealing element portion 220a and a second sealing element portion 220b. In one or more other embodiments, the sealing element 220 additionally includes a third sealing element portion 220c, as well as potentially one or more other additional sealing element portions. The sealing element 220, including the first sealing element portion 220a, the second sealing element portion 220b, and the third sealing element portion 220c, is operable to move between a radially retracted state, such as that shown in FIGS. 2A and 2B, and a radially expanded state, such as that shown in FIGS. 2C through 2D (e.g., partially radially expanded state) and FIGS. 2E through 2F (e.g., fully radially expanded state). While a single sealing element 220 is illustrated in FIGS. 2A through 2F, other embodiments exist wherein multiple sealing elements 220 are employed, whether together or spaced apart in series along the mandrel 210. In the embodiment of FIGS. 2A through 2F, the sealing element 220 comprises a non-swellable elastomer, among other types and materials.

In the illustrated embodiment of FIGS. 2A through 2F, first and second backup shoes 240a, 240b, straddle first and second ends 225a, 225b, respectively, of the sealing element 220. Further to the embodiment of FIGS. 2A through 2F, first and second collar sleeves 250a, 250b straddle the first and second backup shoes 240a, 240b, respectively. In the embodiment of FIGS. 2A through 2F, a setting sleeve 260 (e.g., an axially fixed setting sleeve) is coupled with the first end 225a of the sealing element 220 (e.g., through the first backup shoe 240a and first collar sleeve 250a). In one or more other embodiments, the first collar sleeve 250a and the setting sleeve 260 are a single combined feature, as opposed to the two separate features shown in FIGS. 2A through 2F.

Those skilled in the art understand and appreciate the desire and/or need for the first and second backup shoes 240a, 240b, including preventing extrusion of the sealing element 220 about the first and second collar sleeves 250a, 250b. Similarly, those skilled in the art appreciate the desire and/or need for the first and second collar sleeves 250a, 250b. For example, in the illustrated embodiment of FIGS. 2A through 2F, the first and second collar sleeves 250a, 250b are configured to axially slide relative to one another to move the sealing element 220 between the radially retracted state, such as that shown in FIGS. 2A and 2B, and a radially expanded state, such as that shown in FIGS. 2C through 2D (e.g., partially radially expanded state) and FIGS. 2E through 2F (e.g., fully radially expanded state).

In the embodiment of FIGS. 2A through 2F, the sealing element 200 additionally includes a deployable spacer 230. In the illustrated embodiment, the sealing element 200 includes a first deployable spacer 230a positioned between the first sealing element portion 220a and the second sealing element portion 220b, as well as a second deployable spacer 230b positioned between the second sealing element portion 220b and the third sealing element portion 220c. In at least one embodiment, each adjacent pair of sealing element portions includes their own deployable spacer. Thus, as shown here, three sealing element portions would include two deployable spacers. Accordingly, if the sealing element 200 were to include five sealing element portions, it would likely also include four deployable spacers positioned therebetween. In at least one embodiment, the deployable spacers 230a, 230b are configured to deploy from an undeployed state (e.g., as shown in FIGS. 2A and 2B) to a deployed state (e.g., as shown in FIGS. 2C through 2F).

In at least one embodiment, each of the deployable spacers 230a, 230b includes two flanges. In at least one embodiment, a first of the two flanges 232a is configured to a control deployment of one adjacent sealing element portion and a second of the two flanges 232b is configured to control a deployment of another adjacent sealing element portion. For example, a first of the two flanges 232a of the first deployable spacer 230a would control a deployment of the first adjacent sealing element portion 220a and a second of the two flanges 232b of the first deployable spacer 230a would also control a deployment of the second adjacent sealing element portion 220b. Similarly, a first of the two flanges 232a of the second deployable spacer 230b would control a deployment of the second adjacent sealing element portion 220b and a second of the two flanges 232b of the second deployable spacer 230b would also control a deployment of the third adjacent sealing element portion 220c. In at least one embodiment, the flanges 232 could have structural features (e.g., weakened spots, removed sections (e.g., holes, slots, etc.), etc.) that would allow them to deploy easier.

Further to one or more embodiments disclosed herein, in at least one embodiment, the first of the two flanges 232a and the second of the two flanges 232b (e.g., for a given deployable spacer 230) are configured to separately deploy, for example sequentially deploy. In at least one embodiment, an axial interior of the two flanges (e.g., the first flange 232a of the second deployable spacer 230b and the second flange 232b of the first deployable spacer 230a) are configured to deploy prior to an axial exterior of the two flanges. This may occur naturally as the sealing element 220 is being compressed, or may be intentionally created using different sizes, shapes, and/or materials amongst the two flanges. For example, in at least one embodiment the sequential deployment is achieved by making the sealing elements 220a, 220b, 220c of different materials of varying stiffness, modulus of elasticity, etc., or in another embodiment by having different sizes of grooves in the ID that makes the sealing elements 220a, 220b, 220c (and therefore the flanges 232) sequentially deploy.

In one or more embodiments, such as is shown, each of the deployable spacers 230a, 230b includes a base member 234 having the two flanges connected thereto, the base member positioned proximate the mandrel 210. Further to this embodiment, the base member 234 may have a wide portion 236 proximate the mandrel 210 and a narrow portion 238 distal the mandrel 210. In at least this one embodiment, the wide portion 236 is configured to resist lifting or overturning of the deployable spacers 230a, 230b as the sealing element portions 220a, 220b, 220c move between their radially retracted state and their radially expanded state. In at least one other embodiment, the base member 234 includes a first base member portion coupled to one of the flanges 232 and a separate second base member portion coupled to the other of the flanges 232.

In at least one embodiment, the deployable spacers 230a. 230b are multi-piece designs, the multiple pieces of the deployment spacers connected using one or more fastening techniques, including screws, welds, etc. For example, in at least one embodiment the base member(s) 234 could be physically attached to the mandrel 210, and the flanges 232 mechanically connected to the base member(s) 234 at a later time (e.g., when the sealing assembly 200 is at the rig). Such an embodiment, for example employing later attached segmented flanges 232, would allow different types of flanges 232 to be employed based upon wellbore conditions (e.g., bore size, temperatures, etc.).

The deployable spacers 230a, 230b may comprise many different materials and remain within the scope of the disclosure. In at least one embodiment, however, the deployable spacers 230a, 230b comprise a deployable ductile metal, such as AISI 1018 steel or SAE 316L grade stainless steel. In yet another embodiment, the deployable spacers 230a, 230b comprise a deployable plastic or polymer. For example, in at least one embodiment, at least a portion of the deployable spacers 230a, 230b comprise a material having a yield strength of 40 ksi or less, if not 30 ksi or less.

FIGS. 2A and 2B illustrate the sealing assembly 200 in a run-in-hole state, and thus its scaling element 220 is in a radially retracted state. For example, each of the first, second and thirds sealing element portions 220a, 220b, 220c are in their radially retracted state. Furthermore, each of the deployable spacers 230a, 230b, and their associated flanges 232a, 232b, are in the undeployed state. Similarly, the first and second backup shoes 240a, 240b are in their undeployed state. In at least one embodiment, the sealing assembly 200, including the deployable spacers 230a, 230b, and their associated flanges 232a, 232b, would potentially have better swab-off resistance than conventional sealing assemblies without the deployable spacers 230a, 230b, thus allowing the sealing assembly 200 to be run-in-hole at a faster rate.

FIGS. 2C and 2D illustrate the sealing assembly 200 as the first and second collar sleeves 250a, 250b start to axially translate relative to one another. As shown in this embodiment, the axial translation causes the second sealing element portion 220b (e.g., the center most sealing element portion) to compress and radially expand. In one or more embodiments, the second sealing element portion 220b buckles to radially expand. In at least this one embodiment, the axial interior flanges of the first deployable spacer 230a and the second deployable spacer 230b gradually deploy to control a deployment of the second sealing element portion 220b. For example, the axial interior flanges of the first deployable spacer 230a and the second deployable spacer 230b substantially prevent the second sealing element portion 220b from tipping over, and thus considerably enhances the post deployment (e.g., post buckling) stiffness of the second scaling element portion 220b.

FIGS. 2E and 2F illustrate the sealing assembly 200 as the first and second collar sleeves 250a, 250b finish axially translating relative to one another. As shown in this embodiment, the final axial translation causes the first and third sealing element portions 220a. 220c (e.g., the outer most sealing element portions) to compress and radially expand. In one or more embodiments, the first and third sealing element portions 220a, 220c buckle to radially expand. In at least this one embodiment, the axial exterior flanges of the first deployable spacer 230a and the second deployable spacer 230b gradually deploy to control a deployment of the first and third sealing element portions 220a, 220c. For example, the axial exterior flanges of the first deployable spacer 230a and the second deployable spacer 230b substantially prevent the first and third sealing element portions 220a, 220c from tipping over, and thus considerably enhance the post deployment (e.g., post buckling) stiffness of the first and third sealing element portions 220a, 220c. In at least one embodiment, the flanges of the first and second deployable spacers 230a, 230b may eventually be folded in a fully deployed position (e.g., as shown with the flanges being vertically oriented), which allows the sealing assembly 200 to fully set.

The first and second backup shoes 240a, 240b, in the illustrated embodiment, also gradually deploy to control a deployment of the first and third sealing element portions 220a, 220c. For example, the first and second backup shoes 240a. 240b also help in preventing the first and third sealing element portions 220a, 220c from tipping over, and thus considerably enhances the post deployment (e.g., post buckling) stiffness of the first and third sealing element portions 220a, 220c.

Thus, in accordance with this one embodiment, the first deployable spacer 230a and the second deployable spacer 230b gradually deploy to orderly (e.g., as opposed to random) control the sealing element deployment, which considerably enhances the post-buckling stiffness of the sealing elements, and effectively transfers the load to backup shoes with minimum risk of rubber extrusion. Accordingly, the performance of the backup shoes 240a, 240b is greatly improved, and if there is a proper balance between strength and flexibility of the backup shoes 240a, 240b, the successful deployment of the backup shoes 240a, 240b is ensured as well.

Turning now to FIGS. 2G through 2H, illustrated are different cross-sectional views of various deployment states of a sealing assembly 200g designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 200g of FIGS. 2G through 2H is similar in many respects to the sealing assembly 200 of FIGS. 2A through 2B. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 200g differs, for the most part, from the sealing assembly 200 in that the sealing assembly 200g employs a base member 234g that includes a first base member portion 234g′ coupled to one of the flanges 232 (e.g., the first flange 232a) and a separate second base member portion 234g″ coupled to the other of the flanges 232 (e.g., the second flange 232b).

Turning now to FIGS. 3A through 3F, illustrated are different cross-sectional views of various deployment states of a sealing assembly 300 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 300 of FIGS. 3A through 3F is similar in many respects to the sealing assembly 200 of FIGS. 2A through 2F. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The scaling assembly 300 differs, for the most part, from the scaling assembly 200 in that the sealing assembly 300 employs one or more two-part backup shoes 340. For example, in one or more embodiments, a first two-part backup shoe 340a is located proximate the first end 225a of the sealing element 220 and a second two-part backup shoe 340b is located proximate the second end 225b of the sealing element 220.

In at least one embodiment, each of the first two-part backup shoe 340a and the second two-part backup shoe 340b includes a first backup shoe portion 342 and a separate second backup shoe portion 344. In at least one embodiment, the first backup shoe portion 342 is located proximate the collar sleeve 250a, 250b, and the second backup shoe portion 344 is located between the first backup shoe portion 342 and the sealing element 220. In at least one other embodiment, the first backup shoe portion 342 includes a substantially vertical section 342a and a slanted section 342b. In one or more embodiments, the slanted section 342b is located proximate the mandrel 210, whereas the substantially vertical section 342a is located distal the mandrel 210. Furthermore, in one embodiment of the disclosure, the slanted section 342b slants toward the sealing element 220.

In at least one embodiment, the first backup shoe portion 342 and the separate second backup shoe portion 344 (e.g., that may include a substantially vertical section 344b (within 15 degrees of vertical)), are configured to move independent of each other. Further to this embodiment, the first backup shoe portion 342 and the separate second backup shoe portion 344 may comprise a similar material. In at least one other embodiment, the first backup shoe portion 342, the separate second backup shoe portion 344 and the deployable spacers 230a, 230b comprise a similar material. For example, in at least one embodiment, the first backup shoe portion 342, the second backup shoe portion 344 and the deployable spacers 230a, 230b each have a yield strength of 40 ksi or less.

FIGS. 3A and 3B illustrates the sealing assembly 300 in a run-in-hole state, and thus its sealing element 220 is in a radially retracted state. For example, each of the first, second and thirds sealing element portions 220a, 220b. 220c are in their radially retracted state. Furthermore, each of the deployable spacers 230a, 230b, and their associated flanges 232a, 232b, are in the undeployed state. Similarly, the first and second two-part backup shoes 340a, 340b are in the undeployed state.

FIGS. 3C and 3D illustrate the sealing assembly 300 as the first and second collar sleeves 250a, 250b start to axially translate relative to one another. The first and second two-part backup shoes 340a, 340b are still in the undeployed state.

FIGS. 3E and 3F illustrate the sealing assembly as the first and second collar sleeves 250a, 250b finish axially translating relative to one another. As shown in this embodiment, the final axial translation causes the first and third sealing element portions 220a, 220c (e.g., the outer most sealing element portions) to compress and radially expand. In at least this one embodiment, the axial exterior flanges of the first deployable spacer 230a and the second deployable spacer 230b gradually deploy to control a deployment of the first and third sealing element portions 220a, 220b. For example, the axial exterior flanges of the first deployable spacer 230a and the second deployable spacer 230b substantially prevent the first and third sealing element portions 220a. 220c from tipping over, and thus considerably enhances the post deployment (e.g., post buckling) stiffness of the first and third sealing element portions 220a, 220c. In at least one embodiment, the flanges of the first and second deployable spacers 230a. 230b may eventually be folded in a fully deployed position (e.g., as shown with the flanges being vertically oriented) that allows the sealing assembly 200 to fully set. The first and second two-part backup shoes 340a, 340b also gradually deploy to control a deployment of the first and third sealing element portions 220a, 220b. Accordingly, the second backup shoe portions 344 deploy radially outward in relation to the first backup shoe portions 342. For example, the second backup shoe portions 344 may control a radial outer edge of the first and third sealing element portions 220a, 220c, whereas the first backup shoe portions 342 may control the radial inner edge of the first and third sealing element portions 220a, 220c.

Turning now to FIGS. 4A through 4F, illustrated are different cross-sectional views of various deployment states of a sealing assembly 400 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 400 of FIGS. 4A through 4F is similar in many respects to the sealing assembly 200 of FIGS. 2A through 2F. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 400 differs, for the most part, from the sealing assembly 200 in that the sealing assembly 400 does not employ a deployable spacer 230, but instead employs a deployable control band 430 positioned radially outside a radial inner surface of its sealing element 420. In the illustrated embodiment, the deployable control band is positioned radially outside of a radial outer surface of the sealing element 420. The deployable control band 430, in one or more embodiments, is configured to deploy from an undeployed state to a deployed state as the sealing element 420 moves from the radially retracted state to the radially expanded state. The embodiment of FIGS. 4A through 4F illustrates that the sealing element 420 includes only a single sealing element portion. Nevertheless, other embodiments may exist wherein the sealing element 420 includes multiple sealing element portions, such as discussed above.

In the illustrated embodiment, the sealing assembly 400 includes first and second deployable control bands 430a, 430b. The first and second deployable control bands 430a, 430b are both positioned about the radial outer surface of the sealing element 420, but are also spaced apart from one another. In at least one embodiment, the first and second deployable control bands 430a, 430b are substantially equally spaced apart between the first end 225a and the second end 225b of the sealing element 420. The term “substantially equally spaced,” as used herein, is intended to mean that the first and second deployable control bands 430a, 430b are within 20 percent of being exactly equally spaced. Accordingly, in the illustrated embodiment the first and second deployable control bands 430a, 430b would separate the sealing element 420 into three spaced apart sections 420a, 420b, 420c (e.g., three substantially equal (e.g., within 20 percent of exactly equal) spaced apart sections). While two deployable control bands 430a, 430b are employed in the illustrated embodiment, more than two deployable control bands may be used and remain within the purview of the disclosure.

In at least one embodiment, the first and second deployable control bands 430a, 430b include a control band stiffness that is greater than a stiffness of the sealing element 420. The term “stiffness,” as used herein, relates to the amount of force required to cause a given amount of deformation of a component under consideration. The greater amount of force needed to cause the given amount of deformation, the stiffer the component is. In at least one embodiment, the stiffness and strength of the deployable control bands are designed such that they break up once the sealing elements have been deployed in an acceptable controlled manner. In at least one other embodiment, the deployable control bands will not buckle, as they are not in compression, but in contrast are in tension and will eventually breakup as designed.

The stiffness of each of the first and second deployable control bands 430a, 430b is designed with the goal that each spaced apart section 420a, 420b, 420c between the first and second deployable control bands 430a, 430b and the first and second backup shoes 240a, 240b will buckle at about the same time, allowing good load transfer of load from one side to another. This will also allow portions of the buckled sections to support each other, avoiding tipping to one side or another. Accordingly, in at least one embodiment, the first and second deployable control bands 430a, 430b (e.g., pairs of related control bands) would have a similar stiffness. In at least one embodiment, the sealing assembly 400 including the deployable control bands 430a, 430b would potentially have better swab-off resistance than conventional sealing assemblies without the deployable control bands 430a, 430b, thus allowing the sealing assembly 400 to be run-in-hole at a faster rate.

FIGS. 4A and 4B illustrate the sealing assembly 400 in a run-in-hole state, and thus its sealing element 420 is in a radially retracted state. For example, each of the spaced apart sections 420a, 420b, 420 of the sealing element 420 are in their radially retracted state. Furthermore, the first and second deployable control bands 430a, 430b are in the undeployed state. Similarly, the first and second backup shoes 240a. 240b are in their undeployed state.

FIGS. 4C and 4D illustrate the sealing assembly 400 as the first and second collar sleeves 250a, 250b start to axially translate relative to one another. As shown in this embodiment, a combination of the axial translation of the first and second collar sleeves 250a. 250b and the first and second deployable control bands 430a, 430b causes the center spaced apart section 420b to compress and radially expand. In one or more embodiments, the center spaced apart section 420b buckles to radially expand, thus forming two buckled sections as shown.

FIGS. 4E and 4F illustrate the sealing assembly 400 as the first and second collar sleeves 250a, 250b finish axially translating relative to one another. As shown in this embodiment, the final axial translation causes the first and third spaced apart sections 420a, 420c (e.g., the outer most spaced apart sections) to compress and radially expand. In one or more embodiments, the first and third spaced apart sections 420a, 420c buckle to radially expand, each again forming two buckled sections as shown. Moreover, in at least one embodiment, the first and second deployable control bands 430a, 430b deploy from their undeployed state to their deployed state, such as is shown. In the illustrated embodiment, the first and second deployable control bands 430a, 430b remain intact after the sealing element 420 moves to the radially expanded state.

As shown in FIGS. 4E and 4F, the first and second backup shoes 240a, 240b gradually deploy to control a deployment of the first and third spaced apart sections 420a, 420b. For example, the first and second backup shoes 240a, 240b also help in preventing the first and third spaced apart sections 420a, 420c from tipping over, and thus considerably enhance the post deployment (e.g., post buckling) stiffness of the first and third spaced apart sections 420a, 420c as well.

Turning now to FIGS. 5A through 5F, illustrated are different cross-sectional views of various deployment states of a sealing assembly 500 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 500 of FIGS. 5A through 5F is similar in many respects to the sealing assembly 400 of FIGS. 4A through 4F. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 500 differs, for the most part, from the sealing assembly 400 in that the deployable control bands 530a, 530b of the sealing assembly 500 are configured to break and release after the sealing element 420 moves to the radially expanded state.

Turning now to FIGS. 6A through 6H, illustrated are different cross-sectional views of various deployment states of a sealing assembly 600 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 600 of FIGS. 6A through 6H is similar in many respects to the sealing assembly 400 of FIGS. 4A through 4F. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 600 differs, for the most part, from the scaling assembly 400 in that the sealing assembly 600 additionally includes third and fourth deployable control bands 630c, 630d positioned about the outer surface, the third and fourth deployable control bands 630c, 630d positioned on opposing axial sides of the first and second deployable control bands 430a, 430b. Accordingly, in the illustrated embodiment the first, second, third, and fourth deployable control bands 430a, 430b, 630c, 630d separate the sealing element 620 into first, second, third, fourth and fifth spaced apart sections 620a, 620b, 620c, 620d, 620e.

In at least one embodiment, the first and second deployable control bands 430a, 430b have a first control band stiffness, and the third and fourth deployable control bands 630c, 630d have a second control band stiffness. In at least one other embodiment, the second control band stiffness is different than the first control band stiffness. For example, in at least one embodiment the second control band stiffness is greater than the first control band stiffness, for example in an effort to cause the third spaced apart section 620c (e.g., middle section) to buckle first, followed by the second and fourth spaced apart section 620b, 620d to buckle second, and the first and fifth spaced apart section 620a, 620e to buckle last. For example, the deployable control band's stiffness and strength are designed such that a desirable sequence of scaling element deployment is achieved.

The differing stiffnesses may be created using a number of different processes. For example, in at least one embodiment the first and second deployable control bands 430a, 430b comprise a material having the first control band stiffness and the third and fourth deployable control band 630c, 630d comprise a different material having the second different control band stiffness. In yet another embodiment, the materials may be the same, but the size and/or shape is changed to modulate the stiffness.

Turning now to FIGS. 7A through 7H, illustrated are different cross-sectional views of various deployment states of a sealing assembly 700 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 700 of FIGS. 7A through 7H is similar in many respects to the sealing assembly 600 of FIGS. 6A through 6H. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 700 differs, for the most part, from the sealing assembly 600 in that the deployable control bands 430a, 430b, 630c, 630d of the sealing assembly 700 are configured to break and release after the sealing element 420 moves to the radially expanded state.

Turning now to FIGS. 8A through 8F, illustrated are different cross-sectional views of various deployment states of a sealing assembly 800 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 800 of FIGS. 8A through 8F is similar in many respects to the sealing assembly 400 of FIGS. 4A through 4F. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 800 differs, for the most part, from the scaling assembly 400 in that the deployable control bands 830a, 830b of the sealing assembly 800 are embedded within the sealing element 820.

Aspects disclosed herein include:

A. A scaling assembly, the sealing assembly including: 1) a mandrel; 2) a sealing element positioned about the mandrel, the sealing element including: a) a first sealing element portion and a second scaling element portion; and b) a deployable spacer positioned between the first sealing element portion and the second sealing element portion; 3) a first collar sleeve coupled proximate a first end of the sealing element; and 4) 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 deployable spacer is configured 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, the sealing element including: i) a first sealing element portion and a second sealing element portion; and ii) a deployable spacer positioned between the first sealing element portion and the second sealing element portion; c) a first collar sleeve coupled proximate a first end of the sealing element; and c) 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 scaling element between a radially retracted state a radially expanded state, and further wherein the deployable spacer is configured 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 scaling element positioned about the mandrel, the sealing element including: i) a first sealing element portion and a second sealing element portion; and ii) a deployable spacer positioned between the first sealing element portion and the second sealing element portion; c) a first collar sleeve coupled proximate a first end of the sealing element; and d) 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 deployable spacer is configured 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 deployable spacer to deploy from the undeployed state to the deployed state.

D. A sealing assembly, the sealing assembly including: 1) a mandrel; 2) a scaling element positioned about the mandrel, the sealing element having a radial inner surface and a radial outer surface; 3) a deployable control band positioned radially outside the radial inner surface; 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 deployable control band is configured 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.

E. 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, the sealing element having a radial inner surface and a radial outer surface; c) a deployable control band positioned radially outside the radial inner surface; 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 deployable control band is configured 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.

F. 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, the sealing element having a radial inner surface and a radial outer surface; c) a deployable control band positioned radially outside the radial inner surface; 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 deployable control band is configured 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 deployable control band to deploy from the undeployed state to the deployed state.

Aspects A, B, C, D, E and F may have one or more of the following additional elements in combination: Element 1: wherein the deployable spacer includes two flanges, and further wherein a first of the two flanges is configured to control a deployment of the first sealing element portion and a second of the two flanges is configured to control a deployment of the second sealing element portion. Element 2: wherein the first of the two flanges and the second of the two flanges are configured to separately deploy. Element 3: wherein the deployable spacer includes a base member having the two flanges connected thereto, the base member positioned proximate the mandrel. Element 4: wherein the base member has a wide portion proximate the mandrel and a narrow portion distal the mandrel, the wide portion configured to resist lifting or overturning of the deployable spacer as the sealing element moves between the radially retracted state the radially expanded state. Element 5: wherein the base member includes a first base member portion coupled to the first of the two flanges and a separate second base member portion coupled to the second of the two flanges. Element 6: wherein the two flanges have one or more weakened spots, the weakened spots configured to allow the two flanges to deploy easier. Element 7: wherein the weakened spots are removed sections. Element 8: wherein at least a portion of the deployable spacer comprises a material having a yield strength of 40 ksi or less. Element 9: further including a first backup shoe positioned between the first collar sleeve and the first end of the sealing element, and a second backup shoe positioned between the second collar sleeve and the second end of the sealing element. Element 10: wherein the first backup shoe includes a first backup shoe portion and a separate second backup shoe portion, the first backup shoe portion located proximate the first collar sleeve, and the second backup shoe portion located between the first backup shoe portion and the first sealing element portion. Element 11: wherein the first backup shoe portion, the second backup shoe portion and the deployable spacer comprise a similar material. Element 12: wherein the first backup shoe portion, the second backup shoe portion and the deployable spacer each have a yield strength of 40 ksi or less. Element 13: wherein the deployable control band is a first deployable control band, and further including a second deployable control band positioned about the radially outer surface. Element 14: further including third and fourth deployable control bands positioned about the outer surface, the third and fourth deployable control bands positioned on opposing axial sides of the first and second deployable control bands. Element 15: wherein the first and second deployable control bands have a first control band stiffness, and further wherein the third and fourth deployable control bands have a second control band stiffness. Element 16: wherein the second control band stiffness is different than the first control band stiffness. Element 17: wherein the second control band stiffness is greater than the first control band stiffness. Element 18: wherein the first and second deployable control bands comprise a material having the first control band stiffness and the third and fourth deployable control bands comprise a different material having the second different control band stiffness. Element 19: wherein the first and second control bands having a similar stiffness, the similar stiffness configured to cause a portion of the sealing element therebetween to buckle at the same time. Element 20: wherein the first and second deployable control bands are configured to remain intact after the sealing element moves to the radially expanded state. Element 21: wherein the first and second deployable control bands are configured to break after the sealing element moves to the radially expanded state. Element 22: wherein the deployable control band positioned radially outside the radial outer surface. Element 23: wherein the deployable control band is embedded within the sealing element.

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.

	Number	Date	Country
	63516912	Aug 2023	US
	63516934	Aug 2023	US

SEALING ASSEMBLY EMPLOYING A DEPLOYABLE CONTROL BAND

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