Patent Application
20240209714
The field relates to sealing elements used in oil and gas operations. The sealing element includes a sloped, energizing end and a sloped stationary end. An energizing sleeve with a corresponding sloped surface is used to energize the sealing element to create a seal.
The features and advantages of certain embodiments will be more readily appreciated when considered in conjunction with the accompanying figures. The figures are not to be construed as limiting any of the preferred embodiments.
Oil and gas hydrocarbons are naturally occurring in some subterranean formations. In the oil and gas industry, a subterranean formation containing oil and/or gas is referred to as a reservoir. A reservoir can be located under land or offshore. Reservoirs are typically located in the range of a few hundred feet (shallow reservoirs) to a few tens of thousands of feet (ultra-deep reservoirs). In order to produce oil or gas, a wellbore is drilled into a reservoir or adjacent to a reservoir. The oil, gas, or water produced from a reservoir is called a reservoir fluid.
As used herein, a “fluid” is a substance having a continuous phase that can flow and conform to the outline of its container when the substance is tested at a temperature of 71° F. (22° C.) and a pressure of one atmosphere “atm” (0.1 megapascals “MPa”). A fluid can be a liquid or gas. A homogenous fluid has only one phase; whereas a heterogeneous fluid has more than one distinct phase. A colloid is an example of a heterogeneous fluid. A heterogeneous fluid can be a slurry, which includes a continuous liquid phase and undissolved solid particles as the dispersed phase; an emulsion, which includes a continuous liquid phase and at least one dispersed phase of immiscible liquid droplets; a foam, which includes a continuous liquid phase and a gas as the dispersed phase; or a mist, which includes a continuous gas phase and liquid droplets as the dispersed phase. As used herein, the term “base fluid” means the solvent of a solution or the continuous phase of a heterogeneous fluid and is the liquid that is in the greatest percentage by volume of a treatment fluid.
A well can include, without limitation, an oil, gas, or water production well, an injection well, or a geothermal well. As used herein, a “well” includes at least one wellbore. A wellbore can include vertical, inclined, and horizontal portions, and it can be straight, curved, or branched. As used herein, the term “wellbore” includes any cased, and any uncased, open-hole portion of the wellbore. A near-wellbore region is the subterranean material and rock of the subterranean formation surrounding the wellbore. As used herein, a “well” also includes the near-wellbore region. The near-wellbore region is generally considered to be the region within approximately 100 feet radially of the wellbore. As used herein, “into a subterranean formation” means and includes into any portion of the well, including into the wellbore, into the near-wellbore region via the wellbore, or into the subterranean formation via the wellbore.
A wellbore is formed using a drill bit. A drill string can be used to aid the drill bit in drilling through the subterranean formation to form the wellbore. The drill string can include a drilling pipe. During drilling operations, a drilling fluid, sometimes referred to as a drilling mud, may be circulated downwardly through the drilling pipe, and back up the annulus between the wellbore and the outside of the drilling pipe. The drilling fluid performs various functions, such as cooling the drill bit, maintaining the desired pressure in the well, and carrying drill cuttings upwardly through the annulus between the wellbore and the drilling pipe.
A portion of a wellbore can be an open hole or cased hole. In an open-hole wellbore portion, a tubing string can be placed into the wellbore. The tubing string allows fluids to be introduced into or flowed from a remote portion of the wellbore. In a cased-hole wellbore portion, a casing is placed into the wellbore that can also contain a tubing string. A wellbore can contain an annulus. Examples of an annulus include but are not limited to the space between the wellbore and the outside of a tubing string in an open-hole wellbore; the space between the wellbore and the outside of a casing in a cased-hole wellbore; and the space between the inside of a casing and the outside of a tubing string in a cased-hole wellbore.
There are a variety of oil and gas operations that require a seal to be made. By way of a first example, packer assemblies include a sealing element that can form a seal within an annulus located between the outside of the packer assembly and the inside of a casing or tubing string or wall of a wellbore. The packer assembly can be used to isolate one subterranean formation zone from another. By way of another example, there are a variety of downhole tools that utilize internal sealing elements, such as O-rings, that prevent fluid flow past the sealing element, which can allow pressure to be increased above the tool. Such internal sealing elements can be used for sliding sleeves as part of a valve assembly or for sliding sleeves to open and/or close fluid flow ports. By way of another example, anchoring devices can include a sealing element that aids in anchoring the anchoring device to an inside of a casing or tubing string by providing an annular seal for the anchoring device.
Current sealing elements used in oil and gas operations typically include ends that are perpendicular to a longitudinal axis of the wellbore or downhole tool and have a shape much like a donut. However, due to this shape, it may be difficult to adequately seal when there are tight tolerances at the location of the sealing element. Moreover, there are variances in the inner diameter (I.D.) of a casing or tubing string or outer housings for downhole tools—oftentimes having a difference of 1/16 inch or more spanning across the sealing element. Thus, these inner diameters are not consistent nor uniform and create challenges in obtaining an adequate seal. Thus, there is a need for improved sealing elements that solve the problems discussed above.
It has been discovered that sealing element can include a sloped energizing end and a sloped stationary end with an engagement portion being located between the ends. An energizing sleeve can include a sloped surface that corresponds to the sloped energizing end to energize the sealing element to create a seal. The sealing element can be used in areas where tight tolerances are present, to replace O-rings, and can create a better seal than current sealing element designs—especially due to variances in the I.D. of casing or tubing strings or downhole tools.
A sealing element for wellbore operations can include: an energizing end comprising a sloped surface; a stationary end comprising a sloped surface; and an engagement surface located between the energizing end and the stationary end, wherein the sloped surface of the energizing end is configured to engage with a sloped surface of an energizing sleeve to energize the sealing element to create a seal via the engagement surface.
A method of creating a seal in a wellbore can include: positioning a downhole tool at a location within the wellbore, the downhole tool comprising: an inner mandrel; and the sealing element located circumferentially around the inner mandrel; and causing or allowing a sloped surface of an energizing sleeve to engage with the sloped surface of the energizing end, wherein after engagement, the engagement surface of the sealing element moves radially away from the inner mandrel to create the seal in the wellbore.
It is to be understood that the discussion of any of the embodiments regarding the sealing element is intended to apply to all of the appartus, system, and method embodiments without the need to repeat the various embodiments throughout. Any reference to the unit “gallons” means U.S. gallons.
Turning to the figures,
The sealing element 100 also includes a stationary end 110. The stationary end 110 includes a sloped surface 112. The stationary end 110 can also include a perpendicular surface 111. The perpendicular surface 111 can be perpendicular to a longitudinal axis of the mandrel 400. As used herein with reference to the perpendicular surfaces 111/121, “perpendicular” means some portion or the entire portion of the surfaces are 90° to the longitudinal axis of the mandrel 400 and can include a curvature at the top of the sealing element 100, for example as shown in
The sealing element 100 also includes the engagement surface 130 that is located between the energizing end 120 and the stationary end 110. The engagement surface 130 can have a variety of lengths as measured from the perpendicular surface 121 and the perpendicular surface 111 if included or between the energizing end 120 and the stationary end 110. Lengths of the engagement surface 130 can range, for example, from 1 to 1.5 inches. The sealing element 100 can also have a thickness as measured by subtracting the inner diameter from the outer diameter and dividing by 2 ((O.D.−I.D.)/2) in the range of 1 to 1.125 inches.
The stationary end 110 of the sealing element 100 can abut a stationary tool component 300, such as a stationary sleeve or mule shoe. The stationary tool component 300 can be attached to an outside of the mandrel 400 via threads 401 , an adhesive, or other type of fastener (e.g., shear pins, lock rings, or ratchets). The stationary tool component 300 can prevent movement of the stationary end 110 of the sealing element 100 during setting.
The sloped surface 122 of the energizing end 120 can be configured to engage with a sloped surface 201 of an energizing sleeve 200. As can be seen in the figures, the sloped surface 122 and the perpendicular surface 121 of the energizing end 120 can form an angle θ2. The sloped surface 112 and the perpendicular surface 111 of the stationary end 110 can form an angle θ1. According to any of the embodiments and as shown in
An abutment end of the stationary tool component 300 can be configured to match the angle θ1 of the sloped surface 112 of the stationary end 110 . As can be seen by way of example, angle θ1 can range from 100° to 160° and extend away from the engagement surface 130 and the energizing end 120 along the mandrel 400. The matching slopes can help prevent movement of the stationary end 110 of the sealing element 100 during setting.
As can be seen in
Methods of creating a seal in a wellbore can include positioning a downhole tool at a location within the wellbore. The downhole tool can include the mandrel 400 and the sealing element 100. As shown by way of example in
As shown by way of another example in
The methods can include causing or allowing the sloped surface 201 of the energizing sleeve 200 to engage with the sloped surface 122 of the energizing end 120. According to any of the embodiments, movement of the energizing sleeve 200 can be accomplished by mechanical or hydraulic actuation of the sleeve. With reference to
With reference to
With reference to
The downhole tool can include a system to prevent the energizing sleeve 200 from moving back away from the energizing end 120 during or after setting—commonly called backlash. By way of a first example and as shown in
By way of a second example and as shown in
Lock rings 210 and lock ring grooves 211 may be used when it is highly probable or certain that the energizing sleeve 200 will travel a sufficient distance towards the energizing end 120 such that the lock rings 210 lock within the desired lock ring groove 211. By way of example, if there are two lock ring grooves 211 positioned some distance between each other, it may be necessary for a lock ring to lock within the lock ring groove located closest to the perpendicular surface 121. The ratcheting system may be used if it is possible a lock ring may not travel to the desired lock ring groove. The ratcheting system can be more advantageous to use because the ratchets can have small increments between each ratchet, for example, 1/32 of an inch or less to provide minimum backlash. The lock rings and lock ring grooves or the ratcheting system can also help ensure that the energizing sleeve 200 keeps the sealing element 100 extended away from the mandrel 400 and the integrity of the seal created is maintained.
As shown in
The downhole tool can include other components, such as but not exclusively limited to, one or more O-rings 220. The methods can further include other steps such as performing an oil and gas operation after setting of the sealing element.
As discussed above, the sealing element 100 can be used in a variety of downhole tools and oil and gas operations. The sealing element can also be used to seal an annulus for injection of an adhesive into the annulus. By way of example, some downhole tool components can be attached to other tool components or to the inside of a casing or tubing string via an adhesive that forms a bond between the components within the annulus instead of threads. An example of such a downhole tool is a float assembly wherein the float collar body can be bonded to the inside of a casing string via an adhesive that is injected into an annulus between the outside of the tool body and the inside of the casing string.
The sealing element 100 can be made from a variety of materials. According to any of the embodiments, the sealing element 100 is not made from a thermally expanding material or a swellable material, and instead, relies on actuation of the energizing sleeve 200 to cause the material to move or expand radially away from the mandrel 400 during setting. Such materials can broadly be called elastomeric materials. Examples of suitable materials for the sealing element include but are not limited to elastic polymers commonly called elastomers, rubbers, nitrile rubbers, or fluoroelastomers.
An embodiment of the present disclosure is a sealing element for wellbore operations comprising: an energizing end comprising a sloped surface and a perpendicular surface; a stationary end comprising a sloped surface and a perpendicular surface; and an engagement surface located between the energizing end and the stationary end, wherein the sloped surface of the energizing end is configured to engage with a sloped surface of an energizing sleeve to energize the sealing element to create a seal via the engagement surface. Optionally, the stationary end of the sealing element is configured to abut a stationary tool component. Optionally, the stationary tool component prevents movement of the stationary end of the sealing element during setting. Optionally, the stationary tool component is a stationary sleeve or mule shoe. Optionally, the sloped surface and the perpendicular surface of the energizing end forms an angle. Optionally, the angle is in the range of 100° to 160°. Optionally, the angle is in the range of 200° to 280°. Optionally, the sloped surface of the energizing sleeve is configured to match the angle. Optionally, the sloped surface and the perpendicular surface of the stationary end forms an angle. Optionally, the angle is in the range from 100° to 160°. Optionally, the sealing element further comprises a set of support shoes located partially or wholly along the perpendicular surface of the energizing end and the perpendicular surface of the stationary end. Optionally, the sealing element is part of a packer assembly or an anchoring device. Optionally, the engagement surface engages with an inner diameter of a tool housing and creates a seal within the inside of the tool housing. Optionally, the energizing sleeve further comprises one or more lock rings configured to lock within one or more lock ring grooves located on a mandrel or tool housing. Optionally, the energizing sleeve further comprises ratchets configured to engage with ratchets located on a mandrel or tool housing. Optionally, the sealing element is made from elastomers, rubbers, nitrile rubbers, or fluoroelastomers. Optionally, two or more additional sealing elements are located adjacent to the sealing element.
Another embodiment of the present disclosure is a method of creating a seal in a wellbore comprising: positioning a downhole tool at a location within the wellbore, the downhole tool comprising: an inner mandrel; and a sealing element located circumferentially around the inner mandrel, wherein the sealing element comprises: an energizing end comprising a sloped surface and a perpendicular surface; a stationary end comprising a sloped surface and a perpendicular surface; and an engagement surface located between the energizing end and the stationary end; and causing or allowing a sloped surface of an energizing sleeve to engage with the sloped surface of the energizing end, wherein after engagement, the engagement surface of the sealing element moves radially away from the inner mandrel to create the seal in the wellbore. Optionally, the engagement surface creates the seal between the outside of the inner mandrel and the inside of a casing string or tubing string. Optionally, the engagement surface creates the seal between the outside of the inner mandrel and the inside of a tool housing. Optionally, the stationary end of the sealing element is configured to abut a stationary tool component. Optionally, the stationary tool component prevents movement of the stationary end of the sealing element during setting. Optionally, the stationary tool component is a stationary sleeve or mule shoe. Optionally, the sloped surface and the perpendicular surface of the energizing end forms an angle. Optionally, the angle is in the range of 100° to 160°. Optionally, the angle is in the range of 200° to 280°. Optionally, the sloped surface of the energizing sleeve is configured to match the angle. Optionally, the sloped surface and the perpendicular surface of the stationary end forms an angle. Optionally, the angle is in the range from 100° to 160°. Optionally, the sealing element further comprises a set of support shoes located partially or wholly along the perpendicular surface of the energizing end and the perpendicular surface of the stationary end. Optionally, the sealing element is part of a packer assembly or an anchoring device. Optionally, the engagement surface engages with an inner diameter of a tool housing and creates a seal within the inside of the tool housing. Optionally, the energizing sleeve further comprises one or more lock rings configured to lock within one or more lock ring grooves located on a mandrel or tool housing. Optionally, the energizing sleeve further comprises ratchets configured to engage with ratchets located on a mandrel or tool housing. Optionally, the sealing element is made from elastomers, rubbers, nitrile rubbers, or fluoroelastomers. Optionally, two or more additional sealing elements are located adjacent to the sealing element.
Therefore, the apparatus, methods, and systems of the present disclosure are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is, therefore, evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.
As used herein, the words “comprise,” “have,” “include,” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps. While compositions, systems, and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions, systems, and methods also can “consist essentially of” or “consist of” the various components and steps. It should also be understood that, as used herein, “first,” “second,” and “third,” are assigned arbitrarily and are merely intended to differentiate between two or more fluids, valves, etc., as the case may be, and does not indicate any sequence. Furthermore, it is to be understood that the mere use of the word “first” does not require that there be any “second,” and the mere use of the word “second” does not require that there be any “third,” etc.
Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
