CA2134762C - Straight bore metal-to-metal wellbore seal apparatus and method of sealing in a wellbore - Google Patents

Abstract

A seal apparatus is provided for use in a subterranean wellbore having a wellbore tubular (13) disposed therein. The wellbore tubular defines a wellboresurface (27). The seal includes a number of components which cooperate together.
A conveyance tubular (17) is provided, which is positionable within the subterranean wellbore at a selected location relative to the wellbore surface. A sealing ring (19) is provided, and disposed about at least a portion of the conveyance tubular. The sealing ring has a first surface (31) proximate the conveyance tubular and a second surface (33) which is removed in distance from the conveyance tubular. The second surface defines a sealing surface, and includes a plurality of portions, with selected ones (91, 93, 95, 97, 99, 101, 103) of the plurality of portions of the sealing ring extending radially from the conveyance tubular in at least one radial dimension. The selected portions define at least one metal seal point for selectively and sealingly engaging the wellbore surface. The seal apparatus is operable in a plurality of modes, including a running mode of operation and a sealing mode of operation. In the running mode of operation, the seal ring is maintained in a radially-reduced position, out of engagement with the wellbore surface. In a sealing mode of operation the at least one metal seal point of the sealing ring is in sealing metal-to-metal engagement with the wellbore surface, providing a fluid-tight seal at a selected location between the conveyance tubular and the wellbore tubular. The seal apparatus of the present invention further includes an actuator member (21), which is selectively and remotely actuatable, for urging the sealing ring between the running and sealing modes ofoperation.

Description

2~ 347 ~
STRAIGHT BORE METAL-TO-METAL WELLBORE SEAL APPARATUS
AND METHOD OF SEALING IN A WELLBORE
BACKGROUND OF ~l~il; INVENTION

1. Fleld of the Invention:

s The present invention relates generally to metal-to-metal seals for use in oil and gas wellbores, and spe~ifi~lly to metal-to-metal seals which are run into the wellbore and set against wellbore sl~rf~-es 2. De3~ tion of the Prior Art:

Wellbore col--p~ion operations frequently require the make-up of a high quality, gas-tight seals, between a wo~ ing or production string and a wellbore tubular string, such as a casing string, which are int~nded for long service lives. Seals which include elastomeric colllponents are subject to e~ ual deterioration after prolonged eA~o~ule to corrosive fluids and high len~ es. Also, when energized, elastomeric colll~?onents are likely to flow along extrusion p~ way;~ if lln.~

Furthermore, as prior art seal devices are lowered over great ~ t~nc~s into oil and gas wellbores, elastomeric co---~nel-ts are e A~o~d to axial forcesfrom fluids in the well, which som~times cause the removal, or "swabbing-offn, of the elaslu---~ic co---ponent, severely i---p~;-;n~ the operation of the seal.
Metal components can be used to obt~in gas tight seals, but are generally suited for rather pristine environment~ other than wellbores. One problem with metal sealing co---pon~;nts is that, like elastomeric co-..~nents, metal sealingco...pollen~ will eventually become degraded after prolonged eA~osu~ to corrosive fluids.

.~

SUMMARY OF THE INVENTION ~ ~

It is an objective of an aspect of the present invention to provide a metal-to-metal seal for use in se. ling against a straight bore tubular mPmbP,r disposed 5 in a wellbore.

It is an objective of an aspect of the present invention to provide a wellbore seal which combines the advantages of elastomerdc and metal-to-met. l seals.

It is an objective of an aspect of the present invention to provide a 10 wellbore seal which in~,1udes both met.,l-to-metal and elastomedc sealing memhPrs which operate in co--.bination to provide a high quality, gas-tight sealin a wellbore.

It is an objective of an aspect of the present invention to provide a seal app~dlus for use in a wellpore having a sealing surface which includes a 15 plurality of ~ d~r portions which define metal se~ points which engage a wellbore surface during a se~ing mode of operation.

It is an objective of an aspect of the present invention to provide a seal a~)l)alalus for use in a wellbore having a se. ling surface which in~ludes a plurality of P tPnd~Pr portions which define metal seal points which engage a 20 wellbore surface during a sealing mode of operation, said sealing app~dlus further in~lu-~ing a layer of resilient mqte~iql disposed over the sealing surf~ce, whe.~;n the extender portions provide a skeletal structure for the layer of resilient m,qt.e iql to prevent swabbing-off of the layer of resilient mqtPriql during a running mode of operat,ion.

2s These and other objectives are achieved as is now described. A seal ap~dlus is provided for use in a sub~~ ean wellbore having a wellbore B

WO 94/20728 213 ~ 7 G 2 PCT/US94/00181 tubular disposed therein such as a casing string, which is of unknown condition. The wellbore tubular defines a wellbore surface, which may have irregularities or defects therein such as nicks, cuts, grooves, gouged regions, corroded regions, and eccentricities and the like. Furthermore, the wellbore 5 tubular may have an inner diameter which varies over industry-accepted tolerance range; for example, a conventional casing tubular having a nine and five eighths (9 5/8) inches outer diameter may have a central bore with a diameter which is in the range of 8.379 to 8.670 inches, which represents an industry-accepted tolerance range for this type of tubular product.
The seal includes a number of components which cooperate together. A conveyance tubular is provided, which is positionable within the sul ler,anean wellbore at a selected location relative to the wellbore surface.
Typically, the conveyance tubular may col"~rise a workstring or a production 15 string which may extend several thousand feet or more. A sealing ring is provided, and disposed about at least a portion of the conveyance tubular. The sealing ring has a first surface proximate the conveyance tubular and a second surface which is removed in distance from the conveyance tubular. The second surface defines a sealing surface, and it includes a plurality of portions, with20 selected ones of the plurality of portions of the sealing ring extending radially from the conveyance tubular in at least one radial dimension. The selected portions define at least one metal seal point for selectively and sealingly engaging the wellbore surface.

The seal apparatus is operable in a plurality of modes, including a running mode of operation and a sealing mode of operation. In the running mode of operation, the sealing ring is maintained in a radially-reduced position, out of engagement with the wellbore surface. In this mode, the conveyance tubular may be run deep into the wellbore. In the sealing mode of operation, the metal seal point of the sealing ring is in sealing metal-to-metal engagementwith the wellL,ore surface of unknown, and in-fact unknowable condition, providing a fluid-tight seal at a selected location between the conveyance tubular and the wellbore tubular. The seal ap~ar~at~of the present invention further includes an ~ctu~or member, which is selectively and remotely actu~t~hle, for urging the sealing ring between the running and sealing modes of operation. Preferably, the actuator member is responsive to set down weight applied to the conveyance tubular string.

In the preferred embodiment of the present invention, the inner surface of the wellbore tubular comprises the wellbore surface against which the seal operates, and the first surface of the sealing ring comprises an inner surface which is proximate an outer surface of the conveyance tubular, the 10 second surface of the sealing ring comprises an outer surface which sealinglyengages the inner surface of the wellbore tubular during the sealing mode of operation. In the present invention, the sealing ring will deform sufficiently to provide a gas-tight seal, even though the inner surface may have irregularities or defects thereon.
Also, in the preferred embodiment, the inner surface of the sealing ring at least in-part defines a clearance which is between the sealing ring and the conveyance tubular. The actu~tor member includes a wedge compo,-ent which is driven into this cavity to selectively radially expand the sealing ring20 between the radially-reduced running mode of operation and the radially-expanded sealing mode of operation. Preferably, the sealing ring is radially expanded in shape by deformation through the wedging action of the actlJ~tor member.

In the ~IJrefer~ed embodiment, the metal seal point of the sealing ring comprises at least one circu"~fere"lial seal bead which is generally triangular in cross-section, and which is urged to engage the wellbore surface during the sealing mode of operation. In one embodiment of the present invention, the metal seal points of the sealing ring are designed to be softer than the material which con,~rises the sealing surface, and thus will deform if sufficient force is applied to the sealing ring to expand it radially outward; in another embodiment, the metal seal points are formed of a material which is harder than the material which comprises the wellbore surface, and thus which WO 94/20728 ' - i ' PCT/US94/00181 will penetrate the wellbore surface if sufficient force is applied to outwardly radially expand the sealing ring. Also, preferably, the seal apparatus further includes a layer of resilient malerial disposed over at least a portion of the sealing surface of the sealing ring. The layer of resilient material has an inner 5 surface which is in engagement with the sealing surface of the sealing ring.
Selected ones of the plurality of portions of the sealing ring extend radially outward and into the layer of resilient material, and are in gripping engagementtherewith. These radially-extended portions prevent the layer of resilient material from swabbing-off during the running mode of operation. In the 10 preferred embodiment, the layer of resilient material includes an exterior surface of substantially uniform radial dimension, which sealingly engages the wellbore surface during the sealing mode of operation, in supplementation of the sealing engagement between the metal seal point and the wellbore surface. In the preferred embodiment, the layer of resiliel ll material further operates to prevent 15 entrapment of wellbore fluids between selected ones of the metal seal points during the sealing mode of operation, while the seal points serve also to prevent extrusion of the layer of resilient ",alerial.

rlereraL,ly, the portions of the sealing surface of the sealing ring 20 which define the extender memL,er~ extend into the layer of resilient i"alerial, and provide a skeletal structure (that is, a structural framework) for the layer of resilient " ldlerial~ to prevent swabbing-off of the layer of resilient material during the running mode of operation. The plurality of extender members are oriented at selected angles relative to the sealing ring to counteract directional forces25 acting on the layer of resilient material during the running mode of operation.
r,eferably, the plurality of extender members include at least one extender member oriented generally outward and downward from the sealing surface of ~ the sealing ring to counteract upward axial forces acting on the layer of resilient material during the running mode of operation, and at least one extender 30 member oriented generally outward and upward from the sealing surface of the sealing ring to counteract downward axial forces acting on the layer of resilient material during the running mode of operation.

-6- 2~347~2 As stated above, in the prcfellcd embodiment of the present invention, the inner surface of sealing ring at least in-part defines a cavity bel~o~n the sealing ring and the conveyance tubular, which is ~el~Pr~qlly triangular in cross-section. The q~-tu-qtor member lç- .. in~t~s at a wedge portion which is alsogenPrqlly triangular in cross-~s~ctinn~ and which eYtPnds a ~Pl~ted dictq~ into the cavity during the running mode of oper~q~tion, but which is urged deeper in the cavity during the sealing mode of opPrqtion. The sealing ring is formed of as~Pl~Pct~Pd mqtPriql which yields to expand a s~lect~ ~1ist-qn~ relative to the 10 convey~ ce tubular in response to insertion of the wedge portion into the cavity.
In the prcf~led embodiment, the artn~tQr mçmbP~r includes an ~q~ctl~qtor sleeve which circul,lr~l~,ltially en~qees the collveyance tubular, with the wedge ring coupled to the lowermost end of the actuator sleeve, and means for applying SPl~Pct~P~ axial force to the qçtll-qtor sleeve. A locking ",~l~qni~m is also 15 provided in the plef~lled embo limpnt which aUows only duwl~ward movement of the actllqtor sleeve relative to the conveyance tubular to pr~ ient the met~-to-met~l seal of the present invention from ~ dçntly ~iis~Pngqging from the sealingmode of operation.

Other aspects of this invention are as follows:

A seal app~lus for use in a s.ll)t~ll~can weUbore having a remotely-located downhole wellbore tubular disposed therein, said wellbore tubular ~Pfinine a remotely-located downhole wellbore surface of unknown condition, comrn~ing a conveyance tubular po~iti~ nqhle within said s~l~ çqn wellbore on a weUbore tubular string at a SPl~t~P~ location relative to sAid wellbore sllrf~

a sealing ring, disposed about at least a portion of said conveyance tubular, said sealing ring having a first surface proximate said conveyance tubular and a second surface, said second surface being a sealing surface with a ~2:
~ .

-6a- ~ ~ 3 47 ~ 2 plurality of portions, with sPl~ted ones of said plurality of portions of said sealing ring eYten~ing radially from said conveyance tubular in at least one radial dimencinn and defining at least one metal seal point for selective sealing eng~ment with said wellbore surfaee;

whe~in said seal apl~alus is operable in a plurality of modes of op~.ratinn, inclu(lir~

running mode of operation whele;il said sealing ring is ~ in~;n~ in a radially-reduced position, out of engagement with said wellbore surface for o coll~ance downward through said ~ubte~l~lean wellbore;

a sealing mode of operation, wherein said at least one metal seal point of said sealing ring is in sealing metal-to-metal eng~m~nt with said wellbore surf eP, providing a fluid-tight seal at a ~l~ted loc~tinn b~t~ said conveyance tubular and said wellbore tubular; and a conical wedge ring, the wedge ring being selectively and remotely slidably insertable bel~oen the sealing ring and the conveyance tubular to selectively cause the wedge ring to urge said sealing ring b~lw~n said running and sealing modes of operation.

In a wellbore conl~inillg fluid therein and having a tubular member 2o ~icpo~, therein which includes a central bore which defines a wellbore surf~
the method of sealing compri.~ing:

providing a metal conveyance tubular with a cylindrical outer s~rf~e~;

providing a metal sealing ring with at least one circular metal eYtPnder portion eYten-ling radially outward from an outer surface of said metal sealing ring, and having a cor,loul~d inner surface;

E~
., ' -6b- 2 ~ 3 ~7 6 2 placing said metal sealing ring around said metal conveyance tubular so that said con~uled inner surface at least in-part defines an annular cavity around said metal conveyance tubular;

providing a metal conical wedge ring having a sloped outer surface;

placing said metal conical wedge ring around said meal conveyance tubular and ~i~;posing at least a portion of it in said annular cavity;

lowering said metal conveyance tubular, said metal sealing ring, and said metal conical wedge ring to a desired downhole remote location of unlmown con-lition within said wellbore within said central bore of said tubular mPmbPr;
applying an axial load to said metal conical wedge ring to drive said metal conical wedge ring belween said metal conveyance tubular and said metal sealing ring and cause said metal sealing ring to deform by ex~n-ling radially oulward to urge said at least one circular metal extender portion into sealing metal-to-metal engagement with said wellbore surface of said tubular member;
and whe~ein an annular region defined bel~ said conveyance tubular and said tubular memhpr is ~l-lde~ by a gas-tight barrier which is composed subst~nti~lly entirely of metal components.

Ad~itio~l objects, fealurGs and advantages will be al~pa~Gnt in the written description which follows.

BRIEF DESCRIPIION OF 1~1~; DRAWINGS

The novel fealu~s believed char~teri~ti~ of the invention are set forth in the appended claims. The invention itself, however, as well as a prefGllGd . .

4 7 ~ ~
mode of use, further objects and advantages thereof, will best be understood by ~f~l~nce to the following det~il~ desc,iplion of an illustrative embo~im~-nt when read in conjlm-;lion with the acco",pallying drawings, wherein:

Flgure 1 is a one-quarter iongi~u~lin~l section view of the pr~fe.,ed c~ nt of the seal a~ s of the present invention in a running mode of ope~ti~n~ po~d conce-l~;c~lly within a wellbore tubular;

WO 94/20728 213\ 4 7 6 ~ PCT/US94/00181 Figure 2 is a one-quarter longitudinal section view of the prefer, ed embodiment of the seal apparalus of the present invention in a sealing mode of operation, in sealing engagement with an interior surface of a wellbore tubular;
Figure 3a is a partial longitudinal section view of a prior art mandrel with an elastomeric outer layer disposed thereon;

Figure 3b is a partial longitudinal section view of a prior art 10 mandrel with an elastomeric outer layer swabbing-off the mandrel in response to axial forces applied thereto;

Figure 4 is a partial longitudinal section view of the preferred seal apparatus of the present invention in a position intermediate that of the running 15 and sealing modes of operations;

Figure 5 is a partial longitudinal section view of the prefer~ed embodiment of the seal apparatus of the present invention in a sealing mode of operation;
Figure 6 is a partial longitudinal section view of an alternative embodiment of the seal apparal.ls of the present invention in a sealing mode of operation;

Figure 7 is a fragmentary longitudinal section view of the seal apparatus of the present invention, depicting the actuator linkage which allows a lra"srer of axial force in only one direction which serves to lock the seal apparatus in the sealing mode of operation in sealing engagement with the wellbore surface;
Figure 8 is a simplified partial longitudinal section view of the preferred seal apparatus of the present invention depicting the geometric configuration of the sealing surface of the sealing ring, which should be read ~, .. ,~ .
, , . ~". ., ~, .

with reference to Tables 1 and 2 which provide actual dimensions of the preferred embodiment;

Figures 9a, 9b, and 9c, depict wellbore tubulars which are in 5 poor conditions, and specifically depict tubulars which are (a) out-of-round, (b) include gouges, and (c) have corrosion damage; and Figure 10 schematically depicts the ulili~alion of the present invention to seal a region between a conveyance tubular and a wellbore 10 tubular, which is of unknown condition.
DETAILED DESCRIPTION OF THE INVENTION

Figure 1 is a one-quarter longitudinal section view of the preferred embodiment of the seal apparalus 11 of the present invention in a running 15 mode of operation, and disposed concentrically within wellbore tubular 13.
Conveyance tubular 17 is preferably coupled to force l,ans",illi"g sleeve 18 which is part of a tubular workstring (not depicted) which is used to lower conveyance tubular 17 to a selected location within wellbore 25 relative to tubular members 13. The seal apparatus 11 of the present invention may be 20 conveyed via a tubular workstring to a remote wellbore location, many thousands of feet from the earth's surface, to a selected location within wellbore 25 relative to a tubular member 13, which has been maintained in wellbore 25 for a lengthy period of time, perhaps years, and which may be of an unknown, and unknowable, condition. Therefore, seal apparatus 11 has great utility in 25 workover operations, wherein a wellbore is reengineered or reconditioned to enhance production. Typically, such workover operations are directed toward developing oil and gas production from one or more new production zones, and/or ceasing production from a previous production zone. Since seal apparatus 11 is intended to be conveyed many thousands of feet within a 30 wellbore, through the central bore of a wellbore tubular which is of unknown condition, a substantial clearance must be provided to ensure that seal apparatus 11 does not become stuck during running-in operations.

WO 94/20728 213 4 7 ~ ~ PCT/US94/00181 g As is shown in Figure 1, seal apparatus 11 is adapted in radial dimension for passage through central bore 27 of tubular member 13. Seal apparatus 11 is depicted in Figure 1 in a radially-reduced running mode of operation, during which seal apparatus 11 is out of wnld~l with wellbore surface 15 which defines central bore 27 of tubular member 13. In the event that seal apparatus 11 is run downward through the central bore of the casing string, at least three-sixteenths (3/16) of an inch of radial clearance is provided all the way around seal apparatus 11 to ensure that seal apparatus 11 does not become stuck within the casing string. If, for other appliG~tions, seal apparatus 10 11 is intended to be run through the central bore of a production tubing string, at least three-sixteenths (3/16) of an inch of radial clearance all the way around seal apparatus 11 would be required in order to prevent it from becoming stuck within the production string. In contrast, in Figure 2, seal apparatus 11 is shown in a radially-enlarged sealing mode of operation, in which components 15 of seal apparatus 11 are in gas-tight sealing engagement with wellbore surface 15 of tubular member 13. In the present invention, seal apparatus 11 may radially expand only a few thousandths of an inch or as great as three-sixteenths (3/16) to fivo ei~hll ,s (5/8) of an inch. In the embodiment described herein, such an expansion represents a five (5) to fifteen (15) percent expansion 20 of the outward diameter of the metal ring portion of seal apparatus 11.

Returning now to Figure 1, seal apparatus 11 of the preferred embodiment of the present invention includes sealing ring 19 which is circumferentially disposed about at least a portion of external surface 29 of conveyance tubular 17. As is shown in Figure 1, sealing ring 19 includes interior surface 31 and exterior surface 33, with interior surface 31 including upper portion 35 and lower portion 37, with upper portion 35 at least in-part ~ defining an annular cavity 39 which extends circul11ferel1~ially about external surface 29 of conveyance tubular 17 and sealing ring 19, and which is generally triangular in cross-section. Interior surface 31 of sealing ring 19 further includes lower portion 37 which circumferentially engages external surface 29 of conveyance tubular 17.

WO 94/20728 21~ 4~ 6~ PCT/US94100181 As shown in Figure 1 actuator member 21 extends downward into annular cavity 39 and completely fills it. Actuator member 21 includes conical wedge ring 41 force-transferring sleeve 18 and ~ctua~or linkage 43.
In the ~refer,ed embodiment wedge ring 43 and force-l,ailsrerlillg sleeve 18 5 are coupled by external threads 45 on the upper",osl end of wedge ring 41 and by internal threads 47 at the lowermost end of force-l, ans~erring sleeve 18Actuator linkage 43 further includes ratchet ring 49 and retainer ring 51.
Ratchet ring 49 is annular in shape and includes an interior surface upon which are disposed inwardly-facing ratchet teeth 53 which are machined in the 10 "down" position. These inwardly-facing ratchet teeth 53 are adapted for engaging outwardly-facing ratchet teeth 55 which are circu~ erenlially disposed along a portion of external surface 29 of conveyance tubular 17 and which are machined in the "up" position. Ratchet teeth 55 57 are adapted to allow only downward movement of ratchet ring 51 and to oppose upward movement of 15 ratchet ring 49 relative to conveyance tubular 17.

Figure 2 is a one-quarter longitudinal section view of the preferred embodiment of the seal apparatus 11 of the present invention in a sealing mode of operation in sealing engagement with wellbore surface 15 of tubular member 20 13. As shown therein downward movement of force-~ransferti,lg sleeve 18 will cause wedge ring 41 to be urged downward into annular cavity 39 which applies a radial force to sealing ring 19 causing the material which forms sealing ring 19 to deform by expanding radially outward and into contact with wellbore surface 15 of tubular member 13. Downward movement of 25 force-l,ansfer,i,lg sleeve 18 also causes ratchet ring 49 to travel downward along external surface 29 of conveyance tubular 17. As stated above the orientation of ratchet teeth 53 55 ensure that movement of ratchet ring 49 is limited to one direction namely downward relative to conveyance tubular 17.

Sealing ring 19 is prevented from moving downward in response to downward dis~lLcement of force-transferring sleeve 18 by operation of buttress member 57 which is secured in a fixed position relative to conveyance WO 94/20728 - 2 I 3 ~ ~ 6 2 PCT/USg4/00181 tubular 17 by threaded coupling 63 and the mating of internal shoulder 59 of buttress member 57 and external shoulder 61 of conveyance tubular 17.

The potential leakage pathway at the interface of force-transferring sleeve 18 and conveyance tubular 17 is sealed by operation of O-ring seal 65 which is disposed in O-ring cavity 67 at external surface 29 of conveyance tubular 17, which operates to provide a dynamic, gas-tight seal with interior surface 69 of force-transferring sleeve 18.

As shown in Figure 2, sealing ring 19 includes a layer of resilient material 71, which is in the preferred embodiment an elastomeric layer which is formed upon, or bonded, by conventional means, to exterior surface 33 of sealing ring 19.

Figures 3a and 3b are partial longitudinal section views of a prior art mandrel with an elastomeric outer layer disposed thereon, with Figure 3b depicting the swabbing-off of the ela~lo",eric layer from the mandrel in response to axial forces applied thereto. Figure 3a is a simplified depiction ofa design which is common in wellbore completion equipment, in which elastomer band 72 is bonded to an exterior surface of mandrel 73 by use of adhesive 75 (which is not visible in either Figure 3a or 3b). During running modes of operation, mandrel 73 will be lowered into a wellbore having fluids disposed therein. Fluid flow within the well in combination with the pressure di~ere"lial created by the occlusion of a portion of the wellbore by mandrel 73 will create axial force 77 which may detach elastomer band 72 from mandrel 73, resulting in "swabbing-off" of elastomer band 72. Of course, the loss or displ~cement of elastomer band 72 could seriously impair the operation of a wellbore tool, which, for example, may be depending upon elasloi"er band 72 to supply a sealing engagement with other wellbore components.

Seal apparatus 11 of the present invention is designed to avoid the swabbing-off of a layer of resilient material 71, but also functions to provide a seal which combines many of the attractive features of metal-to-metal seals t WO 94/20728 2 13 ~ 7 6 2 PCT/US94/00181 and elastomeric seals, as will be described now with referer,ce to Figures 4 and 5.

Figure 4 is a partial longitudinal section view of the preferred seal 5 apparatus 11 of the present invention in a position intermediate that of the running and sealing modes of operations which are depicted in Figures 1 and 2. Figure 5 is a partial longitudinal section view of the ~.refer,ad embodiment of seal apparatus 11 of the present invention in a sealing mode of operation, in gas-tight and fluid-tight sealing engagement with wellbore surface 15 of tubular member 13. As shown, wedge ring 41 includes inner surface 83 which slidably engages external surface 29 of conveyance tubular 17. The potential leak path at the interface of inner surface 83 and external surface 29 is sealedagainst leakage by operation of O-ring seal 81 which is disposed in O-ring cavity 79, which is formed in conveyance tubular 17 at external surface 29.
Wedge ring 41 further includes outer surface 85 which slidably engages interior surface 31 of sealing ring 19. The potential leak path at the interface of interior surface 31 and outer surface 85 is sealed against fluid leakage by operation of O-ring seal 87 which is disposed in O-ring cavity 89 which is formed in sealing ring 19 at interior surface 31. O-ring seal 87 provides a gas-tight and fluid-tight dynamic seal at the sliding interface of the surfaces.

As is shown in Figure 4, inner surface 83 of wedge ring 41 is parallel with the central longitudinal axis of conveyance tubular 17. In contrast, outer surface 85 of wedge ring 41 is disposed at an angle from the central longitudinal axis of conveyance tubular 17. As shown, the taper in wedge ring 41 which is defined by the inclination of outer surface 85 ensures that upper portions of wedge ring 41 will be thicker in radial dimension than the lower portions of wedge ring 41. In the preferred embodiment of the present invention, wedge ring 41 includes outer surface 85 which is disposed at three (3) degrees of inclination from the longitudinal central axis of conveyance tubular 17.

W0 94/20728 213 ~ 7 6 2 As is shown in Figure 4, sealing ring 19 includes raised portions 91, 93, 95, 97, 99, 101, and 103 which extend radially outward from the body portion 105 of sealing ring 19 a plurality of differing radial dimensions, and which define a plurality of extender members which extend from body portion 105, and which 5 serve a variety of functions including: engaging in a metal-to-metal sealing engagement with wellbore surface 15, to provide back-up resilient seals which supplement the sealing action of the metal-to-metal seals, preventing the entrapment of corrosive or other wellbore fluids between selected metal seal points, and to provide a skeletal framework for a layer of resilient material 7110 which extends over most of the exterior "sealing" surface 33 of sealing ring 19 and which prevents ~'swabbing-off~ of the layer of resilient material 71 due to axial forces applied to the layer of resilient material 71 during the running mode of operation. As shown in Figure 4, layer of resilient material 71 defines a substantially uniform sealing surface 107, which is generally cylindrical in shape, which completely covers raised portions 93, 95, 97, 99, 101, and partially covers raised portions 91, 103.

The functions of raised portions 91, 95, 97, 99, 101, 103, and the layer of resilient material 71 can best be explained with reference to Figures 5 and 20 6 which depict, in partial longitudinal section view, two embodiments of the seal apparatus 11 of the present invention in sealing modes of operation. The embodiment shown in Figure 5 is the prerer~ed embodiment of the present invention, while the embodiment shown in Figure 6 is an alternative embodiment of the present invention. The dirrerences between these 25 embodiments is easily explained with rererence to Figures 5 and 6. As shown in Figure 5, metal seal points 109, 111, and 113 are composed of a material which is softer than the material which forms wellbore surface 15 of tubular member 13; therefore, the outermost extents (that is "tips") of metal seal points 109, 111, and 113 are blunted or slightly deformed after coming into 30 engagement with wellbore surface 15 of tubular member 13. While blunted, they still provide a zero extrusion gap and a gas-tight seal between sealing ring 19 and wellbore surface 15 of tubular member 13. In contrast, in the embodiment of Figure 6, metal seal points 115, 117, and 119 are composed of a material which is harder than that which forms wellbore surface 15 of tubular member 13; therefore, metal seal points 115, 117, and 119 will in fact penetrate the material which forms wellbore surface 15 of tubular member 13, also providing a zero extrusion gap for a gas-tight seal.

In the preferred embodiment of Figure 5, metal seal points 109, 111, 113 are formed of 1020 steel, which has a known, industry-sta,)c~afd modulus of elasticity and Poisson ratio; while tubular member 13, in one embodiment, may comprise a polished seal bore which is formed of 4140 steel.
In the alternative embodiment of Figure 6, metal seal points 115, 117, and 119 should be formed of a harder steel. Of course, the seal apparatus 11 of the present invention may also function to provide a metal-to-metal sealing engagement with conventional wellbore tubulars, such as tubing and casing strings, which are for a particular well, of known hardness, but unknown 15 condition, and may include nicks, gouges, and corroded regions or which may be out of round.

Returning once again to Figure 5, the cooperation of the metal and resilient sealing components will be described in detail. This desc,i~JIion 20 is equally applicable to the embodiment of Figure 6. The principal functions of sealing ring 19, with layer of resilient material 71 disposed thereon, include providing a high quality, gas-tight metal-to-metal seal between sealing ring 19 and wellbore surface 15 of tubular member 13, providing a back-up resilient seal between the layer of resilient material 71 and wellbore surface 15 of tubular 25 member 13, preventing the extrusion of portions of the layer of resilient material 71 from between selected metal seal points, and preventing the accumulation or entrapment of corrosive or other wellbore fluids around or between selected metal seal points.

As is shown in Figure 5, as wedge ring 41 is wedged downward into annular cavity 39, thicker portions of wedge ring 41 are urged between conveyance tubular 17 and sealing ring 19 (which are both stationary). Sealing ring 19 is maintained in a fixed position relative to both conveyance tubular 17 WO 94/20728 213 ~ 7 62 PCT/US94/00181 _~ -15 -and tubular member 13 by operation of buttress member 57. Wedge ring 41 will apply a force to sealing ring 19 which includes both axial and radial forcecomponents. Force is provided to wedge ring 41 by conventional means, such as applying set down weight from a drilling or work-over rig to a workstring which includes force-translating sleeve 18. Aller"alely, the axial force can originate from conventional power charge setting tools. The axial force component provided by wedge ring 41 serves to overcome the frictional resistance to the insertion of wedge ring 41 into annular cavity 39. The radial force component (which is a sine function of the axial force component, and which depends upon the angle of inclination of outer surface 85 of wedge ring 41) serves to work against the material which comprises sealing ring 19, causing deformation of sealing ring 19 by outwardly radially expanding sealing ring 19 between the radially-reduced position of the running mode of operation and the radially-expanded position of the sealing mode of operation.
In the ~reter, ed embodiment of the present invention, conveyance tubular 17 is formed of 4140 steel, having known and industry standard modulus of elasticity and Poisson ratio, in to the form of a cylinder having an outer diameter of 7 inches and an inner diameter of 6.25 inches. In the preferred embodiment, sealing ring 19 is formed of 1020 steel. (The dimensions of the preferred sealing ring 19 of the present invention will be described in greater detail herebelow with reference to Figure 8.) Conveyance tubular 17 will not collapse or yield in response to radial force applied to sealing ring 19 by operation of wedge ring 41; instead, conveyance tubular 17 will provide a firm buttress to wedge ring 41.

Accordingly, sealing ring 19 will expand radially outward in response to the radial component of the axial force applied thereto by operationof wedge ring 41. The operational result is that metal seal points 109, 111, and113 will be urged radially outward into engagement with wellbore surface 15 of tubular member 13. In the prete"ed embodiment, since metal seal points 109, 111, 113 are formed of a material comparable in hardness to wellbore surface 15, they will become blunted and deformed and may in-fact extend slightly into ~, , welibore surface, yet will provide a gas-tight, extrusion resislant metal-to-metal seal with wellbore surface 15 of tubular member 13.

As sealing ring 19 and layer of resilient material 71 are urged radially outward, wellbore fluids, including corrosive fluids, which would otherwise have been trapped between metal seal points 109, 111, and 113, are expelled by displacement either upward or downward relative to sealing ring 19.

The layer of resilient material 71, which in the prefer, ed embodiment comprises an elastomeric band, will itself come into sealing engagement with wellbore surface 15 of tubular member 13, providing a back up seal to the seals provided by metal seal points 109, 111, and 113. The sealing action of the layer of resilient material 71 can be quite good, providedwellbore temperatures in the vicinity of seal apparatus 11 are below 450 degrees Fahrenheit. Temperatures above 450 degrees Fahrenheit will quickly impair the sealing function of the layer of resilient material 71, which is preferably formed of an elastomeric material. However, thermoplastic or other materials can be used to form the layer of resilient material 71, which have still higher operating temperature ranges, and which are thus useful in wellbore regions which have temperatures which exceed 450 degrees Fahrenheit.

Irrespective of the range of temperatures encountered in the wellbore, the sealing engagement between metal seal points 109, 111, and 113 also serve to provide an extrusion barrier to portions 121, 123 of the layer of resilient material 71 which is trapped between seal points 109, 111, 113 respectively. Thus, when wellbore temperatures are high, portions 121, 123 serve primarily as a mechanism for evacuating wellbore fluids from between seal points 109, 111, 113; however, when temperatures encountered in the wellbore are within the range of operating temperatures associated with the material which comprises the layer of resilient material 71, portions 121, 123 serve as back-up elastomeric-type resilient seals, and cooperate with the metal-to-metal seals of metal seal points 109, 111, 113 and wellbore surface 15 of tubular member 13. As shown in Figure 5, at a low temperature range, seal wo 94/20728 2 13 i ~ 6 2 apparatus 11 of the present invention provides three metal-to-metal seals and two resilient seals.

As explained above with regard to Figures 3a and 3b, during 5 running modes of operation, seal apparatus 11 may be run thousands of feet into a wellbore, during which wellbore fluids create axial forces which act uponthe layer of resilient material 71, and which tend to cause the material to swab-off. The design and orientation of raised portions 91, 93,95,97,99,101, and 103 (of Figure 4) define a structural framework upon which the layer of 10 resilient material 71 iS formed or bonded, which deters and resists the axialforces which would otherwise urge the layer of resilient ",aLe,ial 71 to swab-off sealing ring 19.

For example, with rererence now to Figure 4, raised portions 91, 103 provide a leading edge for sealing ring 19 which respectively shield the layer of resilient material 71 from axial forces encountered during downward and upward displacement within the wellbore. Raised portion 93 defines an extender member which is oriented generally outward and upward from the sealing surface 33 of sealing ring 19, which extends into the layer of resilient20 material 71, and counteracts or resists downward axial forces acting on the layer of resilient material 71 during the running mode of operation. Conversely,raised portion 101 defines an extender member which is oriented generally outward and downward from sealing surface 33 of sealing ring 19, which extends into the layer of resilie,)t material 71, and which resists or counteracts 25 upward axial forces acting on the layer of resilient material 71.

Likewise, the raised shoulder defined by raised portion 95 extends into the layer of resilient material 71, and is oriented generally outward and upward from the sealing surface 33 of sealing ring 19, to resist or counlerac~
downward axial forces acting on the layer of res ';ent material 71. Conversely, the shoulder defined by raised portion 99 extends into the layer of resilient malerial 71 and is oriented generally outward and downward from sealing surface 33 of sealing ring 19, and serves to resist or counteract upward axial WO 94120728 ~ 21317 ~ 2 PCT/US94100181 forces acting on the layer of resilient material 17 during the running mode of operation.

Raised portion 97 defines an extender member which is oriented 5 directly radially outward, and which is thus equally resistive to both upward and downward axial forces, and cannot be considered a directional-specific extender member. In this manner, raised portions 91, 93, 95, 97, 99, 101, and 103 cooperate together to minimize the opportunity for swabbing-off of the layerof resilient material 71 from sealing surface 33 of sealing ring 19.
Figure 8 is a cross-section view of sealing ring 19 of the preferred embodiment of the present invention, and is used to provide a precise physical descri,c lion of the various components which together comprise sealing ring 19.Physical dimensions, including distances and angles are indicated on the figure 15 by single letters for length and width dimensions, and double letters for angles.
Please note that lateral dimension lines on Figure 8 indicate diameter of the portion, unless specifically indicated otherwise. For example, the letter "L"
indica~es the outer diameter from the outermost radial surface of raised portion103 of sealing ring 19. Other measurements, such as "I", indicate the distance 20 between the dimension lines which are provided as an overlay on the cross-section view of sealing ring 19. Length and width dimensions are provided in Table 1, and angle measurements are provided in Table 2.

As can be determined from Figure 8, table 1, and table 2, in the 25 preren ed embodiment of the present invention, seal ap~,aralus 11 has an outer diameter of 8.210 inches, and an inner diameter which ranges from 7.45 inches to 7.780 inches, and which is thus suited for conveyance into a wellbore on a conveyance tubular which has an outer diameter of 7.45 inches or less. Of course, Figure 8 depicts seal apparatus 11 in an undeformed condition. For 30 this particular embodiment of seal apparatus 11, outward radial deror" ,alion is expected to be in the range of three-sixteenths (3/16) to five-sixteenths (5/16)of an inch, to close an expected clearance between the outer diameter of seal apparatus 11 and an adjoining wellbore tubular, such as a casing string, which WO 94/20728 21 3 4 7 6 ~ PCT/US94/00181 in this case, will have an outer diameter of nine and five-eights (9 5/8) inches, and an inner diameter somewhere in the acceptable range of 8.379 inches to 8.670 inches. The wellbore tubular may have been in the wellbore for an extended period of time, and thus exposed to corrosive wellbore fluids, high 5 temperatures, high pressures, and may have been subjected to mechanical damage during the running in or out of other wellbore tools. Therefore, as depicted in Figures 9a, 9b, and 9c, the wellbore tubular 13 may include substantial defects, such as an eccentric (out-of-round) central bore, which is depicted in Figure 9a, a gouge or nick, such as depicted in Figure 9b, or a 10 corroded surface, such as depicted in Figure 9c. In other applicalions, seal apparatus 11 may be designed to seal against different sizes of tubular products, including other sizes of casing. Conventional casing ranges in outer diameter from four inches to sixteen inches. Seal apparatus 11 would be scaled upward or downward to allow (1) a running clearance between the seal 15 apparatus 11 and the wellbore tubular of about three-sixteenths of an inch all the way around seal apparatus 11, and (2) radial expansion of the metal ring component of seal apparatus 11 which is at least large enough to span the running clearance. Such expansion can be as small as a few thousandths of an inch to as much as fifteen percent (15%) of the outer diameter of the metal 20 ring component of seal apparatus 11. r, e~erably, the metal ring component ofseal apparatus 11 will be expanded radially in an amount which is in the range of five percent to fifteen percent (5% -15%) of the outer diameter of the metal ring component.

This significant expansion allows for a good metal-to-metal seal, even though the wellbore tubular may have defects on its central bore, or may vary in inner diameter size over an acceptable tolerance range. Therefore, seal ap,l)aral.ls 11 may operate to provide a gas-tight, metal-to-meal seal with a wellbore tubular of (1) unknown condition and/or (2) unknown inner diameter.
The present invention allows for a high-integrity, and long-service-life seal with tubulars of a wide range of conditions and a wide range of diameter sizes. The condition and size OT Ule wellbore tubular need not be known or investigated;

WO 94/20728 2 1 3 ~ ~ 6 ~ PCT/US94/00181 this is a significant benefit since it may be impossible to know the condition or exact inner diameter of remotely-located, permanently placed wellbore tubulars.

Figure 7 is a fragmentary longitudinal section view of a portion of seal apparatus 11 of the present invention, depicting actuator linkage 43 which allows a transfer of axial force in only one direction to urge the seal apparatus 11 into sealing engagement with wellbore surface 15. Actuator linkage 43 was discussed above generally in connection with Figure 2. As shown in Figure 7, external threads 131 of the upper portion of wedge ring 41 engage internal threads 133 of the lowermost portion of force-transferring sleeve 18. Wedge ring 41 includes interior inclined surface 135 which engages exterior inclined surface of ratchet ring 49. Ratchet ring 49 includes inwardly-facing ratchet teeth 53 which engage outwardly facing ratchet teeth 55 of conveyance tubular 17, as axial force 139 is applied to force-transferring sleeve 18. Retaining ring 51 comprises, in the ~,refer,ed embodiment, a snap ring. O-ring 141 is disposed between retainer ring 51 and ratchet ring 49 and functions as a rubber spring to hold the retainer ring in place.

Actuator linkage 43 of the present invention operates to lock wedge ring 41 in a fixed position relative to sealing ring 19 once the sealing mode of operation of obtained. This ensures that the metal-to-metal seal obtained by seal apparatus 11 of the present invention is permanently energized and ,nainlai, led in the sealing mode of operation to prevent accidental, or unintentional, release of the sealing engagement between sealing ring 19 and wellbore surface 15 of tubular member 13.

The present invention may also be characterized as a method of sealing in a wellbore having a tubular member disposed therein which defines a wellbore surface. The method includes steps of providing a metal 30 conveyance tubular with a cylindrical outer surface, and providing a metal sealing ring with at least one circular metal extender portion extending radially outward from the outer surface of the metal sealing ring. The metal sealing ringshould also be provided with a contoured inner surface. The metal sealing ring WO 94120728 213 4 7 62 ' ~ ~ ' PCTtUS94/00181 ._ is placed around the metal conveyance tubular so that the contoured inner surface at least in-part defines an annular cavity around the metal conveyance tubular. A metal conical wedge ring is provided which has a sloped outer surface. The metal conical wedge ring is placed around the metal conveyance 5 tubular and disposed at least in-part within the annular cavity between the metal conveyance tubular and the metal sealing ring.

The metal conveyance tubular, metal sealing ring, and metal conical wedge ring are lowered into the wellbore to a desired location within the 10 central bore of the tubular member. Then, an axial load is applied to the metal conical wedge ring to drive it between the metal conveyance tubular and the metal sealing ring, causing the metal sealing ring to deform by expanding radially outward. At least one circular metal extender portion which is disposedon the outermost surface of the metal seal ring is urged into sealing 15 metal-to-metal engagement with the wellbore surface of the tubular member.

In this manner, the annular region which is defined between the conveyance tubular and the tubular member is occluded by a gas-tight barrier which is composed substanlially entirely of metal components. Since the 20 sealing barrier is composed of metal, preferably steel, the metal-to-metal seal apparatus of the present invention can provide a seal which can withstand extremely high pressure differentials, as opposed to conventional seals which form an annular barrier which at least in-part includes subsLa,1lial elastomericcomponents.
Figure 10 is a simplified schematic view of utilization of work-over rig 201 to create and lower production string 203 within wellbore 215. As is shown, work-over rig 201 includes conventional hoisting equipment 207 for raising and lowering production string 203 within wellbore 215, power tongs 30 205 for making-up and breaking-down the production tubing string, as needed, and gripping equipment 209 which serves to engage production string 203 during make-up operations. As is shown, wellbore 215 includes casing string 213 with interior ~urface 211 which defines a central bore. Typically, casing 213 may have been installed within wellbore 215 many years prior to the workover operation, and may be composed of a known grade of steel, which is in an unknown, and quite possibly unknowable condition, and may include nicks, cuts, gouges, corroded regions, and out-of-round regions. Additionally, 5 casing 213 may have an inner diameter which is within a range of acceptable inner diameter for particular casing type and size. As is shown, seal apparatus 11 may be aligned next to a particular region 219 of wellbore 215 which may have these and other defects in the interior surface which defines the central bore. Region 219 may be located several hundred or several thousand feet from work-over rig 201. In the present invention, seal apparatus 11 is utilized to seal annular region 217 between production string 203 and casing 213, notwithstanding the fact that region 219 of casing 213 may have many of the above-identified defects which would normally pose a severe problem for sealing operations. In the present invention, seal apparatus 11 has a sufficiently small radial dimension during running operations to pass through hundreds or thousands of feet of wellbore without becoming stuck, but expands radially outward in an amount which is sufficient to forcefully engage region 219 of casing 213 in a manner which either (1) deforms selected ones of the raised portions, or (2) urges selected ones of the raised portions to penetrate into casing 213 at region 219, to provide a gas-tight, metal-to-metal seal which effectively seals annular region 217.

Laboratory tests have revealed that the metal-to-metal seal ap,uara~us of the present invention can withstand pressure dir~erer,lials of between 10,000 and 16,000 pounds per square inch, at extremely high temperatures. It is believed that the metal-to-metal seal of the present invention can provide a gas-tight barrier to pressure di~erenlials of 20,000 pounds per square inch or greater. It can thus be appreciated that the seal apparatus and method of the present invention can provide a high quality, gas-tight sealing engagement, which may find many commercial uses in wellbore drilling and completion operations.

8 213 ~ 7 6 2 PCT/US94/00181 The present invention represents a significant advance over prior art devices. The clearance provided around the seal apparatus, which can be identified as the "running clearance," is sufficiently large to allow the seal apparatus to be run into remote locations within a wellbore which may be 5 thousands and thousands of feet away from the earth's surface. The seal apparatus is then subjected to a large amount of force, causing the metal ring component of the seal apparatus to deform radially outward to span the running clearance between the seal apparatus and a remotely-located wellbore tubular member. In the embodiment described herein, the radial running 10 clearance between the seal apparatus and the wellbore tubular is approximately three-sixteenths (3/16) of an inch. In the embodiment shown herein, the outward radial expansion of the metal ring component of the seal apparatus can be only a few thousandths of an inch, or as great as three-sixteenths (3/16) of an inch to five-sixteenths (5/16) of an inch. This rather large range 15 of radial expansion of the metal ring component ensures that the seal apparatus will provide a gas-tight, long-service-life, metal-to-metal seal with the wellbore tubular, even though the condition of the wellbore tubular is entirely unknown.

The wellbore tubular may have nicks, gouges, corroded regions, 20 or irregularities in the shape of the inner bore. Furthermore, even if the wellbore tubular is not damaged in any respect, it may have an inner diameter which falls within an industr,v-accepted range of acceptal,le inner diameters.
The variance of the inner diameters of undamaged tubulars spans a significant distance range. The present invention provides a seal ap~,aral,Js which will 25 provide a gas-tight, long-service-life, metal-to-metal wellbore seal which will seal against the wellbore tubular, irrespective of the actual inner diar"eler of the wellbore tubular, provided it is within the total expansion range of the metal seal component of the wellbore tubular.

In the present invention, expansion of the metal seal component can represent a five to fifteen percent (5%-15%) radial expansion of the metal ring component. Although greater percentages of expansion are possible, particularly if dir~re,1t ma~erials are selected to form the metal ring component, ~i~, ,.

21347 ~2 - 24 in the present invention the amount of radial expansion must be at least as great as the running clearance between the seal apparatus and the wellbore tubular against which it is intended to seal. In the embodiment described herein, radial expansion can be as large as five-sixteenths (5/16) of an inch, 5 which exceeds the preferred running clearance between the seal apparatus and the wellbore tubular by two-sixteenths (2/16) of an inch. This significant rangeof possible maximum expansion of the metal ring component allows the seal apparatus to seal against wellbore tubulars which have significant damage, shape irregularities, and inner diameter dimensions.
In the embodiment described herein, the running clearance is completely spanned by expansion of the ring, but an additional sixty to seventy percent of the running clearance may also be spanned. This allows for tight seals against seriously damaged or deformed wellbore tubulars, without 15 requiring the operator to determine the condition of the tubular or dimensions of such tubulars. The operator need only have knowledge of the ~nominal~
(that is, the stated) dimension of the wellbore tubular. For example, engineering records of a particular well may indicate that nine and fivc ei~hls (9 5/8) inches outer diameter casing is disposed at a region of interest within the wellbore.
20 The operator may select a seal apparatus in accordance with the present invention which is sized and constructed to allow for unobstructed running-in operations through all intermediate tubulars between the surface and the nine and five-eights ( 9 5/8) inches casing. Furthermore, the selected seal apparatus will be capable of sufficient outward radial ex~ansion to engage the 25 nine and five eigl,l:j inches casing in a gas-tight seal, even though the inner diameter of the casing varies over an acceptable range, or includes deformities or damage such as corroded regions, gouges, nicks and eccentricities. The significant range of possible expansions of the metal ring component of the sealapparatus ensures that a great number of types of deformities and irregularities, 30 as well as a great range in degree of deformities and irregularities, may be effectively sealed by the present invention.

~213476~
2 5 -- ;~ 1 The present invention may be sized upward or downward to allow for running-in operations through either production tubing or casing, as long asa sufficient running clearance is provided between the tool and the tubular strings between the earth's surface and the desired setting location. All that is 5 further required is that the metal ring component of the apparatus be expandable to an extent which is sufficient to entirely bridge the running clearance, and prererably additional clearance which may be provided by gouges, nicks, corroded regions, eccentricities, or variance of the inner diameter within an acceptable range of diameters.
While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications withoutdeparting from the spirit thereof.

WO 94t20728 PCT/US94/00181 213~ 762 -26-A3.5 inches M 75 degrees B1.75 inches AB 60 degrees C1.50 inches AC 60 degrees D1.00 inches AD 60 degrees E0.10 inches AE 60 degrees F0.015 inches AF 75 degrees G0.015 inches AG 75 degrees H0.015 inches AH 75 degrees 1.50 inches Al 3 degrees J1.00 inches K0.75 inches L8.125 inches M7.75 inches N7.45 inches O0.18 inches P7.803 inches Q7.90 inches R1.84 inches S7.780 inches T8.00 inches U8.125 inches V8.210 inches

Claims (20)

1. A seal apparatus for use in a subterranean wellbore having a remotely-located downhole wellbore tubular disposed therein, said wellbore tubular defining a remotely-located downhole wellbore surface of unknown condition, comprising:

a conveyance tubular positionable within said subterranean wellbore on a wellbore tubular string at a selected location relative to said wellbore surface;

a sealing ring, disposed about at least a portion of said conveyance tubular, said sealing ring having a first surface proximate said conveyance tubular and a second surface, said second surface being a sealing surface with aplurality of portions, with selected ones of said plurality of portions of said sealing ring extending radially from said conveyance tubular in at least one radial dimension and defining at least one metal seal point for selective sealing engagement with said wellbore surface;

wherein said seal apparatus is operable in a plurality of modes of operation, including:

running mode of operation wherein said sealing ring is maintained in a radially-reduced position, out of engagement with said wellbore surface for conveyance downward through said subterranean wellbore;

a sealing mode of operation, wherein said at least one metal seal point of said sealing ring is in sealing metal-to-metal engagement with said wellbore surface, providing a fluid-tight seal at a selected location between said conveyance tubular and said wellbore tubular; and a conical wedge ring, the wedge ring being selectively and remotely slidably insertable between the sealing ring and the conveyance tubular to selectively cause the wedge ring to urge said sealing ring between said running and sealing modes of operation.

2. A seal apparatus according to Claim 1:

wherein said wellbore surface comprises an inner surface of said wellbore tubular;

wherein said first surface of said sealing ring comprises an inner surface which is proximate an outer surface of said conveyance tubular; and wherein said second surface of said sealing ring comprises an outer surface which sealingly engages said inner surface of said wellbore tubular during said sealing mode of operation.

3. A seal apparatus according to Claim 1:

wherein said sealing ring is radially expanded in shape, by deformation wedging action of said wedge ring, from said radially-reduced running mode of operation to said radially-expanded sealing mode of operation.

4. A seal apparatus according to Claim 1:

wherein said wedge ring drives said at least one metal seal point of said sealing ring into penetrating engagement with said wellbore surface of said wellbore tubular during said sealing mode of operation.

5. A seal apparatus according to Claim 1:

wherein said at least one metal seal point of said sealing ring comprises at least one circumferential seal bead which is generally triangular in cross-section, which is urged to penetrate said wellbore surface during said sealing mode of operation by operation of said actuator member.

6. A seal apparatus according to Claim 1:

wherein said seal apparatus further includes a layer of resilient material disposed over at least a portion of said sealing surface of said sealing ring, said layer of resilient material having an inner surface in engagement with said plurality of portions of said sealing ring, with said selected ones of said plurality of portions of said sealing rings extending radially outward and into said layerof resilient material, and in gripping engagement therewith, to prevent said layer of resilient material from swabbing-off during said running mode of operation.

7. A seal apparatus according to Claim 6:

wherein said layer of resilient material comprises an elastomeric band formed upon said sealing ring.

8. A seal apparatus according to Claim 6:

wherein said layer of resilient material includes an exterior surface of substantially uniform radially dimension, which sealingly engages said wellbore surface during said sealing mode of operation in supplementation of said at least one metal seal point of said sealing ring.

9. A seal apparatus according to Claim 7:

wherein said wellbore tubular is in contact with wellbore fluids; and wherein said layer of resilient material prevents entrapment of said wellbore fluids between selected ones of said at least one metal seal point during said sealing mode of operation.

10. A seal apparatus according to Claim 1:

wherein said plurality of portions of said sealing ring extend radially from said conveyance tubular and define a plurality of metal seal points for engagement with said wellbore surface during said sealing mode of operation;

wherein a layer of resilient material is disposed over said sealing surface of said sealing ring and extends between said plurality of metal seal points; and wherein, during said sealing mode of operation, said plurality of metal seal points penetrate said wellbore surface, each providing a seal, and said layer of resilient material is urged into sealing contact with said wellbore surface, and is prevented from extrusion by said metal seal points.

11. A seal apparatus according to Claim 1:

wherein said seal apparatus further includes a layer of resilient material disposed over at least a portion of said sealing surface of said sealing ring;

wherein said sealing surface of said sealing ring includes a plurality of portions which define a plurality of extender members which extend into said layer of resilient material, providing a skeletal structure for said layer of resilient material to prevent swabbing-off of said layer of resilient material during said running mode of operation.

12. A seal apparatus according to Claim 11:

wherein said plurality of extender members are oriented at selective angles relative to said sealing ring to counteract directional forces acting on said layer of resilient material during said running mode of operation.

13. A seal apparatus according to Claim 11:

wherein said plurality of extender members includes at least one extender member oriented generally outward and downward from said sealing surface of said sealing ring to counteract upward axial forces acting on said layer of resilient material during said running mode of operation, and at least one extender member oriented generally outward and upward from said sealing surface of said sealing ring to counteract downward axial forces acting on said layer of resilient material during said running mode of operation.

14. A seal apparatus according to Claim 1:

wherein said first surface of said sealing ring at least in-part defines a cavity between said sealing ring and said conveyance tubular, which is generallytriangular in cross-section;

wherein said wedge ring terminates at a tip portion which is generally triangular in cross-section, and which extends a selected distance into said cavity during said running mode of operation but which is urged deeper into said cavity during said sealing mode of operation;

wherein said sealing ring is formed of a selected material which yields to expand a selected distance relative to said conveyance tubular in response to insertion of said wedge ring into said cavity.

15. A seal apparatus according to Claim 14 further comprising:

an actuator sleeve which circumferentially engages said conveyance tubular, and is coupled to said wedge ring; and means for applying a selected axial force to said actuator sleeve.

16. In a wellbore containing fluid therein and having a tubular member disposed therein which includes a central bore which defines a wellbore surface,the method of sealing comprising:

providing a metal conveyance tubular with a cylindrical outer surface;

providing a metal sealing ring with at least one circular metal extender portion extending radially outward from an outer surface of said metal sealing ring, and having a contoured inner surface;

placing said metal sealing ring around said metal conveyance tubular so that said contoured inner surface at least in-part defines an annular cavity around said metal conveyance tubular;

providing a metal conical wedge ring having a sloped outer surface;

placing said metal conical wedge ring around said meal conveyance tubular and disposing at least a portion of it in said annular cavity;

lowering said metal conveyance tubular, said metal sealing ring, and said metal conical wedge ring to a desired downhole remote location of unknown condition within said wellbore within said central bore of said tubular member;

applying an axial load to said metal conical wedge ring to drive said metal conical wedge ring between said metal conveyance tubular and said metal sealing ring and cause said metal sealing ring to deform by expanding radially outward to urge said at least one circular metal extender portion into sealing metal-to-metal engagement with said wellbore surface of said tubular member;
and wherein an annular region defined between said conveyance tubular and said tubular member is occluded by a gas-tight barrier which is composed substantially entirely of metal components.

17. The method of sealing according to Claim 16, further comprising:

providing a layer of resilient material;

securing said layer of resilient material to said outer surface of said metal sealing ring; and sealing, with at least a portion of said layer of resilient material, against said wellbore surface in supplementation to metal-to-metal sealing engagement of said at least one circular metal extender portion and said wellbore surface.

18. The method of sealing according to Claim 17, wherein said at least one circular metal extender portion comprises a plurality of circular metal extenderportions, further comprising:

evacuating said fluid from between said plurality of circular metal extender portions to prevent entrapment of said fluid between said metal sealingring and said wellbore surface.

19. The method of sealing according to Claim 18, further comprising:

containing at least a portion of said layer of resilient material between selected ones of said plurality of circular metal extender portions in a manner which prevents extrusion.

20. The method of sealing according to Claim 17, further comprising:

counteracting, with said at least one circular metal extender portion, axial forces on said layer of resilient material to prevent detachment of said layer of resilient material from said outer surface of said metal sealing ring.