CN116867952A - Foldable casing packer for metal-to-metal sealing - Google Patents

Foldable casing packer for metal-to-metal sealing Download PDF

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Publication number
CN116867952A
CN116867952A CN202180094513.1A CN202180094513A CN116867952A CN 116867952 A CN116867952 A CN 116867952A CN 202180094513 A CN202180094513 A CN 202180094513A CN 116867952 A CN116867952 A CN 116867952A
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CN
China
Prior art keywords
collapsible
casing packer
packer
piston
hollow metal
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202180094513.1A
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Chinese (zh)
Inventor
P·H·温
C·S·K·罗
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Halliburton Energy Services Inc
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Halliburton Energy Services Inc
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Publication of CN116867952A publication Critical patent/CN116867952A/en
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    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00Sealing or packing boreholes or wells
    • E21B33/10Sealing or packing boreholes or wells in the borehole
    • E21B33/12Packers; Plugs
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B23/00Apparatus for displacing, setting, locking, releasing or removing tools, packers or the like in boreholes or wells
    • E21B23/06Apparatus for displacing, setting, locking, releasing or removing tools, packers or the like in boreholes or wells for setting packers
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00Sealing or packing boreholes or wells
    • E21B33/10Sealing or packing boreholes or wells in the borehole
    • E21B33/12Packers; Plugs
    • E21B33/1208Packers; Plugs characterised by the construction of the sealing or packing means
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00Sealing or packing boreholes or wells
    • E21B33/10Sealing or packing boreholes or wells in the borehole
    • E21B33/12Packers; Plugs
    • E21B33/1208Packers; Plugs characterised by the construction of the sealing or packing means
    • E21B33/1212Packers; Plugs characterised by the construction of the sealing or packing means including a metal-to-metal seal element
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00Sealing or packing boreholes or wells
    • E21B33/10Sealing or packing boreholes or wells in the borehole
    • E21B33/12Packers; Plugs
    • E21B33/124Units with longitudinally-spaced plugs for isolating the intermediate space
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00Sealing or packing boreholes or wells
    • E21B33/10Sealing or packing boreholes or wells in the borehole
    • E21B33/12Packers; Plugs
    • E21B33/128Packers; Plugs with a member expanded radially by axial pressure

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  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mining & Mineral Resources (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Environmental & Geological Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Earth Drilling (AREA)
  • Consolidation Of Soil By Introduction Of Solidifying Substances Into Soil (AREA)
  • Electroluminescent Light Sources (AREA)
  • Piles And Underground Anchors (AREA)
  • Package Closures (AREA)
  • Prostheses (AREA)
  • Laminated Bodies (AREA)
  • Crushing And Grinding (AREA)
  • Diaphragms And Bellows (AREA)

Abstract

The present disclosure provides collapsible casing packers and methods of use. An exemplary method introduces a collapsible casing packer into a wellbore; wherein the collapsible casing packer comprises a collapsible hollow metal casing. The method further includes radially expanding the collapsible hollow metal housing by axially compressing the collapsible hollow metal housing to collapse the collapsible hollow metal housing, wherein the collapsible hollow metal housing is collapsed until a portion of the collapsible hollow metal housing contacts an adjacent surface, thereby isolating a horizon.

Description

Foldable casing packer for metal-to-metal sealing
Technical Field
The present disclosure relates to the use of packers, and more particularly, to the use of collapsible casing packers to provide zonal isolation (zonal isolation) with metal-to-metal sealing and anchoring.
Background
The packer may be used for anchoring in and around a conduit in a wellbore environment and for forming an annular seal, among other reasons. A packer may be used to anchor a conduit concentrically within another conduit or wellbore. The packer may also close a zone in the conduit or wellbore. The seal may restrict all or a portion of fluid and/or pressure communication at the sealing interface. The formation of seals may be an important component of wellbore operations during all phases of drilling, completion and production. In some operations, the isolation and anchoring functions may require separate mechanisms with many moving parts in some packer designs. These complications may increase costs and the incidence of mechanical failure.
In addition, some packers may be radially expandable by stretching the packer material in an axial direction. The greater the expansion, the weaker the sealing ability may be, because the material is subjected to greater and greater tensile stresses due to the reduced cross-section resulting from stretching of the material. This can lead to problems with seal assurance in certain wellbore environments. An improved apparatus and method for a packer for providing zonal isolation with metal-to-metal sealing and anchoring is provided.
Drawings
Illustrative examples of the present disclosure are described in detail below with reference to the attached drawing figures, which are incorporated herein by reference, and wherein:
FIG. 1 is a perspective view of an example of a collapsible casing packer according to examples disclosed herein;
FIG. 2 is a cross-sectional view of the example collapsible casing packer of FIG. 1, in accordance with examples disclosed herein;
FIG. 3 is a cross-sectional view of the example collapsible casing packer of FIGS. 1 and 2 used on a conduit, when in an unfolded state, in accordance with examples disclosed herein;
FIG. 4 is a cross-sectional view of the example collapsible casing packer of FIG. 3 when in a collapsed state, in accordance with examples disclosed herein;
FIG. 5 is a cross-sectional view of another example of a collapsible casing packer disposed on a conduit in an unfolded state, in accordance with examples disclosed herein;
FIG. 6 is a cross-sectional view of the example collapsible casing packer of FIG. 5 when in a collapsed state, in accordance with examples disclosed herein;
FIG. 7 is a cross-sectional view of another example of a collapsible casing packer disposed on a conduit in an unfolded state, in accordance with examples disclosed herein;
FIG. 8 is an enlarged cross-section of the collapsible casing packer of FIG. 7, in accordance with examples disclosed herein;
FIG. 9 is a cross-sectional view of the example collapsible casing packer of FIG. 7 when in a collapsed state, in accordance with examples disclosed herein;
FIG. 10 is a cross-section of an optional locking mechanism for the collapsible casing packer of FIG. 7, in accordance with examples disclosed herein;
FIG. 11 is a cross-section of the optional locking mechanism of FIG. 10 once engaged according to an example disclosed herein;
FIG. 12 is a cross-section showing the collapsible casing packer of FIGS. 7-11 with a sealing element attached over the tip, in accordance with examples disclosed herein;
FIG. 13 is a cross-section of the collapsible casing packer of FIGS. 7-11 showing two sealing elements attached on either side of the tip, in accordance with examples disclosed herein; and is also provided with
FIG. 14 is a cross-section illustrating the collapsible casing packer of FIG. 13 in a collapsed state, according to an example disclosed herein.
The depicted figures are merely exemplary and are not intended to corroborate or imply any limitation with respect to the environments, architectures, designs, or processes in which different examples may be implemented.
Detailed Description
The present disclosure relates to the use of packers, and more particularly, to the use of collapsible casing packers to provide zonal isolation (zonal isolation) with metal-to-metal sealing and anchoring.
In the following detailed description of several illustrative examples, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration examples that may be practiced. These examples are described in sufficient detail to enable those skilled in the art to practice the examples, and it is to be understood that other examples may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosed examples. To avoid detail not necessary to enable those skilled in the art to practice the examples described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative examples is defined only by the appended claims.
Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth, used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the examples of the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. It should be noted that when "about" is at the beginning of the list of values, the "about" modifies each digit of the list of values. Further, in some numerical lists of ranges, some lower limits listed may be greater than some upper limits listed. Those skilled in the art will recognize that selecting a subset will require selecting an upper limit that exceeds a selected lower limit.
Unless specified otherwise, the use of the terms "connected," "engaged," "coupled," "attached," or any other term describing an interaction between elements is not meant to limit the interaction to a direct interaction between the elements and may also include an indirect interaction between the described elements. Furthermore, any use of any form of the terms "connect," "engage," "couple," "attach," or any other term describing interactions between elements includes auxiliary items that are integrally formed together without additional fasteners or coupling devices. In the following discussion and in the claims, the terms "include" and "comprise" are used in an open-ended fashion, and thus should be interpreted to mean "include, but not limited to. As used throughout this document, "or" does not require mutual exclusivity unless otherwise indicated.
The terms uphole and downhole may be used to refer to the position of various components relative to the bottom or end of the well. For example, a first component described as uphole from a second component may be farther from the end of the well than the second component. Similarly, a first component described as downhole from a second component may be positioned closer to the end of the well than the second component.
Examples of the apparatus and methods described herein relate to the use of collapsible casing packers to provide zonal isolation with metal-to-metal seals and anchors. Advantageously, the collapsible casing packer comprises a metal casing that allows for metal-to-metal sealing and/or anchoring within the conduit. Because collapsible casing packers are metallic, they may be more durable in certain wellbore environments than other packer types, such as elastomer swell packers. Yet a further mechanical advantage is that the collapsible casing packer is radially expanded by collapsing the hollow casing in the axial direction, the collapsible casing packer being subjected to compressive rather than tensile stresses in nature, which makes it more durable than a balloon packer. Another advantage is that the collapsible casing packer is not dependent on an inflatable fluid or bladder, or on the use of a fluid or gas control line to actuate the collapsible casing packer. The balloon-dependent packer may thin upon inflation and may have reduced temperature and pressure ratings. Yet another advantage is that collapsible casing packers can be manufactured by additive manufacturing, which allows some instances to have a fully closed casing without openings and still remain hollow. Another advantage is that collapsible casing packers have very few moving parts and may not suffer from the same mechanical problems as other more complex packers. In addition, the reduced component requirements may also reduce costs. Yet another advantage is that the collapsible casing packer, while metallic, is elastically deformable and can be released and retrieved when the axial load is removed. In some examples, the collapsible casing packer may be plastically deformable. In these instances, the collapsible casing packer may not be retrievable in certain operations.
The collapsible casing packer comprises a hollow casing comprising metal. A specific example of a metal is a metal alloy steel, which in some examples may provide corrosion resistance. Other examples of metals may include titanium alloys, or combinations of titanium, steel, and other metals or alloys.
A collapsible casing packer may be used to form a seal at the interface of the collapsible casing and the adjacent surface. The adjacent surface may be a metal surface of a wellbore pipe, a casing surface, a wall of a cement sheath, a wall of the formation itself, or any other wellbore surface. In some examples, adjacent surfaces may have contour variations, rough finishes, and the like. These surfaces are not smooth, uniform and/or coherent in the area to be sealed. These surfaces may have any type of depressions or protrusions, such as, for example, cracks, gaps, pits, holes, indentations, etc. Examples of surfaces that may include these depressions or projections are wellbore walls, such as casing walls or walls of the formation.
In some examples, the collapsible casing packer is produced by additive manufacturing, such as 3-D printed metal casings. The additively manufactured component may not involve precision machining and, in some instances, may include a rough surface finish that may facilitate texturing the exterior of the housing for anchoring. In alternative examples, the housing may be finished to provide a smooth surface. In some examples, the metal shell may include different materials layered throughout the shell (e.g., different grades of steel, different alloys, combinations of alloys such as titanium and steel, etc.) to impart different material properties to different portions of the shell. For example, the apex of the shell may be made more elastically deformable to facilitate flexing to expand the shell, while the walls of the collapsible shell may be made more rigid to increase strength and support. Yet another advantage of additive manufacturing is that collapsible casing packers can be manufactured to be completely sealed without openings and still retain a hollow core. Such a configuration may increase the overall strength of the material. In some examples, the deformable portion of the collapsible casing packer may be plastically deformable and may not return to its original shape, if desired. These specific examples of collapsible casing packers may be used in operations where retrieval of collapsible casing packers is not desired. It should be appreciated that while the collapsible casing packer is described as a potential product of additive manufacturing, the collapsible casing packer may be manufactured via other techniques as desired.
Collapsible casing packers may be used to form seals between adjacent surfaces in a wellbore. Without limitation, collapsible casing packers may be used to form seals on a conduit, formation surface, cement sheath, downhole tool, and the like. For example, collapsible casing packers may be used to form a seal between the outer diameter of a conduit and the surface of a subterranean formation. Alternatively, a collapsible casing packer may be used to form a seal between the outer diameter of the conduit and the cement sheath (e.g., casing). As another example, a collapsible casing packer may be used to form a seal between the outer diameter of one conduit and the inner diameter of another conduit (which may be the same or different). Further, a plurality of collapsible casing packers may be used to form seals between a plurality of conduits (e.g., oilfield tubular strings). In one embodiment, the collapsible casing packer may form a seal on the inner diameter of the conduit to restrict fluid flow through the inner diameter of the conduit, thereby acting like a bridge plug. It should be understood that collapsible casing packers may be used to form a seal between any adjacent surfaces in a wellbore, and that the present disclosure is not limited to the precise examples disclosed herein.
Collapsible casing packers may be used in high temperature formations (e.g., in formations having a horizon at or above 350°f). In these high temperature formations, the use of elastomeric packers or other types of swelling packers may be affected. Advantageously, the collapsible casing packer of the present disclosure is not affected by use in high temperature formations. In some examples, collapsible casing packers of the present disclosure may be used in high temperature formations and exposed to high salinity brine. In particular examples, a collapsible casing packer may be used to form a seal after contact with brine having a salinity of 10% or greater, and when disposed in a wellbore zone having a temperature of 350°f or greater.
FIG. 1 is a perspective view of an example of a collapsible casing packer (generally 5). The collapsible casing packer 5 comprises a collapsible hollow metal casing 10. The collapsible hollow metal housing 10 is folded in the axial direction to start expanding in the radial direction. The collapsible casing packer 5 is wrapped or slipped over a conduit (not shown) by weight, grade and connection as dictated by the well design. The conduit may be any type of conduit used in a wellbore, including drill pipe, rod, tubing, coiled tubing, and the like. The collapsible casing packer 5 further comprises a corrugated design with tips 15 that contact the adjacent surface to form a seal to prevent fluid passage and anchor the conduit to the adjacent surface. In some optional examples, the interior 20 of the collapsible casing packer 5 may form a seal with the outer surface of the conduit, including when the collapsible casing packer 5 is inflated.
FIG. 2 is a cross-sectional view of the example collapsible casing packer 5 of FIG. 1. The collapsible hollow metal housing 10 comprises a cavity 25. Furthermore, the collapsible hollow metal housing 10 may be manufactured by additive manufacturing to provide a collapsible hollow metal housing 10 that has no openings and whose cavity 25 is delimited on all sides by the collapsible hollow metal housing 10 itself.
FIG. 3 is a cross-sectional view of the example collapsible casing packer 5 of FIGS. 1 and 2 in use on a conduit 30, when in an unfolded state. The collapsible casing packer 5 is wrapped or slipped over the conduit 30 by weight, grade and connection as dictated by the well design. The conduit 30 may be any type of conduit used in a wellbore, including drill pipe, rod, tubing, coiled tubing, and the like. The conduit 30 is disposed in a wellbore 35. On one side of the collapsible casing packer 5 is a fixed support 40. The fixed support 40 may be used to prevent slippage or act as a squeeze barrier to prevent the applied pressure from slipping or squeezing the collapsible casing packer 5 in the direction of the applied pressure. In these optional examples, the fixed support 40 may be attached to the catheter 30 using any suitable connection mechanism (such as a threaded connection). The piston 45 applies pressure to the collapsible casing packer 5 to collapse the collapsible hollow metal casing 10 in an axial direction. The folding of the collapsible hollow metal housing 10 in the axial direction forces the collapsible hollow metal housing 10 to expand in the radial direction. This expansion is elastic and after removal of the applied pressure from the piston 45, the collapsible hollow metal housing 10 returns to the unfolded state shown.
The piston 45 may be actuated by any sufficient mechanism including motor actuation with a gear to produce axial movement, hydraulic pressure from the annulus via downhole fluid or annulus fluid having pressure applied from the surface, an internal hydraulic system, or any combination thereof. Because the collapsible casing packer 5 is not inflatable, it does not require a control line to inflate the bladder with fluid or gas to initiate deployment.
FIG. 4 is a cross-sectional view of the example collapsible casing packer 5 of FIG. 3 when in a collapsed state. The piston 45 has been moved in the direction indicated by arrow 50 to apply pressure to the collapsible casing packer 5 in the axial direction. The applied pressure causes the collapsible hollow metal housing 10 to collapse in an axial direction, thereby initiating expansion in a radial direction. When the collapsible hollow metal housing 10 expands in a radial direction, the tip 15 contacts the adjacent surface 55. The adjacent surface 55 may be a surface of the conduit 30, such as a casing, tubing, or the like, or may be a surface of a wall of the wellbore 35. When the tip 15 contacts the adjacent surface 55, a seal is formed at the interface and the collapsible housing packer 5 anchors the conduit 30 to the adjacent surface 55. The optional fixed support 40 prevents the collapsible housing packer 5 from sliding when pressure is applied by the piston 45. In some examples, actuation of the piston 45 may be stopped and pressure applied to the collapsible casing packer 5 may be released. Since the collapsible casing packer 5 is elastically deformable, the collapsible casing packer 5 returns to the unfolded state of fig. 3 after the applied pressure is removed. This restoration allows the sealing and anchoring of the collapsible casing packer 5 to be removed as needed and allows the collapsible casing packer 5 to be retrieved as needed.
FIG. 5 is a cross-sectional view of another example of a collapsible casing packer (generally 100) disposed on a conduit 110 in an unfolded state. The collapsible casing packer 100 includes a collapsible hollow metal casing 105. The collapsible hollow metal housing 105 collapses in the axial direction to begin expanding in the radial direction. The collapsible casing packer 100 is wrapped or slipped over the conduit 110 by weight, grade and connection as dictated by the well design. Conduit 110 may be any type of conduit used in a wellbore, including drill pipe, rod, tubing, coiled tubing, and the like. The collapsible casing packer 100 further comprises a flat trapezoidal design with flat contact surfaces 115 that contact the adjacent surfaces 120 to form a seal when in a collapsed state to prevent fluid passage and anchor the conduit 110 to the adjacent surfaces 120. In some optional examples, the interior 125 of the collapsible casing packer 100 may seal to the outer surface of the conduit 110, including when the collapsible casing packer 100 is inflated. The collapsible hollow metal housing 105 comprises a cavity 130. Further, the collapsible hollow metal housing 105 may be manufactured by additive manufacturing to provide a collapsible hollow metal housing 105 that has no openings and whose cavity 130 is bounded on all sides by the collapsible hollow metal housing 105 itself.
With continued reference to fig. 5, the conduit 110 is disposed in a wellbore 135. On one side of the collapsible casing packer 100 is a fixed support 140. The fixed support 140 is an optional component and is shown as being absolutely optional in all instances. The fixed support 140 may be used to prevent slippage or act as a squeeze barrier to prevent an applied pressure from slipping or squeezing the collapsible casing packer 100 in the direction of the applied pressure. In these optional examples, fixed support 140 may be attached to catheter 110 using any suitable connection mechanism (such as a threaded connection). Additionally or alternatively, the collapsible casing packer 100 may be attached to the conduit 110 by a threaded connection. Piston 145 applies pressure to collapsible housing packer 100 to collapse collapsible hollow metal housing 105 in an axial direction. The folding of the collapsible hollow metal housing 105 in the axial direction forces the collapsible hollow metal housing 105 to expand in the radial direction. This expansion is elastic and upon removal of the applied pressure from piston 145, collapsible hollow metal housing 105 returns to the unfolded state shown.
Piston 145 may be actuated by any sufficient mechanism, including motor actuation with gears to produce axial movement, hydraulic pressure from the annulus via downhole fluid or annulus fluid having pressure applied from the surface, an internal hydraulic system, or any combination thereof. Because the collapsible casing packer 100 is not inflatable, it does not require control lines to inflate the bladder with fluid or gas to initiate deployment.
FIG. 6 is a cross-sectional view of the example collapsible casing packer 100 of FIG. 5 when in a collapsed state. Piston 145 has been moved in the direction indicated by arrow 150 to apply pressure to collapsible housing packer 100 in an axial direction. The applied pressure causes the collapsible hollow metal housing 105 to collapse in an axial direction, thereby beginning to expand in a radial direction. When the collapsible hollow metal housing 105 expands in a radial direction, the flat contact surface 115 contacts the adjacent surface 120. The adjacent surface 120 may be a surface of a conduit 110, such as a casing, tubing, or the like, or may be a surface of a wall of a wellbore 135. When the flat contact surface 115 contacts the adjacent surface 120, a seal is formed at the interface and the collapsible housing packer 100 anchors the conduit 110 to the adjacent surface 120. The fixed support 140 prevents the collapsible housing packer 100 from sliding when pressure is applied by the piston 145. In some examples, actuation of piston 145 may be stopped and pressure applied to collapsible housing packer 100 may be released. Since the collapsible housing packer 100 is elastically deformable, the collapsible housing packer 100 returns to the unfolded state of fig. 5 after the applied pressure is removed. This restoration allows the sealing and anchoring of the collapsible casing packer 100 to be removed as needed and allows the collapsible casing packer 100 to be retrieved as needed.
FIG. 7 is a cross-sectional view of another example of a collapsible casing packer (generally 200) in an unfolded state disposed on a conduit 210. A plurality of collapsible casing packers 200 are shown connected to one another in series. The collapsible casing packer 200 includes a collapsible hollow metal casing 205. The collapsible hollow metal housing 205 collapses in the axial direction to begin expanding in the radial direction. The collapsible casing packer 200 is wrapped or slipped over the conduit 210 by weight, grade and connection as dictated by the well design. The conduit 210 may be any type of conduit used in a wellbore, including drill pipe, rod, tubing, coiled tubing, and the like. The collapsible casing packer 200 further includes a peaked design having a single tip 215 that contacts the adjacent surface 220 to form a seal when in a collapsed state to prevent fluid passage and anchor the conduit 210 to the adjacent surface 220. In some optional examples, the interior 225 of the collapsible casing packer 200 may include threads or other connection mechanisms to secure the collapsible casing packer 200 to the conduit 210. The collapsible hollow metal housing 205 includes a cavity 230. This particular example of a collapsible casing packer 200 has an opening in the collapsible hollow metal casing 205 adjacent to the conduit 210, and thus the cavity 230 is exposed to the surface of the conduit 210 on the conduit 210 side. However, in some alternative examples, the collapsible hollow metal housing 205 may be manufactured by additive manufacturing to provide a collapsible hollow metal housing 205 that does not have an opening and whose cavity 230 is bounded on all sides by the collapsible hollow metal housing 205 itself.
With continued reference to fig. 7, the conduit 210 is disposed in a wellbore 235. One side of the collapsible casing packer 200 includes a piston housing 240. The piston housing 240 is for housing a piston 245. The piston 245 is a component on the opposite side of the collapsible casing packer 200 from the piston housing 240. Because the piston 245 and the piston housing 240 are on opposite sides of the collapsible casing packer 200, the collapsible casing packer 200 is designed to interlock with each other in series as shown. Thus, the piston housing 240 of one collapsible casing packer 200 serves as the piston housing 240 of the piston 245 of an adjacent collapsible casing packer 200. This modular design allows the collapsible casing packer 200 to be applied as necessary to apply as much sealing and anchoring as necessary.
The piston 245 applies pressure to the collapsible casing packer 200 to collapse the collapsible hollow metal casing 205 in an axial direction. Folding of the collapsible hollow metal housing 205 in the axial direction forces the collapsible hollow metal housing 205 to expand in the radial direction. This expansion may be elastic and upon removal of the applied pressure from the piston 245, the collapsible hollow metal housing 205 may return to the unfolded state shown. Alternatively, in some examples, the expansion may be plastic and the collapsible hollow metal housing 205 may not return to the unfolded state shown after the applied pressure is removed from the piston 245. In some examples, the piston housing 240 may be secured to the catheter 210 to control the uniformity of the compression ratio of all collapsible hollow metal housings 205.
The piston 245 is illustrated as being actuated via fluid pumped through the double wall of the conduit 210. Fluid exits through port 250 into piston setting chamber (piston setting chamber) 255 to push piston 245 and collapse collapsible hollow metal housing 205 in an axial direction. The piston setting chamber 255 is defined by the boundary of the outermost outer wall of the piston 245 and the piston housing 240. In some alternative examples, the piston 245 may be actuated via other mechanisms such as a motor, or by applying hydraulic pressure via an annulus fluid or a downhole fluid that may enter the piston setting chamber 255 via alternative access ports. Because the collapsible casing packer 200 is not inflatable, it does not require a control line to inflate the bladder with fluid or gas to initiate deployment. For horizon isolation, the use of hydraulic pressure will result in a higher contact force than inflation of the bladder, thereby providing better performance than the latter. In some instances, the hydraulic pressure may even be high enough to provide anchoring capability.
FIG. 8 is an enlarged cross-section of the collapsible housing packer 200 of FIG. 7 to better illustrate the piston housing 240, the piston 245, the port 250, and the piston setting chamber 255. Actuation of the piston 245 causes the collapsible hollow metal housing 205 to collapse in an axial direction, as described above, thereby initiating expansion in a radial direction.
FIG. 9 is a cross-sectional view of the example collapsible casing packer 200 of FIG. 7 when in a collapsed state. The piston 245 has been moved in the direction indicated by arrow 260 to apply pressure to the collapsible hollow metal housing 205 in the axial direction. Actuation of the piston 245 is by fluid pumped through the double wall of the conduit 210. Fluid exits conduit 210 via port 250 to enter piston setting chamber 255 to apply pressure to piston 245. The applied pressure causes the collapsible hollow metal housing 205 to collapse in an axial direction, thereby beginning to expand in a radial direction. When the collapsible hollow metal housing 205 expands in a radial direction, the tip 215 contacts the adjacent surface 220. The adjacent surface 220 may be a surface of a conduit such as casing, tubing, or the like, or may be a surface of a wall of the wellbore 235. When the tip 215 contacts the adjacent surface 220, a seal is formed at the interface and the collapsible housing packer 200 anchors the conduit 210 to the adjacent surface 220. In some examples, actuation of the piston 245 may be stopped and pressure applied to the collapsible hollow metal housing 205 may be released. Since the collapsible hollow metal housing 205 is elastically deformable, the collapsible housing packer 200 may return to the unfolded state of fig. 5 after removal of the applied pressure. Alternatively, the collapsible hollow metal housing 205 may be plastically deformable and the collapsible housing packer 200 may not revert to the unfolded state of fig. 5 after removal of the applied pressure. Restoring to the unfolded state allows the sealing and anchoring of the collapsible casing packer 200 to be removed as needed and allows the collapsible casing packer 200 to be retrieved as needed.
FIG. 10 is a cross-section of an optional locking mechanism for the collapsible casing packer of FIG. 7. In some instances, it may be desirable to lock the collapsible casing packer 200 in a collapsed orientation. This may be accomplished by maintaining fluid pressure on the piston 245 or closing the port 250 once the piston 245 has been set (as shown in fig. 7-9). If these methods are not preferred, a groove 270 may be provided on the exterior of catheter 210. A corresponding locking ring 275 may be provided within the piston 245. Upon initiation of actuation of the piston 245, the piston 245 and the locking ring 275 will travel in an axial direction toward the groove 270. Figure 10 illustrates this arrangement when the collapsible casing packer 200 is in an unfolded state.
Fig. 11 is a cross-section of the optional locking mechanism of fig. 10 once engaged. As shown, actuation of the piston 245 has been completed and the piston 245 and the lock ring 275 travel in the axial direction until the lock ring 275 contacts the groove 270. Because the locking ring 275 prevents movement of the collapsible hollow metal housing 205, the collapsible hollow metal housing 205 has now collapsed and remains locked in the collapsed state even if the fluid pressure within the set chamber 255 is removed.
FIG. 12 is a cross-section of the collapsible housing packer 200 of FIGS. 7-11 shown with a sealing element 280 attached over the tip 215. The sealing element 280 may be an elastomeric sealing element and may be used to supplement the sealing capabilities of the collapsible casing packer 200. In some examples, the sealing element may be a swellable elastomer and may swell upon contact with an aqueous and/or oleaginous fluid.
FIG. 13 is a cross-section of the collapsible housing packer 200 of FIGS. 7-11 shown with two sealing elements 280 attached to either side of the tip 215. The sealing element 280 may be an elastomeric sealing element and may be used to supplement the sealing capabilities of the collapsible casing packer 200. In some examples, the sealing element may be a swellable elastomer and may swell upon contact with an aqueous and/or oleaginous fluid. The sealing element 280 of fig. 13 is the same sealing element 280 of fig. 12, but is positioned in a different orientation as shown.
FIG. 14 is a cross-section of the collapsible casing packer 200 of FIG. 13 shown in a collapsed state. The two sealing elements 280 have been pressed against the adjacent surface 220 to supplement the seal formed at the tip 215.
The sealing element 280 may be bonded to the collapsible hollow metal housing 205 using any sufficient mechanism including adhesive, melt, or the like. Further, while the sealing element 280 is shown as being used with the collapsible casing packer 200 of fig. 7-14, it should be understood that the sealing element 280 may be used with any of the examples of collapsible casing packers disclosed herein.
It should be clearly understood that the examples illustrated by fig. 1-14 are merely general applications of the principles of the present disclosure in practice, and that a wide variety of other examples are possible. Accordingly, the scope of the disclosure is not limited in any way to the details of any of the drawings described herein.
It should also be appreciated that the disclosed collapsible casing packer may also directly or indirectly affect various downhole equipment and tools that may come into contact with the collapsible casing packer during operation. Such equipment and tools may include, but are not limited to, wellbore casing, wellbore liners, completion strings, plug strings, drill strings, coiled tubing (coiled tubing), slickline, drill pipe, drill collars (drill pipe), mud motors, downhole motors and/or pumps, surface mount motors and/or pumps, centralizers, turbine tools, mud scrapers (stratchers), floats (e.g., shoes, collars, valves, etc.), logging tools and associated telemetry equipment, actuators (e.g., electromechanical devices, hydro-mechanical devices, etc.), sliding sleeves, production sleeves, plungers, screens, filters, flow control devices (e.g., inflow control devices, autonomous inflow control devices, outflow control devices, etc.), couplers (coupling) (e.g., electrohydraulic wet connections, dry connections, inductive couplers, etc.), control lines (e.g., electrical, fiber optics, hydraulic, etc.), monitoring lines, drill bits and reamers, sensors or distributed sensors, downhole heat exchangers, valves and corresponding drives, tool seals, packers, cement plungers, bridging plungers, and other wellbore isolation devices or components, etc. Any of these components may be included in the system generally described above and depicted in any of the figures.
Methods for horizon isolation are provided in accordance with the present disclosure and illustrated figures. An exemplary method includes introducing a collapsible casing packer into a wellbore; wherein the collapsible casing packer comprises a collapsible hollow metal casing. The method further includes radially expanding the collapsible hollow metal housing by axially compressing the collapsible hollow metal housing to collapse the collapsible hollow metal housing, wherein the collapsible hollow metal housing is collapsed until a portion of the collapsible hollow metal housing contacts an adjacent surface, thereby isolating the horizon.
Additionally or alternatively, the method may include one or more of the following features, individually or in combination. Folding the collapsible hollow metal housing by axially compressing the collapsible hollow metal housing may be performed by applying pressure to the collapsible hollow metal housing with a piston in an axial direction. The collapsible casing packer may include a pointed tip contact surface. The collapsible casing packer may be trapezoidal in shape and include a flat contact surface. The collapsible casing packer may be corrugated in shape. The collapsible hollow metal housing may be hollow without an opening. The collapsible casing packer may further comprise a piston on one end and a piston housing on an opposite end. There may be a plurality of collapsible casing packers connected to each other such that the piston of one collapsible casing packer is received in the piston housing of an adjacent collapsible casing packer. The collapsible casing packer may further comprise a sealing element disposed on a contact surface of the collapsible casing packer.
In accordance with the present disclosure and the illustrated figures, a collapsible casing packer for forming a seal and providing an anchor in a wellbore is provided. An exemplary collapsible casing packer includes a collapsible hollow metal casing configured to collapse in an axial direction and expand in a radial direction.
Additionally or alternatively, the collapsible casing packer may include one or more of the following features, alone or in combination. Folding the collapsible hollow metal housing by axially compressing the collapsible hollow metal housing may be performed by applying pressure to the collapsible hollow metal housing with a piston in an axial direction. The collapsible casing packer may include a pointed tip contact surface. The collapsible casing packer may be trapezoidal in shape and include a flat contact surface. The collapsible casing packer may be corrugated in shape. The collapsible hollow metal housing may be hollow without an opening. The collapsible casing packer may further comprise a piston on one end and a piston housing on an opposite end. There may be a plurality of collapsible casing packers connected to each other such that the piston of one collapsible casing packer is received in the piston housing of an adjacent collapsible casing packer. The collapsible casing packer may further comprise a sealing element disposed on a contact surface of the collapsible casing packer.
A system for zonal isolation in a wellbore is provided in accordance with the present disclosure and the illustrated figures. An exemplary system includes a collapsible casing packer comprising a collapsible hollow metal casing and a piston for collapsing the collapsible metal casing in an axial direction, thereby expanding the collapsible metal casing in a radial direction.
Additionally or alternatively, the system may include one or more of the following features, individually or in combination. Folding the collapsible hollow metal housing by axially compressing the collapsible hollow metal housing may be performed by applying pressure to the collapsible hollow metal housing with a piston in an axial direction. The collapsible casing packer may include a pointed tip contact surface. The collapsible casing packer may be trapezoidal in shape and include a flat contact surface. The collapsible casing packer may be corrugated in shape. The collapsible hollow metal housing may be hollow without an opening. The collapsible casing packer may further comprise a piston on one end and a piston housing on an opposite end. There may be a plurality of collapsible casing packers connected to each other such that the piston of one collapsible casing packer is received in the piston housing of an adjacent collapsible casing packer. The collapsible casing packer may further comprise a sealing element disposed on a contact surface of the collapsible casing packer. The system may further comprise a conduit comprising a groove on the outside of the conduit; wherein the piston comprises a locking ring; and wherein the locking ring is configured to lock into the groove upon actuation of the piston. The piston may be part of a collapsible casing packer and disposed on one end of the collapsible casing packer; wherein the collapsible casing packer further comprises a piston housing on opposite ends; and further wherein there are a plurality of collapsible casing packers connected to each other such that the piston of one collapsible casing packer is received in the piston housing of an adjacent collapsible casing packer.
One or more illustrative examples of the examples disclosed herein are presented and presented. In the interest of clarity, not all features of an actual implementation are described or shown in this disclosure. Thus, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned, as well as those that are inherent therein. The particular examples disclosed above are illustrative only, as the teachings of the 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 examples disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the disclosure. The systems and methods illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein and/or any optional element disclosed herein.
Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims.

Claims (20)

1. A method for horizon isolation, comprising:
introducing a collapsible casing packer into a wellbore; wherein the collapsible casing packer comprises a collapsible hollow metal casing,
the collapsible hollow metal housing is radially expanded by axially compressing the collapsible hollow metal housing to collapse the collapsible hollow metal housing, wherein the collapsible hollow metal housing is collapsed until a portion of the collapsible hollow metal housing contacts an adjacent surface, thereby isolating a horizon.
2. The method of claim 1, wherein the folding of the collapsible hollow metal housing by axially compressing the collapsible hollow metal housing is performed by applying pressure to the collapsible hollow metal housing with a piston in an axial direction.
3. The method of claim 1, wherein the collapsible casing packer comprises a pointed tip contact surface.
4. The method of claim 1, wherein the collapsible casing packer is trapezoidal in shape and includes a flat contact surface.
5. The method of claim 1, wherein the collapsible casing packer is corrugated in shape.
6. The method of claim 1, wherein the collapsible hollow metal housing is hollow without openings.
7. The method of claim 1, wherein the collapsible casing packer further comprises a piston on one end and a piston housing on an opposite end.
8. The method of claim 7, wherein there are a plurality of collapsible casing packers connected to each other such that a piston of one collapsible casing packer is received in a piston housing of an adjacent collapsible casing packer.
9. The method of claim 1, wherein the collapsible casing packer further comprises a sealing element disposed on a contact surface of the collapsible casing packer.
10. A collapsible casing packer, comprising:
a collapsible hollow metal housing configured to collapse in an axial direction and expand in a radial direction.
11. The collapsible casing packer of claim 10, wherein the collapsible casing packer comprises a pointed tip contact surface.
12. The collapsible casing packer of claim 10, wherein the collapsible casing packer is trapezoidal in shape and comprises a flat contact surface.
13. The collapsible casing packer of claim 10, wherein the collapsible casing packer is corrugated in shape.
14. The collapsible casing packer of claim 10, wherein the collapsible hollow metal casing is hollow with no openings.
15. The collapsible casing packer of claim 10, wherein the collapsible casing packer further comprises a piston on one end and a piston housing on an opposite end.
16. The collapsible casing packer of claim 10, wherein the collapsible casing packer further comprises a sealing element disposed on a contact surface of the collapsible casing packer.
17. A system for horizon isolation in a wellbore, the system comprising:
a collapsible casing packer comprising a collapsible hollow metal casing, and
a piston for folding the foldable metal casing in an axial direction, thereby expanding the foldable metal casing in a radial direction.
18. The system of claim 17, further comprising a conduit comprising a groove on an exterior of the conduit; wherein the piston comprises a locking ring; and wherein the locking ring is configured to lock into the groove upon actuation of the piston.
19. The system of claim 17, wherein the piston is a component of the collapsible casing packer and is disposed on one end of the collapsible casing packer; wherein the collapsible casing packer further comprises piston housings on opposite ends; and further wherein there are a plurality of collapsible casing packers connected to each other such that the piston of one collapsible casing packer is received in the piston housing of an adjacent collapsible casing packer.
20. The system of claim 17, wherein the collapsible hollow metal housing is hollow without an opening.
CN202180094513.1A 2021-06-07 2021-06-15 Foldable casing packer for metal-to-metal sealing Pending CN116867952A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US17/340,984 US20220389787A1 (en) 2021-06-07 2021-06-07 Collapsible shell packer for metal-to-metal sealing
US17/340,984 2021-06-07
PCT/US2021/037318 WO2022260685A1 (en) 2021-06-07 2021-06-15 Collapsible shell packer for metal-to-metal sealing

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CN (1) CN116867952A (en)
AU (1) AU2021450384A1 (en)
BR (1) BR112023017476A2 (en)
CA (1) CA3208789A1 (en)
DE (1) DE112021007037T5 (en)
DK (1) DK202330236A1 (en)
ES (1) ES2958091R1 (en)
GB (1) GB2619673A (en)
MX (1) MX2023012927A (en)
NO (1) NO20231034A1 (en)
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GB2375575B (en) * 2000-12-20 2003-04-23 Fmc Technologies Alternative metallic seals
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EP2466064A1 (en) * 2010-12-17 2012-06-20 Welltec A/S Casing anchor
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CA3009146C (en) * 2016-01-21 2021-01-19 Halliburton Energy Services, Inc. Retaining sealing element of wellbore isolation device with slip elements
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GB2587237B (en) * 2019-09-20 2022-06-15 Rubberatkins Ltd Downhole packer apparatus

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PL446825A1 (en) 2024-06-03
US20220389787A1 (en) 2022-12-08
DK202330236A1 (en) 2023-12-20
WO2022260685A1 (en) 2022-12-15
GB202314868D0 (en) 2023-11-08
ES2958091R1 (en) 2024-06-11
NO20231034A1 (en) 2023-09-28
CA3208789A1 (en) 2022-12-15
ES2958091A2 (en) 2024-02-01
BR112023017476A2 (en) 2023-12-19
DE112021007037T5 (en) 2023-11-23
MX2023012927A (en) 2023-11-13
AU2021450384A1 (en) 2023-08-03
RO138137A2 (en) 2024-04-30
GB2619673A (en) 2023-12-13

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