US20110037230A1 - Expandable packer system - Google Patents
Expandable packer system Download PDFInfo
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- US20110037230A1 US20110037230A1 US12/925,319 US92531910A US2011037230A1 US 20110037230 A1 US20110037230 A1 US 20110037230A1 US 92531910 A US92531910 A US 92531910A US 2011037230 A1 US2011037230 A1 US 2011037230A1
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- Prior art keywords
- retainer ring
- expandable casing
- radius
- ring
- casing
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- 238000007789 sealing Methods 0.000 claims abstract description 111
- 239000012530 fluid Substances 0.000 claims 3
- 238000012856 packing Methods 0.000 abstract description 6
- 239000000463 material Substances 0.000 description 10
- 238000001125 extrusion Methods 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 230000004323 axial length Effects 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 229920001971 elastomer Polymers 0.000 description 4
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000000806 elastomer Substances 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
Definitions
- the invention is directed to expandable casing packing element systems for use in oil and gas wells and, in particular, expandable casing packing element systems having extrudable sealing elements for sealing open-hole wells.
- Expandable casing having a sealing element such as a packer have been used to seal the annulus of open-hole wells.
- a sealing element such as a packer
- the expandable casing has disposed on it, or as part of the expandable casing string, a sealing device such as a packer.
- the packer is designed to divide the well by sealing against the well formation, thereby isolating a lower portion of the well from an upper portion of the well.
- a cone or other device can be transported through the bore of the expandable casing. As the cone, such as a swage, travels downward, the expandable casing is expanded by the cone. The expansion of the expandable casing causes the sealing device to contact the formation and separate the open-hole well into at least two isolated regions, one above the sealing device and one below the sealing device.
- the expandable casing and sealing devices disclosed herein include components that, to the inventors' knowledge, are novel and non-obvious from previous expandable casing and sealing devices.
- the expandable casing packing element systems disclosed herein include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings.
- both retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of the a wellbore in three locations.
- the wellbore may be an opened-hole wellbore or a cased wellbore.
- both of the two retainer rings include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.
- Also disclosed is a method comprising the steps of: (a) running an expandable casing string having a packing element system attached thereto into a wellbore defined by an inner wall surface, the packing element system having a sealing element and at least two retainer rings, at one of the at least two retainer rings overlapping the sealing element; (b) applying a radial load to expand the expandable casing, causing the sealing element to be extruded outwardly by at least one of the at least two retainer rings applying an inward force to the sealing element; and (c) continuing to apply the radial load causing the sealing element to move radially outward into sealing engagement with the inner wall surface of the wellbore.
- the wellbore is cased.
- the wellbore is an opened-hole wellbore.
- FIG. 1 is a cross-sectional view of one embodiment of an expandable casing having a sealing device, FIG. 1 showing the expandable casing as it is being expanded from its run-in position to its expanded or set position.
- FIG. 2 is a cross-sectional view of another specific embodiment of an expandable casing having a sealing device, FIG. 2 showing the expandable casing in its run-in position.
- FIG. 3 is a cross-sectional view of the expandable casing shown in FIG. 2 shown in its expanded or set position.
- expandable casing 30 is disposed within well 20 that has been drilled into formation 26 .
- Well 20 is defined by well inner wall surface 22 .
- Expandable casing 30 has upper end 32 , lower end 34 , bore 36 defined by inner wall surface 38 , outer wall surface 39 , and axis 40 .
- Expandable casing 30 includes run-in diameter 42 , set diameter 44 , and transitional diameter 46 .
- Run-in diameter 42 is less than set diameter 44 and transitional diameter 46 illustrates the location of a cone (not shown) or other device used to expand expandable casing 30 from the run-in diameter 42 to the set diameter 44 .
- a cone is described as being used to expand expandable casing 30 from the run-in diameter 42 to the set diameter 44 , it is to be understood that any device or method known to persons of ordinary skill in the art may be used to expand expandable casing 30 .
- upper sealing device 50 is identical to lower sealing device 60 except that upper sealing device 50 is shown in the set position and lower sealing device 60 is shown in the run-in position.
- expandable casing 30 may have only one sealing device 50 , 60 , or more than two sealing devices 50 , 60 .
- both upper and lower sealing devices 50 , 60 will be discussed in greater detail with reference to like numerals.
- Sealing devices 50 , 60 include annular deformable sealing elements 51 having upper ends 52 and lower ends 54 , upper retainer ring 56 , and lower retainer ring 58 .
- Sealing element 51 is a deformable element formed from an deformable material so that radial outward movement of sealing element 51 away from axis 40 and into upper and lower retainer rings 56 , 58 causes sealing element 51 to extrude into sealing contact with inner wall surface 22 of well 20 .
- Suitable materials for forming sealing element 51 include, but are not limited to, elastomers, rubbers, polymers, or thermoplastics.
- sealing element 51 may have any shape desired or necessary to provide the requisite compression, deformation, or “extrusion” to form the seal with inner wall surface 22 of well 20 .
- sealing element 51 is formed in the shape of a sleeve having a thicker center portion as compared to upper and lower ends 52 , 54 . This thicker portion is disposed between upper and lower retainer rings 56 , 58 and, as shown with reference to sealing device 60 , has an outer diameter that is equal to the outer diameter of both upper and lower retainer rings 56 , 58 when in the run-in position.
- sealing element 51 may have an outer diameter that is less than the outer diameter of one or both of upper or lower retainer rings 56 , 58 when in its run-in position or it may have an outer diameter that is greater than the outer diameter of one or both upper or lower retainer rings 56 , 58 when in its run-in position.
- upper and lower ends 52 , 54 are shown protruding above and below upper and lower retainer rings 56 , 58 ; however, upper and lower ends 52 , 54 are not required to protrude above and below upper and lower retainer rings in this manner.
- Sealing element 51 is maintained against outer wall surface 39 of expandable casing 30 using any device or method known to persons of ordinary skill in the art.
- sealing element 51 may be chemically bonded to outer wall surface 39 .
- sealing element 51 can be maintained solely by upper and lower retainer rings 56 , 58 .
- Upper retainer rings 56 and lower retainer rings 58 are expandable members disposed around the outer diameter of sealing element 51 and, thus, can maintain or assist in maintaining sealing element 51 along outer wall surface 39 .
- both upper retainer ring 56 and lower retainer ring 58 have a relatively flat vertical cross-section parallel or substantially parallel to the axial length of the expandable casing 30 .
- both upper and lower retainer rings 56 , 58 have an axial length greater than their width so that the inner diameter surface area of both upper and lower retainer rings 56 , 58 are in contact with sealing element 51 to facilitate extrusion of sealing element 51 during expansion of expandable casing 30 .
- upper and lower retainer rings 56 , 58 are discussed with reference to FIG. 1 , it is to be understood that upper and lower retainer rings 56 , 58 may have any shape desired or necessary to provide the necessary force against sealing element 51 during expansion of expandable casing 30 so that sealing element 51 is extruded to seal against inner wall surface 22 of well 20 .
- upper and lower retainer rings 56 , 58 may be formed from any material known to persons of ordinary skill in the art.
- one or both of upper and lower retainer rings 56 , 58 may be formed from stiffer elastomers, polymers, or metals such as steel.
- expandable casing 30 After expandable casing 30 is properly located within well 20 , a cone (not shown) or other expanding device is run through bore 36 of expandable casing 30 . As the cone travels downward, i.e., downhole, expandable casing 30 is forced radially outward from axis 40 . In so doing, run-in diameter 42 is radially expanded to transition diameter 46 and ultimately to set diameter 44 . As a result of the radial expansion of expandable casing 30 , sealing element 51 is forced into upper and lower retainer rings 56 , 58 . Although upper and lower retainer rings 56 , 58 are radially expandable, they are formed from a material that is stronger, i.e., more resistance to expansion, compared to the material used to form sealing element 51 .
- sealing material 51 is compressed, deformed, or extruded in between outer wall surface 39 of expandable casing and the inner wall surfaces of upper and lower retainer rings 56 , 58 defined by the inner diameters of upper and lower retainer rings 56 , 58 .
- sealing element 51 Due to the compression of sealing element 51 between outer wall surface 39 of expandable casing 30 and the inner wall surfaces of upper and lower retainer rings 56 , 58 , the center portion of sealing element 51 is extruded outwardly in between upper and lower retainer rings 56 , 58 ; upper end 52 of sealing element 51 is extruded outwardly above upper retainer ring 56 ; and lower end 54 of sealing element 51 is extruded outwardly below lower retainer ring 58 until all three portions of sealing element 51 form a seal against inner wall surface 22 of well 20 .
- the distance between the outer diameter of upper and lower retainer rings 56 , 58 and inner wall surface 22 of well 20 is referred to as the extrusion gap.
- expandable casing 130 has upper end 132 , lower end 134 , bore 136 defined by inner wall surface 138 , outer wall surface 139 , and axis 140 .
- Expandable casing 30 includes run-in diameter defined by run-in radius 142 ( FIG. 2 ) and set diameter defined by set radius 144 ( FIG. 3 ). Run-in radius 142 and, thus, the run-in diameter, is less than set radius 144 and, thus, the set diameter.
- Expandable casing 130 is radially expanded using a cone (not shown) or other device used to expand expandable casing 130 from the run-in diameter defined by run-in radius 142 to the set diameter defined by set radius 144 in the same manner as the embodiment discussed above with respect to FIG. 1 .
- expandable casing 130 is in the run-in position. Disposed on outer wall surface 139 of expandable casing 130 is sealing device 150 . Although only a single sealing device 150 is shown, it is to be understood that more than one sealing device may be disposed on outer wall surface 139 of expandable casing 130 .
- Sealing device 150 includes annular sealing element 151 , upper retainer ring 156 and lower retainer ring 158 .
- Annular sealing element 151 is a deformable element formed from a deformable material such as those discussed above with respect to sealing element 51 .
- sealing element 151 has a trapezoid section such that the inner surface of sealing element 151 has a longer axial length along outer wall surface 139 than the axial length of the outer surface defined by the outer diameter of sealing element 151 .
- Upper retainer ring 156 has upper flare portion 157 and lower retainer ring 158 has lower flare portion 159 thereby forming a cavity between upper retainer ring 156 and lower retainer ring 158 with a gap between the lowermost end of upper retainer ring 156 and the uppermost end of lower retainer ring 158 .
- Sealing element 151 is disposed within the cavity. In one specific embodiment, sealing element 151 is maintained along outer wall surface 139 through any device or method known to persons of ordinary skill in the art, such as through chemical bonding or by upper and lower retainer rings 156 , 158 .
- upper and lower retainer rings 156 , 158 may be formed from any material known to persons of ordinary skill in the art.
- one or both of upper and lower retainer rings 156 , 158 may be formed from stiffer elastomers, polymers, or metals such as steel.
- Upper flare portion 157 and lower flare portion 159 may have any shape or angle relative to the remaining vertical portions of upper and lower flare portions.
- upper and lower flare portions 157 , 159 may be at an angle in a range greater than 0 degrees and less than 90 degrees relative to the vertical portions of upper and lower flare portions 157 , 159 .
- the angle at which upper flare portion 157 intersects the remaining portion of upper retainer ring may be different from the angle at which lower flare portion 159 intersects the remaining portion of lower retainer ring 158 .
- both of these angles are within the range from 30 degrees to 60 degrees so that sufficient inward force can be applied to sealing element 151 during expansion of expandable casing 130 to extrude sealing element 151 through the gap between the lowermost and uppermost ends of upper retainer ring 156 and lower retainer ring 158 , respectively.
- upper and lower flare portions 157 , 159 are reciprocally shaped to receive sealing element 151 so that a portion of both upper and lower flare portions 157 , 159 contact sealing element 151 during run-in.
- Upper and lower retainer rings 156 , 158 can be secured to outer wall surface 139 through any device or method known to persons of ordinary skill in the art.
- upper and lower retainer rings 156 , 158 may be welded or epoxied to outer wall surface 139 .
- upper and lower retainer rings 156 , 158 may be secured or formed integral with an expandable mandrel (not shown) that is then secured such as through threads to an expandable casing string.
- sealing element 151 of sealing device 150 is in its run-in position such that it does not protrude outwardly from outer wall surface 139 past upper or lower retainer rings 156 , 158 . It is to be understood that although sealing element 151 is shown as having an outer diameter equal to the outer diameters of upper and lower retainer rings 156 , 158 , sealing element 151 may have either an outer diameter that is less than the outer diameter of one or both of upper or lower retainer rings 156 , 158 when in its run-in position, or an outer diameter that is greater than the outer diameter of one or both of upper or lower retainer rings 156 , 158 when in its run-in position.
- expandable casing 130 After expandable casing 130 is properly located within well (not shown), a cone (not shown) or other expanding device is run through bore 136 of expandable casing 130 . As the cone travels downward, i.e., downhole, expandable casing 130 is forced radially outward from axis 140 . In so doing, the run-in diameter illustrated by run-in radius 142 is radially expanded to a transition diameter (not shown) and ultimately to set diameter illustrated by set radius 144 ( FIG. 3 ). As a result of the radial expansion of expandable casing 130 , sealing element 151 is forced into upper and lower flare portions 157 , 159 of upper and lower retainer rings 156 , 158 .
- upper and lower retainer rings 156 , 158 are radially expandable; however, they are formed from a material that is stronger, i.e., has more resistance to expansion, compared to the material used to form sealing element 151 .
- upper and lower flare portions 157 , 159 bend inward toward axis 140 as expandable casing 130 expands and, thus, compress, deform, or extrude sealing element 151 within the cavity in between outer wall surface 139 of expandable casing 130 and upper and lower flare portions 157 , 159 .
- upper flare portion 157 and lower flare portion 159 become more straightened in line with the remaining portions of upper retainer ring 156 and lower retainer ring 158 , respectively, so that sealing element 151 is forced radially outward.
- sealing element 151 Due to the compression of sealing element 151 between outer wall surface 139 of expandable casing 130 and the upper and lower flare portions 157 , 159 , sealing element 151 is extruded outwardly from the cavity through the gap located between the lowermost end of upper retainer ring 156 and the upper most end of lower retainer ring 158 until sealing element 151 forms a seal against the inner wall surface of the well.
- This distance between the outermost diameters of upper and lower retainer rings 156 , 158 and the inner wall surface of the well is referred to as the extrusion gap.
- the sealing devices may be disposed on an expandable mandrel that is placed within an expandable casing string.
- the expandable casing may have one or more sealing devices 50 or 60 together with one or more sealing devices 150 .
- a spacer may be disposed in between outer wall surface 39 of expandable casing 30 and the inner diameter of sealing element 151 to assist in extrusion of sealing element 151 during expansion of expandable casing 130 .
- the inner diameter of upper retainer ring 56 is not required to be equal to the inner diameter of lower retainer ring 58 .
- upper flare portion 157 is not required to be the same shape as lower flare portion 159 .
- the expandable casing 30 , 130 may be disposed in a cased wellbore as opposed to an open-hole wellbore.
- wellbore as used herein includes a cased wellbore as well as an opened-hole wellbore. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
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Abstract
The expandable casing packing element systems for cased and open-hole wellbores include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings. The retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of a wellbore in three locations. The retainer rings can also include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.
Description
- This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/933,183 filed Jun. 5, 2007.
- The invention is directed to expandable casing packing element systems for use in oil and gas wells and, in particular, expandable casing packing element systems having extrudable sealing elements for sealing open-hole wells.
- Expandable casing having a sealing element such as a packer have been used to seal the annulus of open-hole wells. In operation, after the well is drilled into the earth formation, the expandable casing is run into the well. The expandable casing has disposed on it, or as part of the expandable casing string, a sealing device such as a packer. The packer is designed to divide the well by sealing against the well formation, thereby isolating a lower portion of the well from an upper portion of the well.
- After the expandable casing is run into the desired location in the well, a cone or other device can be transported through the bore of the expandable casing. As the cone, such as a swage, travels downward, the expandable casing is expanded by the cone. The expansion of the expandable casing causes the sealing device to contact the formation and separate the open-hole well into at least two isolated regions, one above the sealing device and one below the sealing device.
- The expandable casing and sealing devices disclosed herein include components that, to the inventors' knowledge, are novel and non-obvious from previous expandable casing and sealing devices.
- Broadly, the expandable casing packing element systems disclosed herein include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings. In one embodiment, both retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of the a wellbore in three locations. The wellbore may be an opened-hole wellbore or a cased wellbore. In another embodiment, both of the two retainer rings include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.
- Also disclosed is a method comprising the steps of: (a) running an expandable casing string having a packing element system attached thereto into a wellbore defined by an inner wall surface, the packing element system having a sealing element and at least two retainer rings, at one of the at least two retainer rings overlapping the sealing element; (b) applying a radial load to expand the expandable casing, causing the sealing element to be extruded outwardly by at least one of the at least two retainer rings applying an inward force to the sealing element; and (c) continuing to apply the radial load causing the sealing element to move radially outward into sealing engagement with the inner wall surface of the wellbore. In one particular embodiment, the wellbore is cased. In another specific embodiment, the wellbore is an opened-hole wellbore.
-
FIG. 1 is a cross-sectional view of one embodiment of an expandable casing having a sealing device,FIG. 1 showing the expandable casing as it is being expanded from its run-in position to its expanded or set position. -
FIG. 2 is a cross-sectional view of another specific embodiment of an expandable casing having a sealing device,FIG. 2 showing the expandable casing in its run-in position. -
FIG. 3 is a cross-sectional view of the expandable casing shown inFIG. 2 shown in its expanded or set position. - While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
- Referring now to
FIG. 1 , in one specific embodiment,expandable casing 30 is disposed within well 20 that has been drilled intoformation 26. Well 20 is defined by wellinner wall surface 22.Expandable casing 30 hasupper end 32,lower end 34,bore 36 defined byinner wall surface 38,outer wall surface 39, andaxis 40.Expandable casing 30 includes run-indiameter 42, setdiameter 44, andtransitional diameter 46. Run-indiameter 42 is less than setdiameter 44 andtransitional diameter 46 illustrates the location of a cone (not shown) or other device used to expandexpandable casing 30 from the run-indiameter 42 to theset diameter 44. Although a cone is described as being used to expandexpandable casing 30 from the run-indiameter 42 to theset diameter 44, it is to be understood that any device or method known to persons of ordinary skill in the art may be used to expandexpandable casing 30. - As illustrated in
FIG. 1 , disposed onouter wall surface 39 ofexpandable casing 30 areupper sealing device 50 andlower sealing device 60. In this embodiment,upper sealing device 50 is identical tolower sealing device 60 except thatupper sealing device 50 is shown in the set position andlower sealing device 60 is shown in the run-in position. It is to be understood, however, thatexpandable casing 30 may have only onesealing device sealing devices lower sealing devices -
Sealing devices deformable sealing elements 51 havingupper ends 52 andlower ends 54,upper retainer ring 56, andlower retainer ring 58.Sealing element 51 is a deformable element formed from an deformable material so that radial outward movement of sealingelement 51 away fromaxis 40 and into upper andlower retainer rings element 51 to extrude into sealing contact withinner wall surface 22 of well 20. Suitable materials for formingsealing element 51 include, but are not limited to, elastomers, rubbers, polymers, or thermoplastics. - Additionally, sealing
element 51 may have any shape desired or necessary to provide the requisite compression, deformation, or “extrusion” to form the seal withinner wall surface 22 of well 20. As shown inFIG. 1 , in this specific embodiment,sealing element 51 is formed in the shape of a sleeve having a thicker center portion as compared to upper andlower ends lower retainer rings sealing device 60, has an outer diameter that is equal to the outer diameter of both upper andlower retainer rings element 51 may have an outer diameter that is less than the outer diameter of one or both of upper orlower retainer rings lower retainer rings - Further, in the embodiment shown in
FIG. 1 , upper andlower ends lower retainer rings lower ends -
Sealing element 51 is maintained againstouter wall surface 39 ofexpandable casing 30 using any device or method known to persons of ordinary skill in the art. For example, sealingelement 51 may be chemically bonded toouter wall surface 39. Alternatively, sealingelement 51 can be maintained solely by upper andlower retainer rings -
Upper retainer rings 56 andlower retainer rings 58 are expandable members disposed around the outer diameter of sealingelement 51 and, thus, can maintain or assist in maintaining sealingelement 51 alongouter wall surface 39. In this embodiment bothupper retainer ring 56 andlower retainer ring 58 have a relatively flat vertical cross-section parallel or substantially parallel to the axial length of theexpandable casing 30. As additionally shown inFIG. 1 , both upper andlower retainer rings lower retainer rings sealing element 51 to facilitate extrusion ofsealing element 51 during expansion ofexpandable casing 30. - Although the shape of upper and
lower retainer rings FIG. 1 , it is to be understood that upper andlower retainer rings element 51 during expansion ofexpandable casing 30 so thatsealing element 51 is extruded to seal againstinner wall surface 22 of well 20. - Further, upper and
lower retainer rings lower retainer rings - After
expandable casing 30 is properly located within well 20, a cone (not shown) or other expanding device is run throughbore 36 ofexpandable casing 30. As the cone travels downward, i.e., downhole,expandable casing 30 is forced radially outward fromaxis 40. In so doing, run-indiameter 42 is radially expanded totransition diameter 46 and ultimately to setdiameter 44. As a result of the radial expansion ofexpandable casing 30, sealingelement 51 is forced into upper andlower retainer rings lower retainer rings sealing element 51. As a result, asexpandable casing 30 is expanded, sealingmaterial 51 is compressed, deformed, or extruded in betweenouter wall surface 39 of expandable casing and the inner wall surfaces of upper andlower retainer rings lower retainer rings sealing element 51 betweenouter wall surface 39 ofexpandable casing 30 and the inner wall surfaces of upper andlower retainer rings sealing element 51 is extruded outwardly in between upper andlower retainer rings upper end 52 ofsealing element 51 is extruded outwardly aboveupper retainer ring 56; andlower end 54 ofsealing element 51 is extruded outwardly belowlower retainer ring 58 until all three portions of sealingelement 51 form a seal againstinner wall surface 22 of well 20. The distance between the outer diameter of upper andlower retainer rings inner wall surface 22 of well 20 is referred to as the extrusion gap. - Referring now to
FIGS. 2-3 , in another embodiment,expandable casing 130 hasupper end 132,lower end 134, bore 136 defined byinner wall surface 138,outer wall surface 139, andaxis 140.Expandable casing 30 includes run-in diameter defined by run-in radius 142 (FIG. 2 ) and set diameter defined by set radius 144 (FIG. 3 ). Run-inradius 142 and, thus, the run-in diameter, is less thanset radius 144 and, thus, the set diameter.Expandable casing 130 is radially expanded using a cone (not shown) or other device used to expandexpandable casing 130 from the run-in diameter defined by run-in radius 142 to the set diameter defined byset radius 144 in the same manner as the embodiment discussed above with respect toFIG. 1 . - As illustrated in
FIG. 2 ,expandable casing 130 is in the run-in position. Disposed onouter wall surface 139 ofexpandable casing 130 is sealingdevice 150. Although only asingle sealing device 150 is shown, it is to be understood that more than one sealing device may be disposed onouter wall surface 139 ofexpandable casing 130. -
Sealing device 150 includesannular sealing element 151,upper retainer ring 156 andlower retainer ring 158.Annular sealing element 151 is a deformable element formed from a deformable material such as those discussed above with respect to sealingelement 51. In this embodiment, sealingelement 151 has a trapezoid section such that the inner surface of sealingelement 151 has a longer axial length alongouter wall surface 139 than the axial length of the outer surface defined by the outer diameter of sealingelement 151. -
Upper retainer ring 156 hasupper flare portion 157 andlower retainer ring 158 haslower flare portion 159 thereby forming a cavity betweenupper retainer ring 156 andlower retainer ring 158 with a gap between the lowermost end ofupper retainer ring 156 and the uppermost end oflower retainer ring 158.Sealing element 151 is disposed within the cavity. In one specific embodiment, sealingelement 151 is maintained alongouter wall surface 139 through any device or method known to persons of ordinary skill in the art, such as through chemical bonding or by upper and lower retainer rings 156, 158. - As with the embodiment shown in
FIG. 1 , upper and lower retainer rings 156, 158 may be formed from any material known to persons of ordinary skill in the art. For example, one or both of upper and lower retainer rings 156, 158 may be formed from stiffer elastomers, polymers, or metals such as steel. -
Upper flare portion 157 andlower flare portion 159 may have any shape or angle relative to the remaining vertical portions of upper and lower flare portions. For example, upper andlower flare portions lower flare portions upper flare portion 157 intersects the remaining portion of upper retainer ring may be different from the angle at whichlower flare portion 159 intersects the remaining portion oflower retainer ring 158. In one specific embodiment, both of these angles are within the range from 30 degrees to 60 degrees so that sufficient inward force can be applied to sealingelement 151 during expansion ofexpandable casing 130 to extrude sealingelement 151 through the gap between the lowermost and uppermost ends ofupper retainer ring 156 andlower retainer ring 158, respectively. In the embodiment shown inFIGS. 2-3 , upper andlower flare portions element 151 so that a portion of both upper andlower flare portions contact sealing element 151 during run-in. - Upper and lower retainer rings 156, 158 can be secured to
outer wall surface 139 through any device or method known to persons of ordinary skill in the art. For example, upper and lower retainer rings 156, 158 may be welded or epoxied toouter wall surface 139. Alternatively, upper and lower retainer rings 156, 158 may be secured or formed integral with an expandable mandrel (not shown) that is then secured such as through threads to an expandable casing string. - As shown in
FIG. 2 , sealingelement 151 of sealingdevice 150 is in its run-in position such that it does not protrude outwardly fromouter wall surface 139 past upper or lower retainer rings 156, 158. It is to be understood that although sealingelement 151 is shown as having an outer diameter equal to the outer diameters of upper and lower retainer rings 156, 158, sealingelement 151 may have either an outer diameter that is less than the outer diameter of one or both of upper or lower retainer rings 156, 158 when in its run-in position, or an outer diameter that is greater than the outer diameter of one or both of upper or lower retainer rings 156, 158 when in its run-in position. - After
expandable casing 130 is properly located within well (not shown), a cone (not shown) or other expanding device is run throughbore 136 ofexpandable casing 130. As the cone travels downward, i.e., downhole,expandable casing 130 is forced radially outward fromaxis 140. In so doing, the run-in diameter illustrated by run-in radius 142 is radially expanded to a transition diameter (not shown) and ultimately to set diameter illustrated by set radius 144 (FIG. 3 ). As a result of the radial expansion ofexpandable casing 130, sealingelement 151 is forced into upper andlower flare portions element 151. As a result, asexpandable casing 130 is expanded, upper andlower flare portions axis 140 asexpandable casing 130 expands and, thus, compress, deform, or extrude sealingelement 151 within the cavity in betweenouter wall surface 139 ofexpandable casing 130 and upper andlower flare portions upper flare portion 157 andlower flare portion 159 become more straightened in line with the remaining portions ofupper retainer ring 156 andlower retainer ring 158, respectively, so that sealingelement 151 is forced radially outward. - Due to the compression of sealing
element 151 betweenouter wall surface 139 ofexpandable casing 130 and the upper andlower flare portions element 151 is extruded outwardly from the cavity through the gap located between the lowermost end ofupper retainer ring 156 and the upper most end oflower retainer ring 158 until sealingelement 151 forms a seal against the inner wall surface of the well. This distance between the outermost diameters of upper and lower retainer rings 156, 158 and the inner wall surface of the well is referred to as the extrusion gap. - It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, the sealing devices may be disposed on an expandable mandrel that is placed within an expandable casing string. Additionally, the expandable casing may have one or
more sealing devices more sealing devices 150. Moreover, a spacer may be disposed in betweenouter wall surface 39 ofexpandable casing 30 and the inner diameter of sealingelement 151 to assist in extrusion of sealingelement 151 during expansion ofexpandable casing 130. Further, the inner diameter ofupper retainer ring 56 is not required to be equal to the inner diameter oflower retainer ring 58. Likewise, the shape ofupper flare portion 157 is not required to be the same shape aslower flare portion 159. Additionally, theexpandable casing
Claims (7)
1-20. (canceled)
21. A sealing device for a radially expandable casing, the sealing device comprising:
a first retainer ring comprising a first end portion and a second end;
a second retainer ring;
a gap disposed between the first retainer ring and the second retainer ring; and
an extrudable sealing element disposed between the first retainer ring and the second retainer ring and in fluid communication with the gap,
the extrudable sealing element being extrudable through the gap when the expandable casing is radially expanded from a first position to a second position,
wherein during expansion of the expandable casing toward the second position, the second end portion of the first retainer ring is moved with respect to an outer wall surface of the expandable casing toward an axis of the expandable casing.
22. The sealing device of claim 21 , wherein the second retainer ring comprising a second retainer ring first end portion and a second retainer ring second end portion, and
wherein during expansion of the expandable casing toward the second position, the second retainer ring second end portion of the second retainer ring is moved with respect to an outer wall surface of the expandable casing toward the axis of the expandable casing.
23. A sealing device for a radially expandable casing, the sealing device comprising:
a first retainer ring comprising a first end portion disposed substantially parallel to an axis of the expandable casing and a second end portion disposed at a first initial angle relative to the first end portion, the first initial angle being less than 90 degrees and more than 0 degrees;
a second retainer ring;
a gap disposed between the first retainer ring and the second retainer ring; and
an extrudable sealing element disposed between the first retainer ring and the second retainer ring and in fluid communication with the gap,
the extrudable sealing element being extrudable through the gap when the expandable casing is radially expanded from a first position to a second position,
wherein during expansion of the expandable casing toward the second position, the first initial angle is reduced.
24. The sealing device of claim 23 , wherein the second retainer ring comprises a second retainer ring first end portion disposed substantially parallel to the axis of the expandable casing and a second retainer ring second end portion disposed at a second initial angle relative to the second retainer ring first end portion, the second initial angle being less than 90 degrees and more than 0 degrees;
wherein during expansion of the expandable casing toward the second position, the second initial angle is reduced.
25. A sealing device for a radially expandable casing, the sealing device comprising:
a first retainer ring;
a second retainer ring;
a gap disposed between the first retainer ring and the second retainer ring; and
an extrudable sealing element disposed between the first retainer ring and the second retainer ring and in fluid communication with the gap, the extrudable sealing element being extrudable through the gap when the expandable casing is radially expanded from a run-in casing radius to a set casing radius, the set casing radius being greater than the run-in casing radius and the difference between the set casing radius and the run-in casing radius defining a casing radius differential,
wherein during expansion of the expandable casing,
a portion of the first retainer ring is radially expanded outward from a first run-in ring radius, as measured from an axis of the expandable casing to the portion of the first retainer ring, to a first set ring radius, as measured from the axis of the expandable casing to the portion of the first retainer ring,
the first set ring radius being greater than the first run-in ring radius, and the difference between the first set ring radius and the first run-in ring radius defining a first ring radius differential, and
wherein the casing radius differential is greater than the first ring radius differential.
26. The sealing device of claim 25 , wherein during expansion of the expandable casing,
a portion of the second retainer ring is radially expanded outward from a second run-in ring radius, as measured from the axis of the expandable casing to the portion of the second retainer ring, to a second set ring radius, as measured from the axis of the expandable casing to the portion of the second retainer ring,
the second set ring radius being greater than the second run-in ring radius, and the difference between the second set ring radius and the second run-in ring radius defining a second ring radius differential, and
wherein the casing radius differential is greater than the second ring radius differential.
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US12/925,319 US7886818B1 (en) | 2007-06-05 | 2010-10-19 | Expandable packer system |
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US12/592,491 US7845402B2 (en) | 2007-06-05 | 2009-11-25 | Expandable packer system |
US12/925,319 US7886818B1 (en) | 2007-06-05 | 2010-10-19 | Expandable packer system |
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US12/592,491 Continuation US7845402B2 (en) | 2007-06-05 | 2009-11-25 | Expandable packer system |
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US20110037230A1 true US20110037230A1 (en) | 2011-02-17 |
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US12/925,319 Active US7886818B1 (en) | 2007-06-05 | 2010-10-19 | Expandable packer system |
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US12/592,491 Active US7845402B2 (en) | 2007-06-05 | 2009-11-25 | Expandable packer system |
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Also Published As
Publication number | Publication date |
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US20100078180A1 (en) | 2010-04-01 |
US7886818B1 (en) | 2011-02-15 |
US20080302543A1 (en) | 2008-12-11 |
US7703542B2 (en) | 2010-04-27 |
US7845402B2 (en) | 2010-12-07 |
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