WO2016171665A1

WO2016171665A1 - Modular swell packer element

Info

Publication number: WO2016171665A1
Application number: PCT/US2015/026772
Authority: WO
Inventors: Henghua JIN; Yucun Lou; Travis HOHENBERGER; Shawn CHESTER
Original assignee: Schlumberger Canada Limited; Services Petroliers Schlumberger; Schlumberger Technology B.V.; Schlumberger Technology Corporation
Priority date: 2015-04-21
Filing date: 2015-04-21
Publication date: 2016-10-27

Abstract

A modular element for a swell packer. The element is constructed of discretely separate material portions bonded to one another. This allows for a flexibility in design and function. For example, an inner swell material portion may be provided that swells at a rate that is faster than the swell rate of an outer swell material portion. Thus, over the course of deployment into the well, the slower swell rate of the outer material portion may help avoid premature swelling to the point of reaching sealing before the packer reaches an intended target location. By the same token, the faster swell rate of the inner modular material portion may allow for a more rapid complete setting of the packer once proper sealing position at the target location is attained. Once more, this, or another more interior, modular material portion, may be of a particularly selected material strength to enhance shear force resistance of the element.

Description

MODULAR SWELL PACKER ELEMENT

BACKGROUND

[0001] Exploring, drilling and completing hydrocarbon and other wells are generally complicated, time consuming, and ultimately very expensive endeavors. As a result, over the years, a significant amount of added emphasis has been placed on well monitoring and maintenance. By the same token, perhaps even more emphasis has been directed at initial well architecture and design. All in all, careful attention to design and maintenance may help maximize production and extend well life. Thus, a substantial return on the investment in the completed well may be better ensured.

[0002] In the case of well design and architecture, maximizing recovery may involve a uniquely tailored well configuration targeting specific reservoir locations. For example, the well may be multilateral in nature with a variety of lateral legs emerging from a main vertical wellbore. Additionally, the well may be multizonal with different zones of the well isolated from one another for sake of targeted production from certain specified zones. Packers may be used to isolate such zones from one another. In many cases, the packers used to isolate zones or anchor hardware are swell packers. Swell packers include a swellable element that is configured to expand over time to provide fluid isolation at a targeted location in the well. The packer is outfitted with a central mandrel or tubular in communication with the oilfield surface such that fluid communication between one zone and another may be controlled therethrough.

[0003] The element of a swell packer may be elastomeric and of a material selected based on downhole conditions such as types of fluids, temperatures, etc. So, for example, where well fluids are expected to be oil-based, the element may be of an oil- swellable material such as natural rubber. Thus, the packer may be advanced through the well to the targeted location where the element is allowed to swell over time. Generally, within a week or two, the packer will be fully set and fluid isolation provided at the location.

[0004] Unfortunately, over the course of deploying, positioning and swelling the packer, the element undergoes a significant amount of stress which may result in damage and ultimately failure of the packer to maintain isolation. For example, at the inner diameter of the element, where it interfaces the underlying mandrel, shear stress is likely to emerge at one end. That is, as the packer is lowered deeper and deeper into the well, greater and greater differential pressures are likely, particularly given the extensive depths common in wells of today. Indeed, as market demands become more aggressive, it is becoming increasingly common for the interface of the leading end of the element to be exposed to 15,000 PSI or more, for example during stimulation and fracturing operations. The result is a significant amount of shear stress being concentrated at the leading edge of the interface between the element and mandrel. In many cases this leads to a tearing or ripping away of the element material from the mandrel.

[0005] In circumstances where the element material begins to tear away from the mandrel, a leak path may emerge. Once more, even after completed swell and setting of the element, the emerging leak path may continue to migrate across the body of the element, ultimately reaching the other end. The final result may be a packer which fails to maintain isolation between different well zones as intended. Once more, remedial action may require shutting down well operations for a time consuming packer retrieval or milling operation and re-deployment with a new packer and associated hardware. Indeed, in some cases, well abandonment or tolerance of less efficient production may be the only practical options.

[0006] Efforts to prevent the emergence and propagation of such leak paths through swellable elements include the use of fold-back or gauge rings, anti-extrusion devices and other forms of reinforcing architecture which may be located on the mandrel at either end of the elements. Additionally, higher strength materials or fillers may be combined with the element material, though at some compromise to swellability of the element itself. Nevertheless, through such measures it is not uncommon to achieve a swell packer which is reliably effective at about 1,000 PSI per foot of element length. For example, a packer employing such architecture and materials which includes a 6 foot swellable element might be expected to reliably hold 6,000 PSI without developing a leak path.

[0007] Unfortunately, downhole pressures are often far in excess of 6,000 PSI. Indeed, pressures of 15,000 PSI to 20,000 PSI are becoming increasingly common. A swell element of 20 feet or longer may be impractical in terms of cost, transportation and assembly. Furthermore, simply extending the length of the element does not necessarily ensure reliability of the element material withstanding differential pressures of 15,000 PSI or more as noted.

[0008] As an added area of concern, shearing damage to the swell element may be pronounced due to the delay between the beginning of swelling and the time the packer is reinforced by becoming firmly set against the inner diameter of the casing which defines the well. Indeed, as noted above, it may take up to a couple of weeks before the element is fully swollen at the target location. Efforts to speed up the swell process may involve the use of swell materials for the element which swell at a faster rate. However, given the greater depths of many wells today, estimating a precise deployment time may be a challenge. Thus, the likelihood exists that the use of faster swelling materials for the element will result in premature swelling before the packer reaches the target location. As a result, remedial dislodging may be required, only now due to a prematurely swollen packer instead of due to a leak path and packer failure. Ultimately, as a matter of practicality, the operator is left utilizing slower swelling materials.

SUMMARY

[0009] A modular swell packer element is provided for a packer to be positioned at a location in a well. The element includes a first swell material bonded about a mandrel and is configured for swelling at a given rate once exposed to fluid in the well. The element also includes a second swell material that is modularly bonded about the first swell material and to swell at a rate that is below the given rate upon its exposure to the fluid. The first swell material may be a strength material for enhancing shear stress resistance of the element or a separate strength material may be modularly located between the mandrel and the first swell material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Fig. 1 is a side cross-sectional view of a swell packer with an embodiment of an element of enhanced shear strength and tailored swell character.

[0011] Fig. 2 is an overview of an oilfield having a well accommodating the swell packer of Fig. 1.

[0012] Fig. 3A is a perspective sectional view of another embodiment of a swell packer element revealing modular material portions thereof disposed about a mandrel.

[0013] Fig. 3B is a schematic representation of an embodiment of calendar wrapping to manufacture the element of Fig. 3 A.

[0014] Fig. 4A is a side partially-sectional view of a swell packer positioned in a well and utilizing the modular element of Fig. 3 A.

[0015] Fig. 4B is a side partially-sectional view of the packer of Fig. 4A during swell of an outer modular material portion of the element.

[0016] Fig. 4C is a side partially-sectional view of the packer of Fig. 4B during swell of a middle modular material portion of the element. [0017] Fig. 5A is a schematic side view of a packer with an element utilizing inner and outer swell material portions for tailoring a swell rate thereof.

[0018] Fig. 5B is a chart contrasting the tailored swell rate of the element of Fig. 5A with elements of non-modular materials.

[0019] Fig. 6 is a flow-chart summarizing an embodiment of employing a modular swell packer element in a well.

DETAILED DESCRIPTION

[0020] Embodiments herein are described with reference to certain types of downhole hardware and architecture. For example, downhole hardware is depicted herein that utilizes a production tubular and zonal isolation supported by an embodiment of a swell packer with modular element material construction. However, a variety of different types of downhole features may benefit from such packer isolation. For example, a base pipe, pup joint or other mandrel aside from a production tubular may support such a packer. Additionally, applications other than production may benefit from isolation with such a packer. This may include other inflow control device compartmentalizations, multistage fracturing, gravel packer replacement and cementing replacement and/or assurance. So long as a modular swell packer element is available for tailored swell rate and/or enhanced resistance to shear stress, appreciable benefit may be realized.

[0021] Referring now to Fig. 1, a side cross-sectional view of a swell packer 100 is shown which utilizes an embodiment of an element 101 that is of a uniquely enhanced shear strength as well as having a tailored swell character. More specifically, the element 101 is made up of different modular material portions 140, 160, each with its own particular performance characteristics. When combined as part of the same element 101, these discretely separate portions 140, 160 synergistically work together to enhance packer performance as detailed further below. For example, an inner modular material portion 140 may be high strength in nature to provide resistance to shear forces whereas an outer modular material portion 160 is responsively swellable upon exposure to well fluids. Alternatively, or in addition, the inner modular material portion 140 may be of a swellable material that swells at a comparatively faster rate than the outer modular material portion 160. In this way, uniquely tailored overall swell character may be provided to the element 101.

[0022] Continuing with reference to Fig. 1, a swell packer 100 is shown set in a well 180 to provide fluid isolation between uphole 187 and downhole 189 zones as alluded to above. Specifically, the packer 100 includes an element 101 which swells to sealably engage a casing 185 which defines the well 180. In the embodiment shown, the element 101 is provided about a mandrel in the form of production tubing 150. So, for example, the isolation provided by the packer 100 may provide control over the uptake of well fluids such that only fluids from the downhole zone 189 may be directed through the production tubing 150.

[0023] In the embodiment shown, differential pressure between the downhole zone 189 and uphole zone 187 may be quite dramatic. For example, it is becoming increasingly common for the packer 100 to be placed at a location in the well 180 that is several thousand feet in depth to hold a pressure differential of 10,000-15,000 PSI or more. Indeed, as shown in Fig. 1, a substantial differential pressure (indicated by arrows 130) is imparted on the packer 100 and element 101 such that a degree of deformation of the element 101 is visible. Specifically, material of the elastomeric element 101 is forced away from a downhole gauge ring 127 and toward an uphole gauge ring 125. A degree of uphole bulging 165 of the material over the uphole ring 125 is also visible. Once more, a lower region of the inner modular material portion 140 begins to expand as shear forces from the differential pressure 130 target the area. [0024] However, as indicated above, the inner modular material portion 140 is made up of a high strength material as opposed to utilizing an element of an impractical length in order to address such shear forces. Indeed, while longer element lengths may be utilized where desired, a standard 12 foot long element or shorter may suffice in this regard. Along these lines, a non-swellable natural rubber, hydrogenated nitrile butadiene rubber (HNBR) or fluoroelastomer may be utilized for this modular portion 140. That is, while material for the outer modular material portion 160 may be selected based primarily on swell characteristics as described further below, the inner modular material portion 140 may be of a material that is selected to resist shearing thereof from the underlying production tubing 150. Thus, enhanced resistance to shear forces is provided and the differential holding capacity of the packer 100 increased by the high strength modular portion 140. Once more, this is achieved in a manner that avoids substantial compromise to swell performance because the outer modular portion 160 may be of a material independently selected based more on swell characteristics.

[0025] Continuing with reference to Fig. 1, both modular material portions 140, 160 may be swellable. That is, even where the inner modular portion 140 is of a high strength material as noted above, it may also be of benefit to utilize a swelling material for this portion 140. In fact as detailed below, the material of the inner modular portion 140 may be specifically selected to swell comparatively faster than the material of the outer modular portion 160.

[0026] In the embodiment shown, during deployment of the packer 100 into the well 180, the element 101 is exposed to downhole fluids. Thus, the outer modular portion 160 may begin to swell to a degree. That is, rather than utilize a potentially unreliable or obstructive covering to delay swelling, in the embodiment shown, the element 101 is left uncovered and exposed to well fluids. Therefore, a slower swelling material may be utilized for the outer modular portion 160 of the element 101. This way, the risk of premature swelling of the element 101 to the point where the packer 100 might first seal and become stuck during deployment to the depicted location is reduced. In the case of deeper and deeper wells, more common in the oilfield of today, this may be of particular benefit given the longer deployment times. By the same token however, the modular nature of the element 101 is such that once the packer 100 is positioned at the location for isolation, a faster swell may ensue as the inner modular material portion 140 begins to become exposed to well fluids. Thus, an initially slow swell for the sake of deployment gives way to fast swell for the sake of fully sealing and setting the packer 100 at the location for isolation.

[0027] By way of example, the inner modular portion 140 may be made up of a comparatively faster swelling ethylene propylene diene monomer (EPDM) whereas the outer modular portion 160 is a slower swelling EPDM composite. Further, where the inner modular portion 140 is to also serve as a high strength layer for sake of resistance to shear stress, it may be highly loaded with filler material such as carbon black. Of course, these materials are only exemplary and a variety of other materials may be utilized whether for sake of enhancing strength of the inner modular portion 140 or tailoring the different swell rates of each modular portion 140, 160 relative one another. Along these lines, thicknesses of each modular portion 140, 160 may be selected to further tailor individual strength and swell characteristics. Similarly, the materials may also be selected based on expected downhole conditions such as temperature and pressure and the effects of such conditions on different types of potential materials.

[0028] Referring now to Fig. 2, an overview of an oilfield 200 is shown. Specifically, the surrounding environment for the swell packer 100 of Fig. 1 is shown during use with a well 180 at the oilfield 200 accommodating the packer 100. In this view, the benefit of a swell packer 100 of enhanced shear force resistance and uniquely tailored swell rates through use of a modular element 101 as shown in Fig. 1 may be more fully appreciated. For example, the well 180 may be several thousand feet in depth, traversing various formation layers 290, 295 before reaching a production region 297. Thus, the production region 297 may be of substantially high pressure. Indeed, with the packer 100 providing fluid isolation immediately thereabove, a differential exceeding 10,000 PSI would not be unexpected between the downhole zone 189 and the uphole zone 187.

[0029] In the embodiment of Fig. 2, the packer 100 is used to secure production tubing 150 in place and fluidly isolate the noted zones 187, 189 from one another. Thus, production from perforations 299 of the production region 297 may be directed exclusively through the production tubing 150. Deployment of the packer 100, installation of the tubing 150 and production of well fluids may be aided and governed by surface equipment 225. In the embodiment shown, a control unit 250 is located adjacent a well head 260 with a production line 275 emerging therefrom. A conventional rig 240 is also depicted to support initial hardware installation or completions as well as any follow on interventions.

[0030] Regardless, with added reference to Fig. 1, given the depths and potential pressures involved as noted above, it may be advantageous to utilize a packer 100 with a modular swell element 101 as detailed herein. In this way premature swelling or sealing of the packer 100 before reaching the full depth of the depicted isolating location may be avoided while at the same time allowing for a more rapid swelling once the packer 100 has reached the location. By the same token, the modular nature of the swell element 101 may also allow for enhanced resistance to shear forces likely present at such depths due to substantial differential pressure between the zones 189, 187.

[0031] Referring now to Fig. 3A, a perspective sectional view of another embodiment of a swell packer 100 and element 101 is shown. In this embodiment, the modular material portions 140, 300, 160 are shown consecutively wrapped about an underlying mandrel in the form of the production tubing 150 of Figs. 1 and 2. In this embodiment, a middle modular material portion 300 is located between the inner 140 and outer 160 modular material portions of Figs. 1 and 2. In this way, additional flexibility may be provided in terms of modular functions of the different portions 140, 300, 160. For example, the inner modular material portion 140 may be a non-swellable high strength member focused on enhancing resistance to shear stress as detailed hereinabove. In this embodiment, the middle modular portion 300 may be of a faster swell material as compared to the outer modular portion 160. Thus, these separate portions 300, 160 may be used together for tailoring the swell rate profile of the element 101 as detailed hereinabove.

[0032] In addition to the advantages noted above, utilizing discrete portions 140, 300, 160 as shown in Fig. 3 A (or as in the embodiment depicted in Fig. 1), allows for the assembly of a packer element 100 based on properties and characteristics of known materials. That is, from a testing and materials standpoint, the development of a new elastomer composition for a more monolithic swell element may be cost prohibitive. This may be especially true where the element is for a particular downhole use of its own unique tolerance requirements in terms of swell rate and shear force resistance. However, for embodiments detailed herein, known off-the-shelf materials may be formed into separate discrete portions 140, 300, 160 and utilized together without the requirement of developing a brand new monolithic elastomer composition for a given application.

[0033] Referring now to Fig. 3B, a schematic representation of an embodiment of calendar wrapping to manufacture the element 101 of Fig. 3 A is shown. That is, from a manufacturing standpoint, the availability of known off-the-shelf materials may be taken advantage of to form the swell element 101. Specifically, a mandrel in the form of production tubing 150 may be positioned adjacent a spool 345 of inner modular material to form the portion 140 depicted. Thus, as the spool 345 and tubing 150 are rotated in opposite directions relative one another, a sheet 340 of the material may move from the spool 345 to the tubing. A resulting layer by layer wrapping of the tubing 150 takes place until the portion is of the desired thickness. Subsequently, this spool 345 may be replaced with a spool 310 of sheet material 301 for forming the middle modular material portion 300 of Fig. 3 A.

[0034] Continuing with added reference to Fig. 3A, in one embodiment, an adhesive is also placed at the outer surface of the production tubing 150 before forming the inner modular material portion 140 as described. In this way, bonding between this portion 140 and the tubing 150 may be enhanced given the likely difference in material types. On the other hand, bonding between other modular portions 140, 300, 160 may already be enhanced due to similarity in polymer material makeup for each portion 140, 300, 160 of the element 101. Indeed, heat based curing during or between wrappings of different elastomer sheet types may take place to ensure bonding between the portions 140, 300, 160. Nevertheless, these portions 140, 300, 160 remain separate and discrete modular members of the element 101.

[0035] Referring now to Figs. 4A-4B, side partially-sectional views of the swell packer 100 of Fig. 3 A are shown in a well 180. Specifically, the modular element 101 of the packer 100 is shown during deployment into the well 180, exposure to well fluids, swelling and eventual setting.

[0036] Fig. 4A reveals initial deployment of the packer 100 into the well 180 with an element 101 having unswollen modular portions 140, 300, 160. As noted above, in this embodiment, the inner modular material portion 140 may be a strength member that is not configured for swelling but may be focused on providing resistance to shear stress as a result of the downhole pressure differential. [0037] With particular reference to Fig. 4B, the packer 100 may begin to swell during deployment as the element 101 is exposed to well fluids over time. However, this swell is limited to the outer modular material portion 160 which may be of a material type and thickness to account for the duration of deployment to the known well depth without prematurely sealing at the casing 185. That is, this portion 160 may be of an intentionally slower swelling material as compared to the underlying middle modular portion 300 which is next in line to undergo swelling. Thus, the time for deployment and positioning of the packer 100 may be accounted for by the design and material choice of this modular portion 160.

[0038] Continuing now with reference to Fig. 4C is a side partially-sectional view of the packer of Fig. 4B is shown during swell of the middle modular material portion 300 of the element 101. Specifically, the swelling of the middle modular material portion 300 begins to take place as well fluids progress across the element 101 from the outer modular portion 140 and eventually reach the middle modular portion 300. Once more, in the embodiment shown, swelling of the middle modular portion 300 is not only faster due to material choice but also eventually provides initial sealing of the element 101 at the casing 185. More complete swelling of the swellable portions 160, 300 may continue, resulting in higher compressive force imparted on the casing 185 and full setting of the packer in place at the isolating location.

[0039] Referring now to Figs. 5A and 5B, a schematic of the element 101 and modular swellable portions 160, 300 is shown in Fig. 5A. This is depicted adjacent a chart of Fig. 5B which contrasts the tailored swell rate profile for the element 101 against non-modular material swell rates. For example, with reference to the chart of Fig. 5B, a purely slow swell rate element made up of material similar to that found in the outer modular portion 160 may undergo an extensive swell time until sealing begins as indicated at 500. This may be advantageous for sake of deployment. However, achieving complete setting of the element also takes an extensive period as indicated at 525. On the other hand, an element of purely faster rate material similar to that found in the middle modular portion 300 may complete setting fairly quickly as indicated at 575. Unfortunately, the time to sealing may also be quite short and not sufficient for allowing proper deployment time to a desired downhole location (see 550).

[0040] Thus, as illustrated at Fig. 5B, embodiments as detailed hereinabove may combine separate modular portions into a single modular element that takes advantage of both a slower time for sealing (500) as well as a faster time for setting (575). In a real world comparison, this may translate into a reduction in the time to achieve full setting by up to several days without compromising the allowance for adequate deployment time so as to avoid premature initial sealing.

[0041] Referring now to Fig. 6, a flow-chart summarizing an embodiment of employing a modular swell packer element in a well is shown. The element is assembled from discrete modular members or portions about a mandrel as detailed above and indicated at 615. Thus, as the packer is deployed into a well as noted at 630, an outer modular member may swell at a given rate tuned to the time for deployment as indicated at 645. Similarly, once the packer is positioned at a target location in the well for fluid isolation as indicated at 660, a modular member below the outer member may swell at a faster rate (see 675). Once more, all the while, in the face of potentially extreme pressure differentials, a modular strength member which is adhered to the mandrel may provide enhanced shear force resistance to the element as indicated at 690.

[0042] Embodiments described hereinabove provide an element for a swell packer that includes modular construction in a way that may allow for enhancing strength and resistance to shear forces as a result of exposure to high differential pressures. Once more, modular construction of the element also allows it to be tuned for both slower and faster swelling stages depending on the circumstances. Specifically, modularity allows for an outer slower swelling material to be initially exposed to well fluids over the course of packer deployment into the well while also allowing a faster swelling underlying material to absorb well fluids for fast swelling during the setting process.

[0043] The preceding description has been presented with reference to presently preferred embodiments. Persons skilled in the art and technology to which these embodiments pertain will appreciate that alterations and changes in the described structures and methods of operation may be practiced without meaningfully departing from the principle, and scope of these embodiments. For example, embodiments detailed herein are directed at an outer modular material portion that may swell at a slower rate as compared to a more inner modular material portion. However, in other embodiments, swell rates may be reversed with the outer modular material portion swelling at a comparatively faster rate. So long as the different modular material portions may be tuned to independently swell at substantially different rates, appreciable benefit may be realized. Along these lines, "substantially different rates" would be any difference in rates that might serve to promote and/or support the intentional application sequence as opposed to more negligibly different rates. Furthermore, the foregoing description should not be read as pertaining only to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope.

Claims

We Claim: 1. A swell packer with a modular element for fluidly isolating a location in a well, the element comprising:

an inner modular material portion bonded about a mandrel and for swelling at a given rate upon exposure to a fluid in the well; and

an outer modular material portion modularly bonded about the inner swell material portion and for swelling at a rate that is substantially different from the given rate upon exposure to the fluid.

2. The swell packer of claim 1 wherein the substantially different rate of swelling for the outer modular material portion is a slower rate than the given rate of swelling for the inner modular material portion.

3. The swell packer of claim 1 wherein the inner modular material portion is an ethylene propylene diene monomer.

4. The swell packer of claim 1 wherein the inner modular material portion is a strength material for enhancing shear stress resistance of the element.

5. The swell packer of claim 4 wherein the inner modular material portion is loaded with a filler for increased strength.

6. The swell packer of claim 1 wherein the outer modular material portion is an ethylene propylene diene monomer composite.

7. The swell packer of claim 1 wherein the mandrel is one of a production tubular, a base pipe and a pup j oint.

8. A modular element of a swell packer for fluid isolation at a location in a well, the element comprising:

an inner modular material portion bonded about a mandrel and of a strength to enhance shear force resistance for the element during the isolation; and

an outer modular material portion bonded about the inner modular material portion for swelling to provide the fluid isolation.

9. The modular element of claim 8 wherein the inner modular material portion is of a material selected from a group consisting of a non-swellable natural rubber, a hydrogenated nitrile butadiene rubber and a fluoroelastomer.

10. The modular element of claim 8 wherein the inner modular material portion is swellable at a rate substantially greater than a rate of the swelling of the outer modular material portion.

11. The modular element of claim 10 wherein the inner modular material portion is of a filler loaded swellable material to provide the strength for enhancing the shear force resistance.

12. The modular element of claim 11 wherein the filler is carbon black.

13. The modular element of claim 8 wherein the modular element is of a length that is up to about 12 feet.

14. The modular element of claim 8 further comprising a middle modular material portion, the middle modular material portion positioned between the inner and outer modular material portions, the middle modular material portion swellable at a rate substantially greater than a rate of the swelling of the outer modular material portion.

15. A method of employing a packer with a modular swell element to provide fluid isolation at a target location in a well, the method comprising:

deploying the packer into the well;

swelling an outer modular member of the element at a given rate during the deploying;

positioning the packer at the target location; and

swelling another modular member of the element below the outer modular member at a rate substantially different than the given rate.

16. The method of claim 15 further comprising utilizing a modular strength member bonded to a central mandrel of the packer and below the other modular member to enhance shear force resistance of the element.

17. The method of claim 15 further comprising utilizing calendar wrapping to assemble the element about a central mandrel from discretely separate modular member spools prior to the deploying of the packer into the well.

18. The method of claim 17 further comprising applying heat based curing to the separate modular members to form the element.

19. The method of claim 15 wherein the packer comprises a central mandrel about which the modular members are provided, the method further comprising performing a downhole application supported by the fluid isolation.

20. The method of claim 19 wherein the downhole application is one of production through the central mandrel, an inflow control device compartmentahzation, multistage fracturing, cementing, and gravel packing.