Abstract: Provided is an apparatus, as well as a method for establishing a seal between a mandrel and a borehole. The apparatus, in one aspect, includes a mandrel, and a packer, the packer including: a constrained portion coupled to the mandrel; and an unconstrained portion made of a swellable material and coupled to the constrained portion, wherein the unconstrained portion is free to move with respect to the mandrel. The apparatus, according to one aspect, further includes a spring positioned between the mandrel and the unconstrained portion and configured to urge the unconstrained portion away from the mandrel, the spring having a spring force less than a yield strength of the swellable material when the swellable material is in an unswelled condition.

Abstract: A seal assembly and methods of use, wherein the seal assembly is formed of an elastomeric enclosure within which a primary cavity is defined. A second cavity in the form of a crushable container is deployed within the primary chamber. An elastomeric compound is contained in one cavity and an elastomeric hardener contained in the other cavity. Upon application of an external force to the elastomeric enclosure, the enclosure is elastically deformed from a first shape to a second shape, wherein the second shape positions the elastomeric enclosure into a sealing configuration between adjacent annular surfaces. The external force also crushes the container, to cause mixing of the elastomeric compound and elastomeric hardener. Once the reaction is complete, the hardened compound retains the deformed shape of the elastomeric enclosure to maintain a seal between the annular surfaces.

Abstract: Methods for positioning an expandable metal sealing element in the wellbore. An example method includes an expandable metal sealing element having a reactive metal and disposed in a location. The method further includes actuating a washout prevention element, contacting the expandable metal sealing element with a fluid that reacts with the reactive metal to produce a reaction product having a volume greater than the reactive metal, and allowing the washout prevention element to prevent at least a portion of the reaction product from flowing away from the location.

Abstract: A single structure usable as a backup shoe or element retainer in a packer assembly for sealing a wellbore can be fabricated using an additive manufacturing process. The single structure can be manufactured to have a high-density region and a low-density region having a density that is lower than the high-density region. The high-density region can include a ribbed-structure to reduce circumferential force applied to the single structure.

Abstract: Provided is a sealing tool, a method for sealing an annulus within a wellbore, and a well system. The sealing tool, in at least one aspect, includes a sealing assembly positioned about a mandrel. In at least one aspect, the sealing assembly includes one or more elastomeric sealing elements having a width (WSE), the one or more elastomeric sealing elements operable to move between a radially relaxed state and a radially expanded state. In at least this aspect, the sealing assembly includes a pair of expandable metal features straddling the one or more elastomeric sealing elements, each of the pair of expandable metal features comprising a metal configured to expand in response to hydrolysis and having a width (WEM), and further wherein the width (WSE) is at least three times the width (WEM).

Abstract: A single structure usable as a backup shoe or element retainer in a packer assembly for sealing a wellbore can be fabricated using an additive manufacturing process. The single structure can have a high-density region and a low-density region having a density that is lower than the high-density region. The low-density region can be deformable to retain a position of another component downhole in a wellbore, such as an elastomeric element useable to expand to create the packer seal within the annulus of the wellbore. The high-density region can include a ribbed-structure to reduce circumferential force applied to the single structure.

Abstract: A wellbore packer system includes a mandrel positionable within a wellbore. The system further includes a wellbore packer positionable around the mandrel. The wellbore packer includes an expandable metal sealing element positionable around a first portion of the mandrel to form a long-term seal within the wellbore in response to exposure of the expandable metal sealing element to wellbore fluid. Additionally, the wellbore packer includes an elastomeric sealing element positionable around a second portion of the mandrel to form a short-term seal in response to receiving a seal-setting force. Moreover, the wellbore packer includes a setting piston positionable to apply the seal-setting force on the elastomeric sealing element.

Abstract: A wellbore packer system includes a mandrel positionable within a wellbore. The system further includes a wellbore packer positionable around the mandrel. The wellbore packer includes an expandable metal sealing element positionable around a first portion of the mandrel to form a long-term seal within the wellbore in response to exposure of the expandable metal sealing element to wellbore fluid. Additionally, the wellbore packer includes an elastomeric sealing element positionable around a second portion of the mandrel to form a short-term seal in response to receiving a seal-setting force. Moreover, the wellbore packer includes a setting piston positionable to apply the seal-setting force on the elastomeric sealing element.

Abstract: Methods for forming a seal in a wellbore. An example method includes positioning an expandable metal sealing element in the wellbore; wherein the expandable metal sealing element comprises a composite material of expandable metal and a reinforcement material. The expandable metal forms a matrix and the reinforcement material is distributed within the matrix. The method further includes contacting the expandable metal sealing element with a fluid that reacts with the expandable metal to produce a reaction product having a volume greater than the expandable metal.

Abstract: A downhole tool can include: an inner mandrel; at least one component, wherein a portion of the at least one component moves in a direction radially away from the inner mandrel when the downhole tool is set; and a protective covering, wherein the protective covering comprises a dissolvable material, and wherein the protective covering partially surrounds an outer diameter of the at least one component when the downhole tool is run-in. The downhole tool can be introduced into a wellbore. The protective covering can dissolve via chemical reactions of metals, metal alloys, or metal oxides, or by melting of a thermoplastic. The downhole tool can be set after the protective covering has dissolved. The tool can be a packer assembly, bridge plug, frac pack plug, or liner hangers. The at least one component of the downhole tool can be a sealing element, a collet, a split wedge, or a slip.

Abstract: A packer has a constrained portion coupled to a mandrel and an unconstrained portion made of a swellable material and coupled to the constrained portion. The unconstrained portion is free to move with respect to the mandrel.

Abstract: A single structure usable as a backup shoe or element retainer in a packer assembly for sealing a wellbore can be fabricated using an additive manufacturing process. The single structure can have a high-density region and a low-density region having a density that is lower than the high-density region. The low-density region can be deformable to retain a position of another component downhole in a wellbore, such as an elastomeric element useable to expand to create the packer seal within the annulus of the wellbore. The high-density region can include a ribbed-structure to reduce circumferential force applied to the single structure.

Abstract: Methods for positioning an expandable metal sealing element in the wellbore. An example method includes an expandable metal sealing element having a reactive metal and disposed in a location. The method further includes actuating a washout prevention element, contacting the expandable metal sealing element with a fluid that reacts with the reactive metal to produce a reaction product having a volume greater than the reactive metal, and allowing the washout prevention element to prevent at least a portion of the reaction product from flowing away from the location.

Abstract: Methods for positioning an expandable metal sealing element in the wellbore. An example method includes an expandable metal sealing element having a reactive metal and disposed in a location. The method further includes actuating a washout prevention element, contacting the expandable metal sealing element with a fluid that reacts with the reactive metal to produce a reaction product having a volume greater than the reactive metal, and allowing the washout prevention element to prevent at least a portion of the reaction product from flowing away from the location.

Abstract: Methods for positioning an expandable metal sealing element in the wellbore. An example method includes an expandable metal sealing element having a reactive metal and disposed in a location. The method further includes actuating a washout prevention element, contacting the expandable metal sealing element with a fluid that reacts with the reactive metal to produce a reaction product having a volume greater than the reactive metal, and allowing the washout prevention element to prevent at least a portion of the reaction product from flowing away from the location.

Abstract: A seal assembly and methods of use, wherein the seal assembly is formed of an elastomeric enclosure within which a primary cavity is defined. A second cavity in the form of a crushable container is deployed within the primary chamber. An elastomeric compound is contained in one cavity and an elastomeric hardener contained in the other cavity. Upon application of an external force to the elastomeric enclosure, the enclosure is elastically deformed from a first shape to a second shape, wherein the second shape positions the elastomeric enclosure into a sealing configuration between adjacent annular surfaces. The external force also crushes the container, to cause mixing of the elastomeric compound and elastomeric hardener. Once the reaction is complete, the hardened compound retains the deformed shape of the elastomeric enclosure to maintain a seal between the annular surfaces.

Abstract: Methods for forming a seal in a wellbore. An example method includes positioning an expandable metal sealing element in the wellbore; wherein the expandable metal sealing element comprises a composite material of expandable metal and a reinforcement material. The expandable metal forms a matrix and the reinforcement material is distributed within the matrix. The method further includes contacting the expandable metal sealing element with a fluid that reacts with the expandable metal to produce a reaction product having a volume greater than the expandable metal.

Abstract: A collet lock assembly for use on a downhole tool allows repeat cycling of a “RELEASE” and “SET” position. In the “RELEASE” position, the collet lock assembly allows bi-directional relative movement of the mandrel in relation to the collet lock assembly, while in the “SET” position, the assembly allows bi-directional load transfer along the mandrel directly into the slip assembly while diverting axial loads away from components positioned along the downhole tool.

Abstract: A collet lock assembly for use on a downhole tool allows repeat cycling of a “RELEASE” and “SET” position. In the “RELEASE” position, the collet lock assembly allows bi-directional relative movement of the mandrel in relation to the collet lock assembly, while in the “SET” position, the assembly allows bi-directional load transfer along the mandrel directly into the slip assembly while diverting axial loads away from components positioned along the downhole tool.