PERMANENT PACKER USING A SLURRY INFLATION MEDIUM
A system for forming a seal in a wellbore includes a slurry source, an expandable inflatable element, and a filter. The slurry may contain particles entrained in a fluid carrier. The filter may be configured to separate the particles from the fluid carrier to form a relatively solid body in the inflatable element. The system may include a pump configured to pressurize the slurry. The pump may flow the slurry from a surface location or from a location in the wellbore. The source may be a bailer configured to receive a pressurized fluid from the pump. The system may use a hydraulic disconnect that conveys the slurry from the source to the inflatable element. The hydraulic disconnect may be configured to disconnect the source from the inflatable element upon a predetermined pressure being reached in the inflatable element. The particles may be formed of a compressible material.
Latest BAKER HUGHES INCORPORATED Patents:
None.
BACKGROUND OF THE DISCLOSURE1. Field of the Disclosure
The present invention relates to the selective isolation of wellbores and boreholes drilled in an earthen formation.
2. Description of the Related Art
Hydrocarbons such as oil and gas are recovered from a subterranean formation using a wellbore drilled into the formation. During drilling of the wellbore and subsequent completion activities, it may be desirable to isolate one or more sections of the wellbore. Conventionally, packers and bridge plugs may be employed in such circumstances. For instance, an annular space surrounding a wellbore tubular may be sealed by a packer. Traditionally, a packer may use a solid ring of rubber or other elastomer that is compressed against an interior well surface to seal off the annulus. A packer may also use a bladder that is inflated using a liquid or a gas. Bridge plugs are well appliances for obstructing the flow continuity of an entire bore and may also often use solid sealing elements as well as pressurized liquids and gases. Inflatable wellbore sealing devices, such as well packers and bridge plugs, may exhibit a loss in sealing effectiveness over the course of time. This may be due to leakage of the pressurized media used to expand the sealing device or other causes such as mechanical fatigue.
The present disclosure addresses the need for wellbore sealing devices that may retain their sealing capacity over a greater length of time, as well as and other needs of the prior art.
SUMMARY OF THE DISCLOSUREIn aspects, the present disclosure provides tools and devices that provide dependable zonal isolation for long term installations in wellbore and boreholes. The sealing devices may utilize solid or semi-solid mass that provide the inflation pressure that are generally insensitive to downhole conditions such as temperature changes, and less susceptible to leakage or mechanical creep of the inflated structure. In aspects, the sealing devices of the present disclosure may be expanded to a diameter that may be two to three times greater than the diameter of the bore of the wellbore tubular through which the sealing device is conveyed into the well. Thus, the sealing device may be utilized in a variety of situations to provide selective zonal isolation in a borehole below a wellbore tubular has a diameter that is two to three time greater than the wellbore tubular.
In aspects, the present disclosure provides a system for forming a seal in a wellbore. The system may include a source containing a slurry having particles entrained in a carrier; an expandable inflatable element having an inlet for receiving the slurry; and a filter positioned at an outlet for the inflatable element. The filter may be configured to separate the particles from the fluid carrier. In one arrangement, the system may include a pump configured to pressurize the slurry. The pump may be configured to flow the slurry from a surface location or from a location in the wellbore. In certain configurations, the source may be a bailer configured to receive a pressurized fluid from the pump. In further arrangements, the system may use a hydraulic disconnect that conveys the slurry from the source to the inflatable element. The hydraulic disconnect may be configured to disconnect the source from the inflatable element upon a predetermined pressure being reached in the inflatable element. In embodiments, the particles may be formed of a compressible material.
In aspects, the present disclosure provides a method for forming a seal in a wellbore by expanding an inflatable element into sealing engagement with a wellbore structure using a mass of compressible particles. In one embodiment, the method may include positioning a sealing device having an inflatable element in the wellbore; flowing a slurry into the inflatable element, the slurry having particles entrained in a fluid carrier; and flowing the fluid carrier out of the inflatable element while retaining the particles in the inflatable element. The method may include pressurizing the particles retained in the inflatable element. In certain arrangements, the method may include flowing the slurry from a surface location. In other arrangements, the method may include flowing the slurry from a downhole location, such as from a bailer. The method may further utilize terminating the flow of slurry into the inflatable element upon a predetermined pressure being reached in the inflatable element.
It should be understood that examples of the more illustrative features of the disclosure have been summarized rather broadly in order that detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the disclosure that will be described hereinafter and which will form the subject of the claims appended hereto.
The advantages and further aspects of the disclosure will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
The present disclosure relates to devices and methods for controlling production of a hydrocarbon producing well. The present disclosure is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present disclosure with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. Further, while embodiments may be described as having one or more features or a combination of two or more features, such a feature or a combination of features should not be construed as essential unless expressly stated as essential.
Referring initially to
Referring now to
The sealing system 60 includes a flow control device 68 for selectively flowing the slurry 64 into the inflatable element 62 and a filter element 70 that allows only the fluid carrier 67 of the slurry 64 to exit the inflatable element 62. The inflatable element 62 may be a unitary body or a multi-layered body. For example, in embodiments, the inflatable element 62 may include a first layer 62a that can be configured to retain a pressurized fluid, a second layer 62b that provides strength, and a third layer 62c that provides sealing capability. In embodiments, the first layer 62a may be formed of a relatively impermeable material such as rubber, the second layer 62b may be formed of metal ribs, such as stainless steel ribs, and the third layer 62c may be formed of a material such a rubber. The flow control device 68 may be a poppet valve, sliding sleeve valve or other suitable valve. In one suitable arrangement, the valve may be actuated to an open position upon application of a suitable pressure differential and closed when the pressure differential is removed. The filter element 70 may be formed as a perforated mandrel having holes or passages. The holes or passages may be sized to allow passage of only the fluid carrier 67 out of the inflatable element 62. Additionally, the sealing system 60 may include devices such as a cross-over sub 72 that directs fluid flow from a bore 74 of the inner tubular 75 to an annulus 76. Thus, the flow control device 68 controls flow into an inlet of the inflatable element 62 and the filter element 70 controls flow out of an outlet of the inflatable element 62. It should be understood that the illustrated arrangement is only exemplary. For instance, instead of being positioned in a center of the inflatable element 62, the filter element 70 may be positioned at an axial end of the inflatable element 62.
It should be appreciated that the components of the slurry 64 can be formed of numerous materials. For example, the particles 66 of the slurry 64 can be formed of two or more materials, each of which has a different material property. For instance, the particles 66 may be a mixture of low elastic modulus material, such as elastomers, and relatively hard or incompressible materials such as ceramics. Moreover, the particles may be all of the same shape or different shapes and of the same size or different sizes. The particles 66 may also be ground or pelletized. In still other variants, the particles 66 and fluid carrier 67 may be formulated to interact in a specified manner. For example, the particles 66 may be formed of materials that expand when the fluid carrier 67 is removed. Moreover, the particles 66 may be formulated to expand in response to an applied heat, such as that present in a downhole environment. In still other embodiments, the particles 66 may be formulated to form a generally solid body upon application of a suitable stimulus such as pressure, heat, or chemical agent. That is, instead of a body or mass formed of discrete elements, the particle 66 blend to form a substantially solid body. Thus, it should be appreciated that the sealing force applied by the particles 66 does not necessarily have to be generated by compression. Rather, chemical interactions, molecular interactions, applied heat, or other mechanisms may be used to activate the particles 66 to expand the inflatable element 62 and generate a sealing force.
Numerous arrangements may be utilized to deploy the sealing device 60 into a wellbore. Illustrative arrangements are discussed below.
Referring now to
Referring now to
It should be appreciated that the combination straining the slurry to accumulate particles 66 in the inflatable element 62 and using hydraulic pressure to compress the accumulated particles 66 converts the slurry 64 from a flowable mixture of solids 66 and liquids 67 to a compressed solid or semi-solid mass of particles capable of applying pressure in the useful form of a sealing force against the casing 40. In the as inflated condition, the first layer 62a retains the particles within the inflation element 62, the second layer 62b provides strength protection from the wellbore environment, and the third layer 62c forms a seal with the adjacent wall due to the compressive force applied by the mass of particles. It should be appreciated that the use of the slurry 64 allows the inflatable element to expand to a diameter that may be two to three times larger than the bore of the tubular 20 (
In one variant of the
In still other variant, the displacement fluid 89 may directly propels the slurry without the need for a piston 92. That is, the displacement fluid 89 may contact the slurry. In still another variant, a fluid in the wellbore may be used as the displacement fluid 89. Such an arrangement may reduce or eliminate the need for fluid to be conveyed from the surface. In still another variant, the return carrier fluid may be utilized is used as the displacement fluid 89, which would also reduce the amount of fluid to be conveyed from the surface. Thus, in variants, fluids available downhole may be used to supplement a surface conveyed displacement fluid or eliminate the need for a surface conveyed displacement fluid.
In some embodiments, the sealing device 60 may be permanently installed. In other embodiments, the sealing device 60 may be configured to be retrievable. Numerous arrangements may be used to make the sealing device 60 configurable. For example, the flow control device 68 may be configured to be shifted to an open position by a suitable setting tool. Once shifted into the open position, a fluid carrier may be back-flowed through the filter element 70 into the inflatable element 62 to fluidize the solid or semi-solid mass of particles 66 in the inflatable element 62. The fluidized particles 66 may then flow out of the inflatable element 62 via the open flow control device 68. In another embodiment, the particles 66 may be formulated to be dissolved, melted, or disintegrated upon application of a suitable stimulus (e.g., pressure, temperature, chemical agent, etc.).
From the above, it should be appreciated that sealing devices of the present disclosure, which may be constructed as inflatable packers or bridge plugs as well as other devices, may provide dependable sealing for long term installations. The solid or semi-solid mass in the sealing devices that provide the inflation pressure may be relatively insensitive to downhole conditions such as temperature changes, and less susceptible to leakage or mechanical creep of the inflated structure.
From the above, it should also be appreciated that sealing devices of the present disclosure may be expanded to a diameter that may be two to three times greater than the diameter of the bore of the wellbore tubular through which the sealing device is conveyed into the well. Thus, the sealing device may be utilized in a variety of situations to provide selective zonal isolation in a borehole below a wellbore tubular has a diameter that is two to three time greater than the wellbore tubular.
The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention. It is intended that the following claims be interpreted to embrace all such modifications and changes.
Claims
1. A system for forming a seal in a wellbore, comprising:
- (a) a body of compressible elements configured to apply a biasing force, the compressible elements being a component of a slurry;
- (b) an expandable inflatable element configured to apply the biasing force to an adjacent object, the inflatable element having an inlet for receiving the slurry and an outlet; and
- (c) a filter positioned at the inflatable element outlet, the filter configured to separate the particles from the fluid carrier.
2. The system of claim 1, further comprising: a pump configured to pressurize the slurry, and wherein the inflatable element includes a plurality of layers, at least one layer of which is formed at least partially of a metal.
3. The system of claim 2, wherein the pump is configured to flow the slurry from a surface location.
4. The system of claim 2, wherein the pump is positioned in the wellbore.
5. The system of claim 4, further comprising a bailer configured to receive a pressurized fluid from the pump and supply the slurry to the inflatable element.
6. The system of claim 1 further comprising a hydraulic disconnect conveying the slurry to the inflatable element, the hydraulic disconnect being configured to disconnect the source from the inflatable element upon a predetermined pressure being reached in the inflatable element, wherein the adjacent body is a wall of a wellbore tubular on which the inflatable element applies the biasing force of the body of compressible elements.
7. The system of claim 1 wherein the particles are formed of an elastomeric material configured to apply the biasing force.
8. A method for forming a seal in a wellbore, comprising:
- positioning a sealing device having an inflatable element in the wellbore;
- flowing a slurry into the inflatable element, the slurry having compressible particles entrained in a fluid carrier;
- flowing the fluid carrier out of the inflatable element while retaining the particles in the inflatable element; and
- applying a biasing force to an adjacent body using the compressible particles.
9. The method of claim 8, further comprising pressurizing the particles retained in the inflatable element to form a body of rarticles that apply the biasing force.
10. The method of claim 8, further comprising flowing the slurry from a surface location.
11. The method of claim 8, further comprising flowing the slurry from a downhole location.
12. The method of claim 11, supplying the slurry from a bailer.
13. The method of claim 8 further comprising terminating the flow of slurry into the inflatable element upon a predetermined pressure being reached in the inflatable element.
14. The method of claim 8 wherein the particles are formed of a an elastomeric material that generate a biasing force when compressed.
15. A method for forming a seal in a wellbore, comprising:
- expanding an inflatable element into sealing engagement with a wellbore tubular using a mass of compressible particles.
16. The method of claim 15, further comprising pressurizing the particles.
17. The method of claim 15, further comprising flowing a slurry containing the compressible particles from a surface location.
18. The method of claim 15, further comprising flowing a slurry containing the compressible particles from a downhole location.
19. The method of claim 18, supplying the slurry from a bailer.
20. The method of claim 15 further comprising terminating a flow of slurry containing the compressible particles into the inflatable element upon a predetermined pressure being reached in the inflatable element.
Type: Application
Filed: Apr 10, 2008
Publication Date: Oct 15, 2009
Applicant: BAKER HUGHES INCORPORATED (Houston, TX)
Inventors: Michael J. Loughlin (Houston, TX), Luis E. Mendez (Houston, TX)
Application Number: 12/100,758
International Classification: E21B 33/126 (20060101);