SEALING ON SERVICE PACKERS

BACKGROUND

Field

[0001]Embodiments of the present disclosure generally relate to retrievable downhole packers, downhole packer assemblies and downhole tools employing packers and packer assemblies.

Description of the Related Art

[0002]In the resource recovery industry, more specifically in hydrocarbon recovery, sealing tools such as bridge plugs and packer elements are used to isolate production zones to control downhole pressure and fluids. Packers, temporary or permanent, include packer elements that provide a seal to prevent fluid flow from the zones downstream from the packer element to the zones upstream of the packer element. During operation, a packer is typically compressed, forcing the packer element to expand radially outwards towards the surrounding casing. The compressive expansion of the packer element results in the packer contacting the casing and creating a seal between the upstream zone and downstream zone of the casing.

[0003]However, the distance that a conventional packer element may expand due to compression of the packer element alone may not be sufficient to provide an adequate seal. In addition, the compression of the packer element can result in damage to the packer element, making retrieval difficult or impossible. Therefore, there is a need for improved retrievable packers and packer systems.

SUMMARY

[0004]In one embodiment, a packer is disclosed. The packer assembly includes a mandrel comprising a lower ledge and a mandrel tapered surface, a lower tubular comprising an upper ledge, a plurality of packer elements disposed around the mandrel tapered surface, and a plurality of separators disposed between the plurality of packer elements.

[0005]In one embodiment, a method of deploying and actuating a packer assembly is disclosed. The method includes deploying a packer assembly within a, applying a force to a mandrel of the packer assembly to move the mandrel relative to a lower tubular, releasing the force from the mandrel, and removing the packer assembly from the casing. Applying the force to the mandrel includes sliding a mandrel tapered surface of the mandrel within a plurality of packer elements, applying a force to an inner diameter of the plurality of packer elements, radially outwardly expanding the plurality of packer elements due to the force on the inner diameter of the plurality of packer elements, and forming a seal between the plurality of packer elements and the casing.

[0006]In yet another embodiment, a packer system is disclosed. The packer system includes a drag block section, a slip assembly comprising a plurality of slips, and a packer assembly. The packer assembly includes a mandrel comprising a lower ledge and a mandrel tapered surface, a lower tubular comprising an upper ledge, a plurality of packer elements disposed around the mandrel tapered surface, and a plurality of separators disposed between the plurality of packer elements.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, and may admit to other equally effective embodiments.

[0008]FIG. 1A is a perspective view of a packer system, according to embodiments herein.

[0009]FIG. 1B is a perspective view of a packer assembly in an unactuated position within a casing, according to embodiments herein.

[0010]FIG. 1C is a cross-sectional view of a packer assembly in the unactuated position within the casing, according to embodiments herein.

[0011]FIG. 1D is a perspective view of a packer assembly in an actuated position within the casing, according to embodiments herein.

[0012]FIG. 1E is a cross-sectional view of a packer assembly in an actuated position within the casing, according to embodiments herein.

[0013]FIG. 2 is a flow diagram of a method of deploying and removing a packer system, according to embodiments herein.

[0014]FIG. 3 is a cross-sectional view of the unitary packer assembly in the unactuated (or running) position within the casing, according to embodiments herein.

[0015]To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

DETAILED DESCRIPTION

[0016]Embodiments of the present disclosure generally relate to retrievable downhole packers, downhole packer assemblies and downhole tools employing packers and packer assemblies.

[0017]FIG. 1A is a perspective view of a packer system 170. One packer system 170 that can benefit from the present disclosure is the BRUTE® Retrievable Service Packer from EXPRO. The packer assembly 100 is run into the wellbore to a desired region in the wellbore for which isolation is desired. The packer system 170 may be attached to tubing both upstream and downstream of the packer system 170 to run the packer system 170 to a desired depth in the wellbore. In some applications, a series of packer systems 170 may be utilized to isolate multiple reservoirs or regions in the wellbore at various depths. The packer system 170 includes a packer assembly 100, a slip assembly 173, and a drag block section 172. The drag block section 172 provides the friction required to start the setting process of the packer system 170. A tool (not shown) brings the packer system 170 into tension and rotates the packer system 170 into a set position. The tool then applies a tailpipe force to the packer system 170, causing a plurality of slips of the slip assembly 173 to extend radially outward and grip the inner surface of the casing surrounding the packer system 170. Simultaneously, the same axial force causes the packer assembly 100 to expand radially outward and form a seal against the casing or other tubular.

[0018]FIG. 1B is a perspective view of the downhole packer assembly 100 of the packer system 170 in an unactuated (or running) position within a casing 102. FIG. 1C is a cross sectional view of the packer assembly of FIG. 1B in the unactuated (or running) position within the casing 102. The casing 102 annularly surrounds the packer assembly 100, forming an outer volume 155. While in the unactuated position, the packer assembly 100 is able to be deployed downhole within the casing 102 having an OD slightly smaller than the ID of the casing. The packer assembly 100 includes a tubular body 101, an upper mandrel 104A, a lower mandrel 104B, a hold down 108A, a lower tubular 108B, one or more packer elements 106 (e.g., an first packer element 106A, a second packer element 106B, and a third packer element 106C are shown), and one or more separators 112 (e.g., a first separator 112A and a second separator 112B are shown). The upper mandrel 104A, the lower mandrel 104B, the hold down 108A, the lower tubular 108B, packer elements 106, and separators 112 circumferentially surround the tubular body 101. The tubular body 101 defines a fluid flow/pumping volume 103. Generally, the term “upper” refers to component that is disposed upstream on the packer system 170, while the term “lower” refers to a component that is disposed downstream on the packer system 170. “Upper” and “lower” are not intended to be limited by direction, such as vertical and horizontal.

[0019]The upper mandrel 104A includes a lower ledge 105, an upper ledge 107, and a first threaded surface 130. The lower mandrel 104B includes a mandrel tapered surface 121, an upper ledge 119, a lower ledge 122, and a first mating threaded surface 131. As used herein, “tapered” is intended to refer to a surface extending at an angle other than substantially parallel or substantially perpendicular to the outer surface of the tubular body 101. The mandrel tapered surface 121 of the lower mandrel 104B supports the packer elements 106 thereon and is in contact with an inner diameter of the packer elements 106. The inner diameter of the packer elements 106 may be a constant inner diameter or a tapered inner diameter to match the mandrel tapered surface 121. Depending on the slope of the mandrel tapered surface 121, the packer elements 106 may have differing IDs and inner tapered surfaces. The first threaded surface 130 of the upper mandrel 104A is threaded onto (or otherwise connected to) the first mating threaded surface 131 of the lower mandrel 104B so that the lower ledge 105 of the upper mandrel 104A abuts the lower ledge 122 of the lower mandrel 104B and the first packer element 106A.

[0020]The lower tubular 108B includes a second threaded surface 132, an inner ledge 111 and an outer ledge 117. The hold down 108A includes a tubular body having a hold down tapered surface 109, an inner ledge 113, an upper ledge 115, an outer ledge 120, and a second mating threaded surface 133. The lower tubular 108B includes the second threaded surface 132 to mount the hold down 108A to the lower tubular 108B. The hold down 108A includes a second mating threaded surface 133 to threadably couple to the second threaded surface 132 of the lower tubular 108B. The hold down 108A and the lower tubular 108B may be threadably coupled together to allow the hold down 108A to be replaced with the same or a different angles surface depending on the application and the mandrel tapered surface 121 of the lower mandrel 104B. A hold down angle of the hold down tapered surface 109 matches the mandrel tapered surface 121 of the lower mandrel 104B. The inner ledge 113 of the hold down 108A abuts the inner ledge 111 of the lower tubular 108B. The upper ledge 115 abuts the lower end of the packer elements 106 occupying the lowest position on the lower mandrel 104B (here, the third packer element 106C).

[0021]Separators 112 are disposed between the packer elements 106. For example, the first separator 112A is disposed between the first packer element 106A and the second packer element 106B and the second separator 112B is disposed between the second packer element 106B and the third packer element 106C. The separators 112 provide a uniform force against the packer elements 106 as the packer elements 106 are moved from the unactuated position to an actuated position. In the actuated position, the packer elements 106 are radially extended and compressed. The packer elements 106 are made of an elastomeric material, such that the packer elements 106 may be easily deformed and reformed between the actuated position and the unactuated position.

[0022]A force (e.g., the tailpipe force applied by the tool) is applied to the upper mandrel 104A. When the force is applied to the upper mandrel 104A, upper mandrel 104A and the lower mandrel 104B move axially downward against the first packer element 106A. The lower ledge 105 of the upper mandrel 104A applies the force against the lower ledge 122 of the lower mandrel 104B and the first packer element 106A. The movement of the upper mandrel 104A and the lower ledge 122 of the lower mandrel 104B forces the mandrel tapered surface 121 of the lower mandrel 104B to slide within the packer elements 106 and forces the packer elements 106 to move radially outwardly (expand) towards the casing 102 to form a seal therewith. Furthermore, the movement of the upper mandrel 104A against the first packer element 106A forces the first packer element 106A (and, subsequently through the separators 112, the second packer element 106B and the third packer element 106C) to expand radially outward as the mandrel tapered surface 121 of the lower mandrel 104B slides within the packer elements 106. In addition, the packer elements 106 are contained between the lower ledge 105 of the upper mandrel 104A and the upper ledge 115 of the hold down 108A and, as a result, are compressed and further expand radially outward into a sealing position against the casing 102. The hold down 108A and the lower tubular 108B are stationary as the force is applied to the upper mandrel 104A. The hold down 108A and the lower tubular 108B are held stationary by the slips 173. As the lower mandrel 104B moves axially downward, the hold down tapered surface 109 of the hold down 108A slides past the mandrel tapered surface 121 of the lower mandrel 104B until the hold down tapered surface 109 abuts the mandrel tapered surface 121. The separators 112 provide a uniform force against the packer elements 106 as the packer elements 106 are moved from the unactuated position to an actuated position. The separators 112 are made of an elastomeric material to enable the separators 112 to expand as the force is applied to the upper mandrel 104A moves the mandrel tapered surface 121.

[0023]FIG. 1D is a perspective view of the packer assembly 100 in an actuated (or radially extended and compressed) position. FIG. 1E is a cross-sectional view of the packer assembly 100 as shown in FIG. 1D in the actuated (or radially extended and compressed) position. In the radially extended and compressed position, the first packer element 106A, the second packer element 106B, and the third packer element 106C are forced to expand radially outward and form a seal against the casing 102 between an upper zone 150 and a lower zone 160. The seal prevents fluid flow from the lower zone 160 to the upper zone 150 or vice versa. The movement of the upper mandrel 104A forces the mandrel tapered surface 121 of the lower mandrel 104B against the packer elements 106, causing the packer elements 106 to slide on the mandrel tapered surface 121 of the lower mandrel 104B and to move radially outwardly (expand) towards a casing 102 to form a seal therewith. The lower ledge 105 of the upper mandrel 104A simultaneously applies the force against the first packer element 106A (and, subsequently through the separators 112, the second packer element 106B and the third packer element 106C). The force applied by the upper mandrel 104A causes the packer elements 106 to compress and expand further radially outward into a sealing position against the casing 102. The separators 112 provide a uniform force against the packer elements 106 as the packer elements 106 are moved from the uncompressed position to the compressed position. The combination of radially expansion from the forces applied by the mandrel tapered surface 121 against the packer elements 106 and the compression of the upper mandrel 104A against the packer elements 106 increases the quality of the seal with the casing 102.

[0024]After the completion of the downhole operations requiring deployment of the packer system 170, the force applied to the upper mandrel 104A is released. The release of the force on the upper mandrel 104A releases the force from the lower mandrel 104B and on the packer elements 106. The radial forces on the packer elements 106 from the mandrel tapered surface 121 are released and the packer elements 106 decompress and contract radially inward toward the tubular body 101. The decompressing of the packer elements 106 enable the packer assembly 100 to be removed from the casing 102.

[0025]FIG. 2 is a flow diagram of a method 200 of using the packer assembly 100. At operation 202, a packer assembly 100 is deployed downhole into a casing 102. The packer assembly 100 is deployed in an unactuated position (as shown in FIGS. 1B and 1C) into the wellbore.

[0026]At operation 204, a force is applied to the upper mandrel 104A. The force applied to the upper mandrel 104A forces the upper mandrel 104A and the lower mandrel 104B to apply the force to a lower ledge 122 of a lower mandrel 104B and a first packer element 106A of one or more packer elements 106. A mandrel tapered surface 121 of the lower mandrel 104B applies the force to the inner diameter of the packer elements 106, which forces the packer elements 106 to expand radially outward. The force applied by the lower ledge 105 of the upper mandrel 104A to the first packer element 106A (and, via one or more separators 112, the first packer element 106A and second packer element 106B) forces the packer elements 106 up the mandrel tapered surface 121 to compress and expand the packer elements 106 radially outward. The forces from the lower ledge 105 and the mandrel tapered surface 121 causes the packer elements 106 to compress and expand radially outward against an upper ledge 115 of the hold down 108A (as shown in FIGS. 1D and 1E).

[0027]The packer elements 106 form a seal against the casing 102 or other tubular (as shown in FIG. 1D and FIG. 1E). The radially outward expansion of the packer elements 106 forms the seal against the casing 102 or other tubular between an upper zone 150 of the outer volume 155 and a lower zone 160 of the outer volume 155. The seal prevents fluid flow from the lower zone 160 to the upper zone 150.

[0028]At operation 206, the force is released from upper mandrel 104A. The release of the force on the upper mandrel 104A releases the force on the lower mandrel 104B and the packer elements 106. The release of the force on the upper mandrel 104A also releases the force on the inner diameter of the packer elements 106 from the mandrel tapered surface 121 of the lower mandrel 104B. The packer elements 106 are decompressed and contract radially inward toward the tubular body 101. At operation 208, the packer assembly 100 is removed from the casing 102.

[0029]FIG. 3 is a cross-sectional view of the unitary packer assembly 300 in the unactuated (or running) position within the casing 102. The unitary packer assembly 300 may be used in place of the packer assembly 100. The unitary packer assembly 300 is similar to the packer assembly 100, however, the unitary packer assembly 300 includes a mandrel 304 and a lower tubular 308. In some embodiments, as shown in FIG. 3, the packer assembly 100 or unitary packer assembly 300 does not include a tubular body 101.

[0030]The mandrel 304 is a unitary piece that combines the upper mandrel 104A and the lower mandrel 104B of the packer assembly 100. The mandrel 104 includes a lower ledge 305. The lower ledge 105 of the mandrel 304 abuts the first packer element 106A.

[0031]The lower tubular 308 is a unitary piece that combines the hold down 108A and the lower tubular 108B of the packer assembly 100. The lower tubular 308 includes a hold down tapered surface 309 and an upper ledge 315. A hold down angle of the hold down tapered surface 309 matches the mandrel tapered surface 121 of the mandrel 304. The upper ledge 315 abuts the lower end of the packer elements 106 occupying the lowest position on the mandrel 304 (here, the third packer element 106C).

[0032]The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, operations, etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B, and C can consist of (i.e., contain only) components A, B, and C, or can contain not only components A, B, and C but also one or more other components. In addition, whenever a composition, an element or a group of elements is preceded with the transitional phrase “comprising” or grammatical equivalents thereof, it is understood that it is contemplated that the same composition or group of elements may be preceded with transitional phrases “consisting essentially of,” “consisting of,” “selected from the group of consisting of,” or “is” preceding the recitation of the composition, element, or elements and vice versa.

[0033]Where reference is made herein to a method comprising two or more defined operations, the defined operations can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other operations which are carried out before any of the defined operations, between two of the defined operations, or after all of the defined operations (except where the context excludes that possibility).

[0034]When introducing elements of the present disclosure or exemplary aspects or implementation(s) thereof, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of the elements.

[0035]The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0036]While the foregoing is directed to implementations of the present disclosure, other and further implementations of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.