U.S. patent application number 10/995593 was filed with the patent office on 2005-05-26 for swelling layer inflatable.
This patent application is currently assigned to Baker Hughes Incorporated. Invention is credited to Badke, Gregory C., Wood, Edward T..
Application Number | 20050110217 10/995593 |
Document ID | / |
Family ID | 34632951 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050110217 |
Kind Code |
A1 |
Wood, Edward T. ; et
al. |
May 26, 2005 |
Swelling layer inflatable
Abstract
An inflatable that features a swelling layer is disclosed. The
swelling layer can be made integral or attached to the element or
it can be bonded or otherwise secured to the mandrel. Upon
inflation with fluid, the element expands into sealing contact with
a surrounding tubular or wellbore. The fluid is absorbed or
otherwise interacts with the swelling layer so that, in a preferred
embodiment, the total occupied volume of the swelling layer and
fluid individually is retained after mixing with the swelling of
the layer acting to hold the seal of the inflatable element even if
a problem develops in the sealing element
Inventors: |
Wood, Edward T.; (Kingwood,
TX) ; Badke, Gregory C.; (Conroe, TX) |
Correspondence
Address: |
DUANE, MORRIS, LLP
3200 SOUTHWEST FREEWAY
SUITE 3150
HOUSTON
TX
77027
US
|
Assignee: |
Baker Hughes Incorporated
|
Family ID: |
34632951 |
Appl. No.: |
10/995593 |
Filed: |
November 22, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60525019 |
Nov 25, 2003 |
|
|
|
Current U.S.
Class: |
277/333 |
Current CPC
Class: |
E21B 33/127 20130101;
E21B 33/1208 20130101; Y10S 277/934 20130101 |
Class at
Publication: |
277/333 |
International
Class: |
E21B 033/127 |
Claims
We claim:
1. A packer, comprising: a mandrel; a sealing element mounted over
said mandrel defining an annular space therebetween; a material in
said annular space, said material capturing at least some of a
medium delivered to said annular space.
2. The packer of claim 1, wherein: said material has an initial
volume V.sub.1 and the delivered medium to said annular space has
an initial volume V.sub.2; whereupon delivery of volume V.sub.2 to
said annular space, the total volume of the delivered fluid and
said material is at least about the sum of volumes V.sub.1 and
V.sub.2.
3. The packer of claim 1, wherein: said material retains at least a
portion of the medium in the event of malfunction of said sealing
element.
4. The packer of claim 1, wherein: said material swells when
contacted by the medium.
5. The packer of claim 1, wherein: said material swells in the
presence of at least one of water and a hydrocarbon.
6. The packer of claim 3, wherein: said material retains the seal
of said sealing element, after inflation, despite a malfunction of
said sealing element.
7. The packer of claim 5, wherein: said material swells in the
presence of both water and a hydrocarbon.
8. The packer of claim 1, wherein: said material is secured to said
element.
9. The packer of claim 1, wherein: said material is secured to said
mandrel.
10. The packer of claim 1, wherein: said material is secured to
neither said mandrel or said element.
11. The packer of claim 1, wherein: said material comprises a
sleeve.
12. The packer of claim 11, wherein: said sleeve is seamless.
13. The packer of claim 1, wherein: said material comprises a
swelling clay.
14. The packer of claim 1, wherein: said material comprises at
least one of EPDM, natural rubber and brombutyl rubber.
15. The packer of claim 3, wherein: said material has an initial
volume V.sub.1 and the delivered medium to said annular space has
an initial volume V.sub.2; whereupon delivery of volume V.sub.2 to
said annular space, the total volume of the delivered fluid and
said material is at least about the sum of volumes V.sub.1 and
V.sub.2.
16. The packer of claim 15, wherein: said material swells when
contacted by the medium.
17. The packer of claim 16, wherein: said material swells in the
presence of at least one of water and a hydrocarbon.
18. The packer of claim 17, wherein: said material retains the seal
of said sealing element despite a malfunction of said sealing
element.
19. The packer of claim 18, wherein: said material comprises a
sleeve.
20. The packer of claim 19, wherein: said material comprises at
least one of a swelling clay, EPDM, natural rubber and brombutyl
rubber.
21. An inflatable packer, comprising: a mandrel; a sealing element
mounted over said mandrel defining an annular space therebetween; a
material in said annular space, said material capturing at least
some of an inflation medium delivered to said annular space.
22. The packer of claim 21, wherein: said material has an initial
volume V.sub.1 and the delivered inflation medium to said annular
space has an initial volume V.sub.2; whereupon delivery of volume
V.sub.2 to said annular space, the total volume of the delivered
fluid and said material is at least about the sum of volumes
V.sub.1 and V.sub.2.
23. The packer of claim 21, wherein: said material retains at least
a portion of the inflation medium in the event of malfunction of
said sealing element.
24. The packer of claim 21, wherein: said material swells when
contacted by the inflation medium.
25. The packer of claim 21, wherein: said material swells in the
presence of at least one of water and a hydrocarbon.
26. The packer of claim 23, wherein: said material retains the seal
of said sealing element, after inflation, despite a malfunction of
said sealing element.
27. The packer of claim 25, wherein: said material swells in the
presence of both water and a hydrocarbon.
28. The packer of claim 21, wherein: said material comprises a
sleeve.
29. The packer of claim 28, wherein: said sleeve is seamless.
30. The packer of claim 21, wherein: said material comprises a
swelling clay.
31. The packer of claim 21, wherein: said material comprises at
least one of EPDM, natural rubber and brombutyl rubber.
Description
PRIORITY INFORMATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/525,019 filed Nov. 25, 2003.
FIELD OF THE INVENTION
[0002] The field of this invention is inflatable packers or bridge
plugs and more particularly those that retain a seal after
inflation despite an element failure or changes in downhole
conditions.
BACKGROUND OF THE INVENTION
[0003] Inflatable packers typically comprise a flexible element
mounted on a mandrel with one stationary collar and one movable
collar at an opposite end. Typically a system of valves is used to
get pressurized fluid into the annular space between the mandrel
and the element to start the inflation process. The inflation
allows the element to expand radially into sealing contact with a
surrounding tubular or wellbore, made possible by the movable
collar riding up toward the stationary collar, which is usually
located near the uphole end. The valve system includes a check
valve to hold the applied pressure in the annular space between the
mandrel and the element. Other types of inflatables known as
External Casing Packers use fixed collars and reinforcement only on
the ends of the element.
[0004] In the earlier designs, the inflation medium was drilling
mud or other liquids. Inflating the element with such liquids had
certain drawbacks. One problem was thermal effects that could cause
a pressure reduction under the inflated element and a loss of seal.
Another drawback was that damage to the element either from
installation or during service in the well over a period of time
could result in a tear or rupture of the element and a loss of seal
as the fluid escaped, either slowly or virtually immediately
depending on the nature of the failure in the element. While the
valve system had provisions for avoiding overpressure, the risks to
the integrity of the element were real and present and resulted in
failures.
[0005] In an effort to improve inflatable performance, cement
slurry was used as the inflation medium. The idea was that the
slurry, in a pumpable condition, would be delivered into the
annular space between the mandrel and the element and under
pressure. The slurry would then set up with the hope that, once set
up, the slurry, now in solid form would help to hold the seal of
the packer even if the element experienced a failure. However
introducing cement slurry created several new problems. First,
there were added risks of getting the slurry through the various
valves of the inlet assembly without fouling their operation.
Second, the use of cement slurry required specialized equipment at
the surface. Some applications, particularly offshore, created
logistical problems in locating such equipment on platforms and
created increased expense due to the logistical issues.
Furthermore, when using cement slurry, time was of the essence in
spotting and pumping the slurry behind the element. It was also
important to quickly remove any excess slurry to avoid having to
drill it out if it impeded later operations. As if all these issues
were not enough of a concern, there was yet another downside to the
use of the cement slurry. The slurry, upon setting, actually
reduced in volume. This made the packer more likely to lose its
sealing contact after it was set.
[0006] The prior art fluid inflatable packers are described in U.S.
Pat. Nos. 4,897,139; 4,967,846 and 5,271,469. Cement inflatable
packers are described in U.S. Pat. No. 5,738,171.
[0007] The present invention addresses the shortcomings of the past
systems for inflation of the element and retention of the seal
after inflation. The element is inflated with a fluid, as before.
However, a layer is inserted in the annular space between the
element and the mandrel that, upon contact with the inflating fluid
absorbs the inflating fluid and expands so that the expanded volume
of the fluid and the expanding layer is preferably as great as the
volume of the two layers prior to absorption. The resulting
advantage is retention of the seal despite a failure in the element
as the expanding layer with the retained fluid provides the
continuing sealing force. Furthermore, there is no volume loss
after inflation as occurred in the prior design using cement slurry
that could undermine the sealing force of the inflated element.
Those and other advantages of the present invention will become
more readily apparent to those skilled in the art from the
description of the preferred embodiment, the drawings and the
claims that appear below.
SUMMARY OF THE INVENTION
[0008] An inflatable that features a swelling layer is disclosed.
The swelling layer can be made integral or attached to the element
or it can be bonded or otherwise secured to the mandrel. Upon
inflation with fluid, the element expands into sealing contact with
a surrounding tubular or wellbore. The fluid is absorbed or
otherwise interacts with the swelling layer so that, in a preferred
embodiment, the total occupied volume of the swelling layer and
fluid individually is retained after mixing with the swelling of
the layer acting to hold the seal of the inflatable element even if
a problem develops in the sealing element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a sectional view of an inflatable having a
swelling layer connected to the element and shown in the run in
position;
[0010] FIG. 2 is an alternative embodiment of FIG. 1 with the
swelling layer separate from the element and shown in the ruin in
position;
[0011] FIG. 3 is the view of FIG. 2 in the inflated position;
and
[0012] FIG. 4 is the view of FIG. 3 showing the activating fluid
absorbed into the swelling material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] FIG. 1 schematically shows an inflatable packer 10 is
section. It has a known inlet valve assembly 12 on a stationary
collar 14 connected to mandrel 16. The inflatable element 18 has
attached to an inner surface 20 a swelling layer 22. Schematically
illustrated at the lower end of the element 18 is lower collar 24.
Inflation fluid, shown schematically as arrow 26 is pumped into
inlet 28. As shown in FIG. 1, the swelling layer has an initial
volume V1. A predetermined volume V2 also schematically represented
in FIG. 1 is pumped into inlet 28. The fluid volume is absorbed
into the volume V1 of the swelling layer. In the preferred
embodiment, the swelling layer 22 swells as it absorbs at least
some of the fluid volume V2. In the preferred embodiment the final
volume V3, shown in FIG. 4, is at least as large and preferably
larger than the sum of V1 and V2 prior to mixing the inflation
fluid, represented by arrow 26 with the swelling layer 22. The
inflation fluid 26 first contacts the innermost end 30 facing
mandrel 16 after the fluid is introduced through the valve assembly
in the embodiment shown in FIG. 1.
[0014] In FIG. 2, the swelling layer 22' is a separate layer from
the element 18'. The swelling 22' layer can be bonded to the
mandrel 16' or loosely mounted over it. The swelling layer in
either embodiment can be a seamless tube or it can have a seam in a
variety of orientations. Alternatively, the swelling layer may be
in the form of a scroll with overlapping ends. It may also be a
series of discrete pieces that are connected or abutting. In FIG. 1
the swelling layer 22 can be integral to the element 18 or be a
discrete layer bonded or otherwise connected to it.
[0015] FIG. 3 illustrates the fluid 26' entering between the
element 18' and the swelling layer 22'. Here again, the final
volume V3' should be at least equal to the initial volume V1' of
the fluid and V2' of the swelling layer 22' before inflation.
[0016] In the preferred embodiment the swelling layer 22 or 22' is
EPDM but other materials such as natural rubber or brombutyl
rubber. These materials, when exposed to a hydrocarbon as the
inflating fluid will swell and retain the inflating fluid and meet
the volume requirements described above. As a result, an inflated
element will continue to hold a seal after inflation. The swelling
action, which goes on over time actually enhances the sealing force
to the extent V3 exceeds the sum of V1 and V2. Additionally, if the
element 18 or 18' develops a leak or tear, the sealing force will
remain as the inflation fluid will be tied up in the swelled layer
22 or 22' and preferably the consistency of the swelled layer will
be strong enough to hold the damaged element in sealing contact in
the wellbore.
[0017] Other options for the swelling layer 22 or 22' include using
swelling clay such as bentonite that expands dramatically in the
presence of water as the inflation fluid and then hardens. To the
extent such a material meets the volume criteria it could be used
in an inflatable. The hardened clay could also serve to retain the
inflation fluid and could be rigid enough to help retain a seal in
the presence of a failure of the element 18 or 18'. Alternatively
the swelling layer 22 or 22' can include a fabric that absorbs
liquid and expands dramatically. A combination of the fabric and
clay such as bentonite is possible as is the further addition of an
EPDM or other material that swells in the presence of oil.
[0018] Oil based drilling fluids contain a mixture of oil and water
and can be used as the inflation medium. Typically the drilling
fluid mixture might be composed of 60% oil and 40% water with
solids to increase the density the fluid. If the inflation fluid is
a mixture of oil and water then a clay such as bentonite or fabric
can swell with the water phase and the EPDM or a rubber can swell
with the oil?
[0019] Those skilled in the art will now appreciate that the
reliability of inflatable packers is improved through the use of a
swelling material that ties up the inflation fluid without
suffering a net volume loss. Instead, the swelling enhances the
sealing grip and helps to retain such grip even if there are
changes in thermal conditions downhole or a failure of the element.
Various configurations of sealing element and swelling layer may be
used. While the preferred material EPDM can be used other swelling
materials when exposed to a variety of fluids can be used.
Alternatively, materials that swell in response to heat, current,
fields of various types or as a result of reactions of various
types can also be used. As long as the volume requirements are met
and the resulting layer is strong enough to retain the sealing load
despite a failure in the element, the material or combination of
materials can be used. Ideally, the inflation medium, whether
liquid or gas, is retained by the swelling layer despite an element
failure.
[0020] The above description is illustrative of the preferred
embodiment and many modifications may be made by those skilled in
the art without departing from the invention whose scope is to be
determined from the literal and equivalent scope of the claims
below:
* * * * *