U.S. patent application number 12/366756 was filed with the patent office on 2009-08-20 for downwell system with differentially swellable packer.
Invention is credited to William S. Butterfield, Eric J. Gustafson, Peter Williamson.
Application Number | 20090205817 12/366756 |
Document ID | / |
Family ID | 40954036 |
Filed Date | 2009-08-20 |
United States Patent
Application |
20090205817 |
Kind Code |
A1 |
Gustafson; Eric J. ; et
al. |
August 20, 2009 |
DOWNWELL SYSTEM WITH DIFFERENTIALLY SWELLABLE PACKER
Abstract
A packer assembly comprises a tubular member and a packer system
that circumferentially overlies the tubular member. The packer
system includes end portions and a central portion disposed between
the end portions. The central portion and the end portions are
formed of material that swells when contacted with a swelling
fluid. The central and end portions are constructed to swell upon
contact with the swelling fluid so that the central portion swells
to a diameter defined by a wall of the wellbore more rapidly than
the end portions. In such a configuration, the central portion of
the packer system can be fully swollen prior to the full swelling
of the end portions.
Inventors: |
Gustafson; Eric J.; (Stevens
City, VA) ; Butterfield; William S.; (Stevens City,
VA) ; Williamson; Peter; (Schriesheim, DE) |
Correspondence
Address: |
MYERS BIGEL SIBLEY & SAJOVEC
PO BOX 37428
RALEIGH
NC
27627
US
|
Family ID: |
40954036 |
Appl. No.: |
12/366756 |
Filed: |
February 6, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61028940 |
Feb 15, 2008 |
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Current U.S.
Class: |
166/118 |
Current CPC
Class: |
E21B 33/1208
20130101 |
Class at
Publication: |
166/118 |
International
Class: |
E21B 33/12 20060101
E21B033/12; E21B 33/127 20060101 E21B033/127 |
Claims
1. A packer assembly for a wellbore, comprising: a tubular member;
and a packer system that circumferentially overlies the tubular
member, the packer system including end portions and a central
portion disposed between the end portions; wherein the central
portion and the end portions are formed of material that swells
when contacted with a swelling fluid; and wherein the central and
end portions are constructed to swell upon contact with the
swelling fluid so that the central portion swells to a diameter
defined by a wall of the wellbore more rapidly than the end
portions.
2. The packer assembly defined in claim 1, wherein the central
portion is formed of a different material than the end
portions.
3. The packer assembly defined in claim 2, wherein the central
portion includes separation caps located at axial ends of the
central portion that encourage swelling of the central portion in a
radial direction.
4. The packer assembly defined in claim 3, wherein the separation
caps include apertures located to permit swelling fluid to contact
the axial ends of the central portion.
5. The packer assembly defined in claim 2, wherein the central
portion abuts a portion of the packer system formed of material
that swells when contacted with a swelling fluid.
6. The packer assembly defined in claim 4, wherein the central
portion abuts an intermediate portion that is sandwiched between
the central portion and one of the end portions.
7. The packer assembly defined in claim 2, wherein the central
portion comprises EPDM and a swelling agent.
8. The packer assembly defined in claim 6, wherein the end portion
comprises EPDM.
9. The packer assembly defined in claim 1, wherein the central
portion and the end portions are part of a unitary packer
member.
10. The packer assembly defined in claim 8, wherein the central
portion has an outer diameter that is greater than an outer
diameter of the end portions.
11. The packer assembly defined in claim 9, wherein the unitary
packer member is tapered from the central portion to the end
portions.
12. The packer assembly defined in claim 8, wherein the central
portion and the end portions comprise the same material.
13. A packer assembly for a wellbore, comprising: a tubular member;
and a packer system that circumferentially overlies the tubular
member, the packer system including end portions and a central
portion disposed between the end portions; wherein the central
portion and the end portions are formed of material that swells
when contacted with a swelling fluid; and wherein the central
portion is formed of a first material, the end portions are formed
of a second, different material, and the first material swells more
rapidly in the swelling fluid than the second material.
14. The packer assembly defined in claim 13, wherein the packer
assembly is gapless between the central portion and the end
portions.
15. The packer assembly defined in claim 13, wherein at least one
gap is present between the central portion and each end portion,
and wherein a separation cap is mounted on axial ends of the
central portion.
16. The packer assembly defined in claim 15, wherein each of the
separation caps includes apertures located to permit swelling fluid
to contact the axial ends of the central portion.
17. The packer assembly defined in claim 13, wherein the first
material comprises EPDM and a swelling agent.
18. The packer assembly defined in claim 17, wherein the second
material comprises EPDM.
19. A packer assembly for a wellbore, comprising: a tubular member;
and a packer system that circumferentially overlies the tubular
member, the packer system including end portions and a central
portion disposed between the end portions; wherein the central
portion and the end portions are formed of material that swells
when contacted with a swelling fluid; and wherein the central
portion has a first diameter and the end portions have a second
diameter that is less than the first diameter.
20. The packer assembly defined in claim 19, wherein the central
portion and the end portions are part of a unitary packer
member.
21. The packer assembly defined in claim 20, wherein the packer
member is tapered from the central portion to the end portions.
22. The packer assembly defined in claim 19, wherein the central
portion and the end portions comprise the same material.
Description
RELATED APPLICATION
[0001] The present application claims priority from U.S.
Provisional Patent Application Ser. No. 61/028,940, filed Feb. 15,
2008, the disclosure of which is hereby incorporated herein in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a wellbore system
for oil exploration, and more particularly to a packer for a
wellbore system.
BACKGROUND OF THE INVENTION
[0003] A downhole wellbore system typically includes a pipe or
other tubular structure that extends into a borehole drilled into
the ground. In some instances, a casing is inserted into the
wellbore to define its outer surface; in other instances, the rock
or soil itself serves as the wall of the wellbore.
[0004] Many wellbore systems include a packer, which is designed to
expand radially outwardly from the pipe against the walls of the
wellbore. The packer is intended to seal segments of the pipe
against the wellbore in order to isolate some sections of the
wellbore from others. For example, it may be desirable to isolate a
section of the formation that includes recoverable petroleum
product from an aquifer.
[0005] Known sealing members for packers include, for example,
mechanical packers which are arranged in the borehole to seal an
annular space between a wellbore casing and a production pipe
extending into the borehole. Such a packer is radially deformable
between a retracted position, in which the packer is lowered into
the borehole, and an expanded position, in which the packer forms a
seal. Activation of the packer can be by mechanical or hydraulic
means. One limitation of the applicability of such packers is that
the seal surfaces typically need to be well defined, and therefore
their use may be limited to wellbores with casings. Also, they can
be somewhat complicated and intricate in their construction and
operation. An exemplary mechanical packer arrangement is discussed
in U.S. Pat. No. 7,070,001 to Whanger et al., the disclosure of
which is hereby incorporated herein in its entirety.
[0006] Another type of annular seal member is formed by a layer of
cement arranged in an annular space between a wellbore casing and
the borehole wall. Although in general cement provides adequate
sealing capability, there are some inherent drawbacks such as
shrinking of the cement during hardening, which can result in
de-bonding of the cement sheath, or cracking of the cement layer
after hardening.
[0007] Additional annular seal members for packers have been formed
of swellable elastomers. These elastomers expand radially when
exposed to an activating liquid, such as water (often saline) or
hydrocarbon, that is present in the wellbore. Exemplary materials
that swell in hydrocarbons include ethylene propylene rubber (EPM
and EPDM), ethylene-propylene-diene terpolymer rubber (EPT), butyl
rubber, brominated butyl rubber, chlorinated butyl rubber),
chlorinated polyethylene, neoprene rubber, styrene butadiene
copolymer rubber (SBR), sulphonated polyethylene, ethylene acrylate
rubber, epichlorohydrin ethylene oxide copolymer, silicone rubbers
and fluorsilicone rubber. Exemplary materials that swell in water
include starch-polyacrylate acid graft copolymer, polyvinyl alcohol
cyclic acid anhydride graft copolymer, isobutylene maleic
anhydride, acrylic acid type polymers, vinylacetate-acrylate
copolymer, polyethylene oxide polymers, carboxymethyl cellulose
type polymers, starch-polyacrylonitrile graft copolymers and the
like and highly swelling clay minerals such as sodium bentonite.
Exemplary swellable packers are discussed in U.S. Pat. No.
7,059,415 to Bosma et al. and U.S. Patent Publication No.
2007/0056735 to Bosma et al., the disclosure of each of which is
hereby incorporated herein in its entirety.
[0008] Although swellable systems are relatively inexpensive and
simple, it can be difficult to control the timing of expansion of
different sections of the packer. For example, if the ends of the
packer seal prior to the center, it may be difficult or impossible
for swelling fluid to reach the center portion of the packer. In
such instances, swelling of the center portion of the packer may
decrease or cease entirely. Incomplete swelling of the central
portions of the packer can cause a delay in time to full set and/or
a reduced capability to seal differential pressures. As such, it
may be desirable to provide a packer system in which this
shortcoming can be addressed.
SUMMARY OF THE INVENTION
[0009] As a first aspect, embodiments of the present invention are
directed to a packer assembly for a wellbore. The packer assembly
comprises a tubular member and a packer system that
circumferentially overlies the tubular member. The packer system
includes end portions and a central portion disposed between the
end portions. The central portion and the end portions are formed
of material that swells when contacted with a swelling fluid. The
central and end portions are constructed to swell upon contact with
the swelling fluid so that the central portion swells to a diameter
defined by a wall of the wellbore more rapidly than the end
portions. In such a configuration, the central portion of the
packer system can be fully swollen prior to the full swelling of
the end portions.
[0010] As a second aspect, embodiments of the present invention are
directed to a packer assembly for a wellbore comprising a tubular
member and a packer system that circumferentially overlies the
tubular member. The packer system includes end portions and a
central portion disposed between the end portions. The central
portion and the end portions are formed of material that swells
when contacted with a swelling fluid. The central portion is formed
of a first material, the end portions are formed of a second,
different material, and the first material swells more rapidly in
the swelling fluid than the second material.
[0011] As a third aspect, embodiments of the present invention are
directed to a packer assembly for a wellbore comprising a tubular
member and a packer system that circumferentially overlies the
tubular member. The packer system includes end portions and a
central portion disposed between the end portions. The central
portion and the end portions are formed of material that swells
when contacted with a swelling fluid. The central portion has a
first diameter and the end portions have a second diameter that is
less than the first diameter.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 is a partial section view of a downwell bore and pipe
with a packer system according to embodiments of the present
invention, with the packing elements of the packer system in an
unswelled condition.
[0013] FIG. 2 is a partial section view of the packer system of
FIG. 1, with the center section experiencing partial swelling.
[0014] FIG. 3 is a partial section view of the packer system of
FIG. 1, with the center section experiencing pronounced swelling
and the intermediate sections experiencing partial swelling.
[0015] FIG. 4 is a partial section view of the packer system of
FIG. 1, with the center and intermediate sections experiencing
pronounced swelling and the end sections experiencing partial
swelling.
[0016] FIG. 5 is a partial section view of the packer system of
FIG. 1, with all sections experiencing pronounced swelling.
[0017] FIG. 6 is a partial section view of a packer system
according to alternative embodiments of the present invention,
wherein individual sections of the packer system are separated by
separating caps.
[0018] FIG. 7 is a top view of an exemplary end cap of the packer
system of FIG. 6.
[0019] FIG. 8 is a partial section view of a packer system
according to additional embodiments of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0020] The present invention will now be described more fully
hereinafter, in which preferred embodiments of the invention are
shown. This invention may, however, be embodied in different forms
and should not be construed as limited to the embodiments set forth
herein. Rather, these embodiments are provided so that this
disclosure will be thorough and complete, and will fully convey the
scope of the invention to those skilled in the art. In the
drawings, like numbers refer to like elements throughout.
Thicknesses and dimensions of some components may be exaggerated
for clarity.
[0021] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and will not be
interpreted in an idealized or overly formal sense unless expressly
so defined herein.
[0022] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. As
used herein the expression "and/or" includes any and all
combinations of one or more of the associated listed items.
[0023] In addition, spatially relative terms, such as "under",
"below", "lower", "over", "upper" and the like, may be used herein
for ease of description to describe one element or feature's
relationship to another element(s) or feature(s) as illustrated in
the figures. It will be understood that the spatially relative
terms are intended to encompass different orientations of the
device in use or operation in addition to the orientation depicted
in the figures. For example, if the device in the figures is turned
over, elements described as "under" or "beneath" other elements or
features would then be oriented "over" the other elements or
features. Thus, the exemplary term "under" can encompass both an
orientation of over and under. The device may be otherwise oriented
(rotated 90 degrees or at other orientations) and the spatially
relative descriptors used herein interpreted accordingly.
[0024] Well-known functions or constructions may not be described
in detail for brevity and/or clarity.
[0025] Turning now to the figures, a downwell tubing assembly,
designated broadly at 20, is shown in FIG. 1. The assembly 20 is
inserted into a wellbore 10, which is defined by walls in the
earth. Although shown here disposed directly into the ground, in
some embodiments the assembly 20 may be disposed within a casing or
other annular member that is inserted in the earth. In addition,
the wellbore 10 is illustrated herein as being substantially
vertical, but may also be substantially horizontally disposed or
disposed at any angle typically used for wells. As used herein, the
term "wellbore" is intended to encompass either of these
scenarios.
[0026] A packer system 30 is mounted to a segment of a base tubing
22. The packer system 30 includes a plurality of packer elements:
in the illustrated embodiment, the system 30 includes a center
element 32, two intermediate elements 34 that sandwich the center
element 32, and two end elements 36 that sandwich the intermediate
elements 34. In the illustrated embodiment, the elements 32, 34, 36
abut each other; however, in some embodiments gaps may exist
between some or all of the elements.
[0027] The elements 32, 34, 36 are formed of a material, typically
an elastomer, that swells when contacted with a swelling fluid.
Most common swelling fluids include water and hydrocarbons. The
elements 32, 34, 36 thus typically comprise materials that are
selected for their ability to swell when in contact with water or
hydrocarbon, depending on the projected location of the packer
system 30 within the wellbore 10. Exemplary elastomeric materials
that swell in hydrocarbons include ethylene propylene rubber (EPM
and EPDM), ethylene-propylene-diene terpolymer rubber (EPT), butyl
rubber, brominated butyl rubber, chlorinated butyl rubber),
chlorinated polyethylene, neoprene rubber, styrene butadiene
copolymer rubber (SBR), sulphonated polyethylene, ethylene acrylate
rubber, epichlorohydrin ethylene oxide copolymer, silicone rubbers
and fluorsilicone rubber. Exemplary elastomeric materials that
swell in water include starch-polyacrylate acid graft copolymer,
polyvinyl alcohol cyclic acid anhydride graft copolymer,
isobutylene maleic anhydride, acrylic acid type polymers,
vinylacetate-acrylate copolymer, polyethylene oxide polymers,
carboxymethyl cellulose type polymers, starch-polyacrylonitrile
graft copolymers and the like.
[0028] A swellable elastomer may also include fillers and additives
that enhance its manufacturing or performance properties and/or
reduce its costs. Exemplary filler materials include inorganic
oxides such as aluminum oxide (Al.sub.2O.sub.3), silicon dioxide
(SiO.sub.2), magnesium oxide (MgO), calcium oxide (CaO), zinc oxide
(ZnO) and titanium dioxide (TiO.sub.2), carbon black (also known as
furnace black), silicates such as clays, talc, wollastonite
(CaSiO.sub.3), magnesium silicate (MgSiO.sub.3), anhydrous aluminum
silicate, and feldspar (KAlSi.sub.3O.sub.8), sulfates such as
barium sulfate and calcium sulfate, metallic powders such as
aluminum, iron, copper, stainless steel, or nickel, carbonates such
as calcium carbonate (CaCo.sub.3) and magnesium carbonate
(MgCo.sub.3), mica, silica (natural, fumed, hydrated, anhydrous or
precipitated), and nitrides and carbides, such as silicon carbide
(SiC) and aluminum nitride (AlN). These fillers may be present in
virtually any form, such as powder, pellet, fiber or sphere.
Exemplary additives include polymerization initiators, activators
and accelerators, curing or vulcanizing agents, plasticizers, heat
stabilizers, antioxidants and antiozonants, coupling agents,
pigments, and the like, that can facilitate processing and enhance
physical properties.
[0029] The swelling elastomer may also include a swelling agent. In
some embodiments, the swelling agent may be a sorbent for
hydrocarbon. The hydrocarbon swelling agent can be a component that
causes the packer material to swell when in contact with
hydrocarbon. In some embodiments, the swelling agent may be a
sorbent for hydrocarbon. Also, in some embodiments the swelling
agent may comprise polyethylene (particularly linear polyethylene)
and/or other polymers, which may be combined with a hydrocarbon wax
or the like. Other suitable swelling agents include thermoplastic
polymer and copolymer mixtures and polyalphaolefins.
[0030] The materials of the elements 32, 34, 36 are selected and/or
formulated to have different swelling rates, with the center
element 32 swelling the most rapidly, the end elements 36 swelling
the slowest, and the intermediate elements 34 swelling at a rate
that falls between those of the center and end elements 32, 36. By
selecting the materials of the elements 32, 34, 36 in this manner,
upon contact with the swelling fluid, the center section 32 will
swell most rapidly, and will therefore fill and seal against the
walls of the wellbore 10 before the intermediate and end elements
do so. The intermediate elements 34 then swells and seals next,
followed by the end elements 36.
[0031] The sequence can be best understood by reference to FIGS.
1-5. In FIG. 1, the elements 32, 34, 36 have not been exposed to
the swelling fluid, so none of the elements 32, 34, 36 have begun
to swell. Upon contact with the swelling fluid, the center element
32 swells more rapidly than the intermediate or end elements 34, 36
(FIG. 2). Thus, the center element 32 swells sufficiently to
contact and seal against the walls of the wellbore 10 before the
intermediate and end sections 34, 36 (FIG. 3). Continued exposure
to the swelling fluid causes the intermediate elements 34 to next
contact and seal against the walls of the wellbore 10 (FIG. 4),
which is then followed by the sealing of the end elements 36
against the walls of the wellbore 10 (FIG. 5).
[0032] With an arrangement such as that described above, in which
the more central elements swell more quickly than the endmost
elements, the end elements 36 do not seal against the walls of the
wellbore 10 prior to the complete swelling and sealing of the
center elements 32. As such, the risk of the ends sealing and
preventing the activating fluid from contacting the center before
it has swollen is reduced.
[0033] As an example, each of the center, intermediate and end
elements 32, 34, 36 may comprise a blend of EPDM and HNBR, with the
center element 32 comprising 100 parts of a swelling agent to each
100 parts of EPDM/HNBR, the intermediate elements 34 comprising 75
parts of swelling agent to each 100 parts of EPDM/HNBR, and the end
elements comprising 50 parts of swelling agent to each 100 parts of
EPDM/HNBR.
[0034] Another packer system, designated broadly at 130, is
illustrated in FIGS. 6 and 7. In this embodiment, the elements 132,
134, 136 are formed of materials with different swelling rates in
the same manner as the elements 32, 34, 36 described above in
connection with the system 30 shown in FIGS. 1-5. However, in the
system 130 the elements 132, 134, 136 do not abut each other, but
instead are spaced apart from each other, and their end surfaces
are covered with separation caps 133, 135, 137. The separation caps
133, 135, 137 prevent the elements 132, 134, 136 from swelling in
an axial direction, which thereby forces the elements 132, 134, 136
to swell more in the radial direction. As shown in FIG. 7, each of
the separation caps 133, 135, 137 includes multiple apertures 137a
that permit swelling fluid to contact the end surfaces of the
elements 132, 134, 136, which contact encourages more rapid
swelling.
[0035] Another packer system, illustrated broadly at 230, is
illustrated in FIG. 8. In this embodiment, the system 230 comprises
a single element 232 formed of a single material, but the element
232 is tapered, such that it has a thicker central portion 233 and
narrower ends 234. Thus, when the element 232 is contacted with a
swelling fluid, the central portion 233 and the end portions 234
both swell, but the central portion 234 contacts and seals against
the walls of the wellbore 10 before the end portions 233 can, even
though the axial end surfaces of the end portions 233 may be
exposed to swelling fluid also.
[0036] Those skilled in this art will appreciate that other
embodiments may also be suitable. For example, the packer system
230 may comprise multiple distinct elements of different diameters
rather than a single tapered element, or a single element may have
a "stepped" profile with sections of different diameters rather
than being tapered. Also, if multiple distinct elements are
employed, the materials of each may vary, such that the system
includes central elements that are not only thicker than the end
elements, but also swell more rapidly. As another alternative, a
coating over the packer elements that breaks down once the packer
system is positioned in the wellbore may be employed, with such
coating being thicker on the end elements (and, therefore, slower
to break down) than on the center elements. Of course, the numbers
of elements may also vary depending on the environment of use.
[0037] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although exemplary
embodiments of this invention have been described, those skilled in
the art will readily appreciate that many modifications are
possible in the exemplary embodiments without materially departing
from the novel teachings and advantages of this invention.
Accordingly, all such modifications are intended to be included
within the scope of this invention as defined in the claims. The
invention is defined by the following claims, with equivalents of
the claims to be included therein.
* * * * *