U.S. patent application number 13/338059 was filed with the patent office on 2013-06-27 for downhole sealing using settable material in an elastic membrane.
The applicant listed for this patent is FRANCOIS M. AUZERAIS, JULIO GUERRERO, SUDEEP MAHESHWARI, ERIK B. NELSON, AGATHE ROBISSON, SHERRY S. ZHU. Invention is credited to FRANCOIS M. AUZERAIS, JULIO GUERRERO, SUDEEP MAHESHWARI, ERIK B. NELSON, AGATHE ROBISSON, SHERRY S. ZHU.
Application Number | 20130161006 13/338059 |
Document ID | / |
Family ID | 48653424 |
Filed Date | 2013-06-27 |
United States Patent
Application |
20130161006 |
Kind Code |
A1 |
ROBISSON; AGATHE ; et
al. |
June 27, 2013 |
DOWNHOLE SEALING USING SETTABLE MATERIAL IN AN ELASTIC MEMBRANE
Abstract
A rubber pocket is described that is suitable for use on tubing,
such as a packer-type seal, on casing, such as a cement-type seal,
or on liners. The rubber pocket may contain cement particles,
rubber particles, swellable particles, cement filled rubber
particles, cement filled swellable particles, calcium oxide,
magnesium oxide, magnesium sulfate, iron (III) oxide, calcium
sulfoaluminate, clay, magnetic particles and/or reactants such as
crosslinkers, retardants or epoxy. The particles may be bulk
spheres, bulk fibers, hollow spheres, hollow fibers, etc. The
rubber pocket or bladder may also be fully or partially filled with
fluids such as polymer reactants. The pocket may also be empty or
contain a small volume of reactants. The slurry or epoxy or other
type of fluid and granular solid or injectable matter can be
injected after the completion positioning downhole.
Inventors: |
ROBISSON; AGATHE;
(CAMBRIDGE, MA) ; AUZERAIS; FRANCOIS M.; (BOSTON,
MA) ; NELSON; ERIK B.; (HOUSTON, TX) ;
GUERRERO; JULIO; (CAMBRIDGE, MA) ; MAHESHWARI;
SUDEEP; (CAMBRIDGE, MA) ; ZHU; SHERRY S.;
(WABAN, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ROBISSON; AGATHE
AUZERAIS; FRANCOIS M.
NELSON; ERIK B.
GUERRERO; JULIO
MAHESHWARI; SUDEEP
ZHU; SHERRY S. |
CAMBRIDGE
BOSTON
HOUSTON
CAMBRIDGE
CAMBRIDGE
WABAN |
MA
MA
TX
MA
MA
MA |
US
US
US
US
US
US |
|
|
Family ID: |
48653424 |
Appl. No.: |
13/338059 |
Filed: |
December 27, 2011 |
Current U.S.
Class: |
166/285 ;
166/118; 166/120 |
Current CPC
Class: |
E21B 33/1208
20130101 |
Class at
Publication: |
166/285 ;
166/118; 166/120 |
International
Class: |
E21B 33/00 20060101
E21B033/00; E21B 33/13 20060101 E21B033/13 |
Claims
1. A sealing system for use in downhole sealing applications, the
system comprising: an elastic membrane adapted to be deployed
downhole; and a settable material housed within the elastic
membrane prior to deployment of the membrane downhole, wherein the
settable material is adapted to, when positioned downhole, set into
an expanded solid form within the elastic membrane so as to form a
sealing function when the system is positioned downhole.
2. A system according to claim 1 wherein the settable material
includes cement particles.
3. A system according to claim 1 wherein the settable material is a
granular material.
4. A system according to claim 1 wherein the settable material
includes one or more types of material selected from a group
consisting of: rubber particles, water swellable particles, oil
swellable particles, cement filled rubber particles, cement filled
swellable particles, epoxy particles, calcium oxide, magnesium
oxide, magnesium sulfate, iron (III) oxide, calcium sulfoaluminate,
clay, and magnetic particles.
5. A system according to claim 1 wherein the settable material
includes one or more types of material selected from a group
consisting of: bulk spheres, bulk fibers, hollow spheres and hollow
fibers.
6. A system according to claim 1 wherein the settable material is a
pliable solid.
7. A system according to claim 1 wherein the settable material is
fluid.
8. A system according to claim 1 wherein the settable material is
expanded upon exposure of the settable material to an introduced
fluid.
9. A system according to claim 8 wherein the introduced fluid is
pumped from the surface or from a downhole tool, through one or
more orifices to make contact with the settable material.
10. A system according to claim 8 wherein the introduced fluid is
diffused from a downhole environment through the elastic membrane
to make contact with the settable material.
11. A system according to claim 8 wherein the introduced fluid is
water.
12. A system according to claim 8 wherein the introduced fluid is
oil.
13. A system according to claim 1 wherein the settable material is
expanded and/or set upon exposure to a temperature change and/or a
magnetic field.
14. A system according to claim 1 further comprising a reactant
material adapted to aid in triggering the expanding and/or setting
of the settable material.
15. A system according to claim 14 wherein the reactant material is
of a type selected from a group consisting of: crosslinkers,
retardants, epoxy, and amine hardener.
16. A system according to claim 1 wherein the elastic membrane is
adapted to expand by at least 100% in size.
17. A system according to claim 1 wherein the system is adapted for
use in an external casing packer.
18. A system according to claim 1 wherein the elastic material is a
rubber material.
19. A method for sealing downhole comprising: deploying an elastic
membrane downhole, the membrane containing a settable material
prior to deployment; expanding the settable material within the
membrane while downhole; and setting the expanded settable material
within the membrane so as to form a solid mass within the elastic
membrane thereby forming a downhole seal.
20. A method according to claim 19 further comprising injecting a
resin into the elastic membrane while downhole.
21. A method according to claim 20 wherein the resin is of a type
selected from a group consisting of classical epoxy resin, fatty
acid oligomers and polyols.
22. A method according to claim 19 further comprising injecting an
initiator and/or hardener into the elastic membrane while
downhole.
23. A method according to claim 22 wherein the initiators and/or
hardeners are of a type selected from a group consisting of: urea,
secondary amines and isocyanate.
24. A method according to claim 19 wherein the settable material is
a granular material.
25. A method according to claim 19 further comprising introducing a
fluid to make contact with the settable material to facilitate the
expanding and/or setting of the settable material.
26. A method according to claim 25 wherein the introduced fluid is
oil or water diffused through the elastic membrane.
27. A method according to claim 25 wherein the introduced fluid is
oil or water pumped from the surface.
28. A method according to claim 19 further comprising exposing the
settable material to heat and/or a magnetic field to facilitate the
expanding and/or setting of the settable material.
Description
FIELD
[0001] The subject disclosure relates to the field of oilfield well
services and completion services. More specifically, the subject
disclosure relates to techniques for sealing applications using an
expandable settable material within an elastic membrane.
BACKGROUND
[0002] In forming downhole seals, such as between a casing wall and
the borehole wall, typically cement is used. However there are
situations when other types of seals may be more desirable.
Examples of such situations are in open hole completions where
mechanical packers or external casing packers may be used to
provide zonal separation or isolation.
SUMMARY
[0003] This summary is provided to introduce a selection of
concepts that are further described below in the detailed
description. This summary is not intended to identify key or
essential features of the claimed subject matter, nor is it
intended to be used as an aid in limiting the scope of the claimed
subject matter.
[0004] In accordance with some embodiments a sealing system is
provided for use in downhole sealing applications. The system
includes an elastic membrane adapted to be deployed downhole; and a
settable material housed within the elastic membrane prior to
deployment of the membrane downhole, wherein the settable material
is adapted to, when positioned downhole, set into an expanded solid
form within the elastic membrane so as to form a sealing function
when the system is positioned downhole.
[0005] According to some embodiments the settable material includes
a granular material such as cement particles. According to other
embodiments, the settable material is a pliable solid, or a fluid.
A fluid may be introduced to facilitate or trigger the expansion
and/or setting of the settable material. The introduced fluid may
be diffused through the membrane or injected through orifices.
According to some embodiments the settable material is expanded
and/or set upon exposure to temperature change and/or a magnetic
field. According to some embodiments a reactant material is used to
aid in triggering the expanding and/or setting of the settable
material.
[0006] According to some embodiments, a method is provided for
downhole sealing. The method includes deploying an elastic membrane
downhole, the membrane containing a settable material prior to
deployment; expanding the settable material within the membrane
while downhole; and setting the expanded settable material within
the membrane so as to form a solid mass within the elastic membrane
thereby forming a downhole seal.
[0007] Further features and advantages will become more readily
apparent from the following detailed description when taken in
conjunction with the accompanying Drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIGS. 1A and 1B illustrate a wellsite setting wherein an
expandable membrane is used for sealing, according to some
embodiments;
[0009] FIGS. 2A and 2B show further detail of a
swellable-expandable structure used for downhole sealing
applications, according to some embodiments;
[0010] FIGS. 3A and 3B illustrate a sealing structure for downhole
applications, according to some other embodiments;
[0011] FIGS. 4A and 4B show a downhole sealing structure in which
an expanding portion and filling material are housed in a recessed
pocket, according to some embodiments;
[0012] FIG. 5 illustrates the expansion of an elastic membrane as
part of a downhole sealing structure, according to some
embodiments;
[0013] FIGS. 6A and 6B show an elastic membrane having a large
expansion ratio in an unexpanded state, according to some
embodiments;
[0014] FIGS. 7 and 8 show an elastic membrane having a large
expansion ratio in a partially expanded state, according to some
embodiments;
[0015] FIG. 9 shows the high expansion ratio membrane in a fully
expanded state, according to some embodiments;
[0016] FIGS. 10A and 10B are top views illustrating the expansion
capabilities of an elastic membrane according to some embodiments;
and
[0017] FIG. 11 is a flow chart showing a process for downhole
sealing according to some embodiments.
DETAILED DESCRIPTION
[0018] Specific details are given in the following description to
provide a thorough understanding of the embodiments. However, it
will be understood by one of ordinary skill in the art that the
embodiments may be practiced without these specific details. For
example, systems, processes, and other elements in the invention
may be shown as components in block diagram form in order not to
obscure the embodiments in unnecessary detail. In other instances,
well-known processes, structures, and techniques may be shown
without unnecessary detail in order to avoid obscuring the
embodiments. Further, like reference numbers and designations in
the various drawings indicate like elements.
[0019] Also, it is noted that individual embodiments may be
described as a process which is depicted as a flowchart, a flow
diagram, a data flow diagram, a structure diagram, or a block
diagram. Although a flowchart may describe the operations as a
sequential process, many of the operations can be performed in
parallel or concurrently. In addition, the order of the operations
may be re-arranged. A process may be terminated when its operations
are completed, but could have additional processes not discussed or
included in a figure. Furthermore, not all operations in any
particularly described process may occur in each embodiment. A
process may correspond to a method, a function, a procedure, a
subroutine, a subprogram, etc. When a process corresponds to a
function, its termination corresponds to a return of the function
to the calling function or the main function.
[0020] Furthermore, embodiments of the invention may be
implemented, at least in part, either manually or automatically.
Manual or automatic implementations may be executed, or at least
assisted, through the use of machines, hardware, software,
firmware, middleware, microcode, hardware description languages or
any combination thereof. When implemented in software, firmware,
middleware or microcode, the program code or code segments to
perform the required tasks may be stored in a machine readable
medium. A processor(s) may perform the required tasks.
[0021] According to some embodiments, a rubber pocket is provided
that is suitable for use on tubing (packer type seal), casing
(cement type seal), or liners. In non limitng examples, the rubber
pocket may contain cement particles, rubber particles, swellable
particles, cement filled rubber particles, cement filled swellable
particles, calcium oxide, magnesium oxide, magnesium sulfate, iron
(III) oxide, calcium sulfoaluminate, clay, magnetic particles,
and/or reactants such as crosslinkers, retardants, or epoxy. The
particles may be bulk spheres, bulk fibers, hollow spheres, hollow
fibers, etc. The rubber pocket or bladder may also be fully or
partially filled with fluids such as polymer reactants. The pocket
may also be empty or contain a small volume of reactants. The
slurry or epoxy or any other type of fluid and granular solid or
injectable matter may be injected after the completion
placement.
[0022] The rubber pocket may be initially compliant and/or small,
because it is a compliant rubber bag or bladder filled with a
granular material, unreacted and/or unswollen. After particle
reaction, the pocket becomes either swollen or stiff, or both. In
non-limiting examples, the activation may be related to water
diffusion, temperature change, magnetic field, etc.
[0023] FIGS. 1A and 1B illustrate a wellsite setting wherein an
expandable membrane is used for sealing, according to some
embodiments. In FIG. 1A, wellsite 100 includes a wellhead 110 and a
wellbore 114 that penetrates a subterranean formation 102. Deployed
on casing 116 is an expandable elastic membrane 120 that is used
for sealing applications. Also shown surrounding the upper and
lower portions of membrane 120 is an upper flange 122 and lower
flange 124 which are dimensioned so as to protect the membrane 120
during deployment downhole. FIG. 1B shows the membrane 120 in an
expanded state thereby forming a seal against the walls of the
wellbore 114 in formation 102.
[0024] FIGS. 2A and 2B show further detail of a
swellable-expandable structure used for downhole sealing
applications, according to some embodiments. FIG. 2A shows the
structure 200 in its initial, un-expanded state, while FIG. 2B
shows the structure 200 in its expanded, sealing state. The
structure 200 includes an elastic membrane 120 which forms a pocket
in which a filler material 210 is enclosed. According to one
embodiment the membrane 120 completely surrounds the material 210,
and according to other embodiments, the membrane 120 is sealed at
ends 212 and 214 such that the material 210 is enclosed by a
combination of membrane 120 and the casing wall 116. The upper and
lower flanges 122 and 124 are provided to protect the structure 200
during deployment downhole. FIG. 2B shows the structure 200 in an
expanded state, such as after water and/or oil diffusion, or field
exposure. According to some embodiments, fluid such as water or oil
diffuses directly through the membrane 120, as shown by the dotted
arrows such as arrow 220.
[0025] The membrane 120 may be initially compliant (easily
deformable and stretchable). According to some embodiments, the
elastic membrane 120 is made of rubber and the filler material 210
is a granular material. According to some other embodiments the
material 210 is a fluid or a small amount of reactant. The granular
material 210 according to some embodiments is cement particles.
According to some embodiments other granular material could be used
alone or in combination (a mixture) such as: oil swellable
particles, water swellable particle, other swellable particles,
grafted cement particles, cement filled rubber particles, cement
filled swellable particles, epoxy particles, particles comprising
calcium oxide, magnesium oxide magnesium sulfate, iron (III) oxide,
calcium sulfoaluminate or combinations thereof, clay particles,
magnetic particles, reactants such as cross-linkers, retardants.
Examples of a fluid or viscous solid material 210 include: cement
slurry, epoxy/organic blends, and epoxy reactants. According to
some embodiments, the particles are of random shape, bulk spheres,
hollow spheres, short or long fibers, and/or hollow fibers.
According to some embodiments, the particles of material 210 are
settable and become stiff, such as cement or epoxy. According to
some embodiments the material 210 swells and sets, such as
cement+CaO, cement+MgO, MgO, and clay. According to yet other
embodiments, the material can reversibly stiffen under a field,
such as by using magnetic particles.
[0026] When in contact with water, or oil, or temperature or a
magnetic field, or with time alone, the granular material 210 will
either swell, or percolate, or stiffen, or a combination of those.
In other words, the material 210 reacts and changes the behavior of
the material. According to some embodiments, the material 210
reversibly stiffen, through the use of magnetic particles within
material 210. The encapsulant membrane or pocket may be permeable
to water, or transparent to the magnetic field, according to the
intended mechanism of operation, as well as compliant enough to
expand according to the expansion properties of the filler material
210 and the application at hand. According to some embodiments
membrane 120 is made of rubber. Rubber has been found to be a good
option for many applications as it is permeable to oil and water,
mostly transparent to fields, very compliant, and super-elastic
(can stretch to several hundreds of percent without failing).
[0027] According to some embodiments the structure 200 is used as
an external casing packer (ECP). ECPs are located in the completion
string to provide formation zone isolation in an open hole
wellbore. The ECP is thus designed to seal against the reservoir
formation walls. Usual technologies for ECPs involve inflatable and
swellable packers.
[0028] FIGS. 3A and 3B illustrate a sealing structure for downhole
applications, according to some other embodiments. According to
some embodiments the structure 300 shown in FIGS. 3A and 3B,
contains a material 210 that is exposed to a fluid that enters the
enclosure through orifices 330, 332 and 334 in the casing wall 116.
This is in contrast to the embodiment of FIGS. 2A and 2B in which
an activating fluid (such as oil or water) diffuses through the
membrane 120. According to some of the embodiments of FIGS. 3A and
3B, the material is enclosed in the membrane 120 prior to
deployment of the structure 300, then when sealing using structure
300 is desired, an activating fluid (such as oil, water and/or some
other reactant) is injected through the orifices 330, 332 and
334.
[0029] According to some other embodiments, the membrane 120 is
nearly or completely empty upon initial deployment downhole. Then
the material 210 is injected into the pocket while downhole.
[0030] As in the case of the embodiments of FIGS. 2A and 2B, the
material 210 reacts upon exposure to an activating fluid, to
temperature, to electrical and/or magnetic field, or time.
[0031] In the case where the membrane 120 is initially almost or
completely empty or the internal volume increases by a large ratio,
material 210 (fluid, mixture of fluid and solid particles, etc.)
can be injected in the bladder through orifices 330, 332 and 334 to
cause expansion. In this case, a small amount of reactant (material
that would trigger the swelling or setting reaction such as a
hardener in an epoxy system) could be inserted in the bladder
during manufacturing, such as a coating on the internal surface of
the membrane 120 and/or on the outer surface of the casing wall 116
or external tubing. The small amount of material reacts with the
injected material downhole to set, swell and/or harden. According
to some embodiments, a granular material is present in the membrane
prior to deployment to reduce the amount of epoxy to inject.
[0032] The small amount of reactants could be amine hardeners,
including but not limited to secondary amines such as
ethylenediamine, diethylenetriamine (DETA) and triethylenetetramine
(TETA). Resin and initiators/hardeners could also be injected as a
mixture through static or metered mixers into the bladder
enclosure. The resins include but are not limited to classical
epoxy resin, fatty acid oligomers, and polyols. The initiators or
hardeners include but are not limited to urea, secondary amines,
and isocyanate. The combination of various resins and hardeners
produces polyamides, classical epoxy, linear epoxy-amines, supra
plastic, self healing rubber, and hybrid networks, hybrid
epoxy-amine supra-networks, hybrid amides, polyurethanes, etc.,
that can polymerize, expand, and fill the bladder enclosure.
[0033] FIGS. 4A and 4B show a downhole sealing structure in which
an expanding portion and a filling material are housed in a
recessed pocket, according to some embodiments. The sealing
structure 400 is initially housed within the recessed pocket 410 of
the casing 116. This design protects the sealing structure 400
during deployment downhole without the use of additional flanges.
The membrane 120, the filling material 210 and the mechanism(s) for
activating, swelling, and/or setting are as described herein with
respect to FIGS. 2A, 2B, 3A and 3B. According to some embodiments
orifices may be included in the casing 116 to inject swelling
material, and/or triggering/activating material into the enclosure
of structure 400.
[0034] Although the sealing applications shown in FIGS. 2A-B, 3A-B
and 4A-B are for sealing between casing 116 and borehole wall 114,
according to some embodiments, the same or similar structures,
materials and reaction/activations are applied to sealing
structures for tubing, such as production tubing within other
tubing or within casing in oilfield applications.
[0035] FIG. 5 illustrates the expansion of an elastic membrane as
part of a downhole sealing structure, according to some
embodiments. Membrane 120 in state 510 is un-expanded. State 512
shows partial expansion and state 514 shows membrane 120 fully
expanded.
[0036] FIGS. 6A and 6B show an elastic membrane having a large
expansion ratio in an unexpanded state, according to some
embodiments. In FIG. 6A, membrane 120 has a folded section 610 that
includes multiple pleated-type folds, such as folds 612 and 614
that allow for additional membrane material to be included. FIG. 6B
is a top view showing the inner side of the folded section
including folds 612 and 614. FIGS. 7 and 8 show an elastic membrane
having a large expansion ratio in a partially expanded state,
according to some embodiments. As can be seen, the folded section
610, including folds 612 and 614 that allow for additional membrane
material. Thus, expansion is provided both from stretching of the
elastic material 120 and also through unfolding of the folded
membrane material. FIG. 9 shows the high expansion ratio membrane
in a fully expanded state, according to some embodiments. Membrane
120 is fully expanded and folded section 610 including folds 612
and 614 are fully unfolded. FIGS. 10A and 10B are top views
illustrating the expansion capabilities of an elastic membrane
according to some embodiments. FIG. 10A shows the membrane 120 in
an unexpanded state and FIG. 10B shows the membrane in a fully
expanded state. Note that the expansion ratio, in diameter, in this
example is about 3.2.
[0037] FIG. 11 is a flow chart showing a process for downhole
sealing according to some embodiments. In process 1110, the
expandable settable material is placed inside the sealing structure
prior to deployment downhole. For example, according to some
embodiments, the material is placed in the sealing structure within
the elastic membrane during manufacture of the sealing structure.
In process 1112, the sealing structure with the expandable membrane
and settable material is deployed downhole. In process 1114 the
sealing structure is expanded. As described herein, in process 1120
according to some embodiments an initiator material can be used to
initiate a reaction that causes the expansion. According to some
embodiments, in process 1122, a fluid such as oil or water is
allowed to diffuse through the expandable membrane into the
expandable settable material, and in process 1124, according to
other embodiments, oil or water or other fluid is pumped into the
structure via orifices in the structure. According to some
embodiments, in processes 1126 and 1128 resin, other material or a
hardener is injected in to the structure to aid in the expansion
and/or setting of the material within the elastic membrane. In
process 1116, the expandable settable material is set while the
structure is in its expanded state such that a solid mass is formed
within the membrane, and a permanent or semi-permanent downhole
seal is formed.
[0038] Although only a few example embodiments have been described
in detail above, those skilled in the art will readily appreciate
that many modifications are possible in the example embodiments
without materially departing from this invention. Accordingly, all
such modifications are intended to be included within the scope of
this disclosure as defined in the following claims. In the claims,
means-plus-function clauses are intended to cover the structures
described herein as performing the recited function and not only
structural equivalents, but also equivalent structures. Thus,
although a nail and a screw may not be structural equivalents in
that a nail employs a cylindrical surface to secure wood parts
together, whereas a screw employs a helical surface, in the
environment of fastening wood parts, a nail and screw may be
equivalent structures. It is the express intention of the applicant
not to invoke 35 U.S.C. .sctn.112, paragraph 6 for any limitations
of any of the claims herein, except for those in which the claim
expressly uses the words "means for" together with an associated
function.
* * * * *