A SEALING ASSEMBLY USING A CYLINDRICAL PROTECTIVE SLEEVE

Abstract

A sealing assembly, a well system, and a method are presented. The sealing assembly, in one aspect, comprises a mandrel and a sealing element positioned around the mandrel. The sealing element, in this aspect, comprises a cylindrical protective sleeve positioned around the sealing element, the cylindrical protective sleeve being configured to break and deploy from an undeployed state to a deployed state as a function of an applied axial or radial stress.

Description

Title of the invention: A SEALING ASSEMBLY USING A CYLINDRICAL PROTECTIVE SLEEVE REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 516 912, filed on August 1, 2023, entitled "SEALING ASSEMBLY EMPLOYING A DEPLOYABLE SPACER", U.S. Provisional Application Serial No. 63 / 516 934, filed on August 1, 2023, entitled "SEALING ASSEMBLY EMPLOYING A DEPLOYABLE CONTROL BAND" and U.S. Provisional Application Serial No. 63 / 516 951, filed on August 1, 2023, entitled "SEALING ASSEMBLY EMPLOYING A CYLINDRICAL EXTRUSION LIMITER", all of which are commonly attributed to this application. CONTEXT

[0002] A typical sealing tool (e.g., packing, bridge plug, fracturing plug, etc.) generally comprises one or more sealing elements or "rubbers" that are used to provide a fluid-tight radial seal between a mandrel of the sealing tool and the casing or borehole in which the sealing tool is located. Such a sealing tool is generally transported in an underground borehole, suspended from casing extending to the earth's surface.

[0003] To avoid damaging the sealing tool elements while the sealing tool is being transported in the wellbore, the sealing elements can be carried on the mandrel in a retracted or uncompressed state, in which they are spaced radially towards the inside of the casing. When the sealing tool is secured, the sealing elements expand radially, thus ensuring a seal against the mandrel and the casing and / or the wellbore. In some embodiments, the sealing elements are axially compressed between overlapping retaining elements, which in turn radially expand the sealing elements. BRIEF DESCRIPTION

[0004] Reference is now made to the following descriptions, taken in conjunction with the accompanying drawings, in which:

[0005] [Fig.1] illustrates a schematic view of a well system designed, manufactured and operated according to one or more embodiments disclosed herein;

[0006] [Fig.2A], [Fig.2B], [Fig.2C], [Fig.2D], [Fig.2E] and [Fig.2F] illustrate different views cross-section of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more disclosure embodiments;

[0007] [Fig.2G] and [Fig.2H] illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more disclosure embodiments;

[0008] [Fig.3A], [Fig.3B], [Fig.3C], [Fig.3D], [Fig.3E] and [Fig.3F] illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more alternative embodiments of disclosure;

[0009] [Fig.4A], [Fig.4B], [Fig.4C], [Fig.4D], [Fig.4E] and [Fig.4F] illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more alternative embodiments of disclosure;

[0010] [Fig.5A], [Fig.5B], [Fig.5C], [Fig.5D], [Fig.5E] and [Fig.5F] illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more alternative embodiments of disclosure;

[0011] [Fig. A], [Fig. B], [Fig. C], [Fig. D], [Fig. E], [Fig. F], [Fig. G] and [Fig. H] illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more alternative embodiments of disclosure;

[0012] [Fig.7A], [Fig.7B], [Fig.7C], [Fig.7D], [Fig.7E], [Fig.7F], [Fig.7G] and [Fig.7H] illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more alternative embodiments of disclosure;

[0013] [Fig.8A], [Fig.8B], [Fig.8C], [Fig.8D], [Fig.8E] and [Fig.8F] illustrate different Cross-sectional views of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more alternative embodiments of disclosure; and

[0014] [Fig.9A], [Fig.9B], [Fig.9C] and [Fig.9D] illustrate different cross-sectional views cross-section of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more alternative embodiments of disclosure. DETAILED DESCRIPTION

[0015] In the drawings and descriptions that follow, similar parts are generally indicated in the specification and the drawings by means of the same reference numbers, respectively. The figures drawn are not necessarily to scale. Certain disclosure features may be shown at an exaggerated scale or in a rather schematic form, and certain details of certain elements may not be shown for the sake of clarity and of conciseness. This disclosure can be implemented in various forms.

[0016] Specific embodiments are described in detail and illustrated in the drawings, it being understood that this disclosure should be considered as an exemplification of the principles of disclosure and is not intended to limit disclosure to what is illustrated and described herein. It should be clearly recognized that the various lessons of the embodiments discussed herein can be used separately or in any appropriate combination to produce the desired results.

[0017] Unless otherwise specified, the use of the terms "connect," "engage," "couple," "attach," or any similar term describing an interaction between elements is not intended to limit the interaction to a direct interaction between the elements and may also include an indirect interaction between the described elements. Unless otherwise specified, the use of the terms "top," "upper," "upward," "upstream," or similar terms should be interpreted as generally away from the bottom, the terminal end of a well; likewise, the use of the terms "bottom," "lower," "downstream," "downstream," or similar terms should be interpreted as generally toward the bottom, the terminal end of a well, regardless of the wellbore's orientation.The use of one or more of the preceding terms should not be interpreted as designating positions along a perfectly vertical axis. Unless otherwise indicated, the use of the term "subterranean formation" should be interpreted as encompassing both exposed underground areas and underground areas covered by water, such as the ocean or fresh water.

[0018] Sealing elements traditionally constitute an essential part of a sealing assembly. However, this disclosure acknowledges that sealing elements tend to encounter difficulties when the rate of expansion (e.g., the distance the sealing elements must travel between their radially retracted and radially expanded states to engage in a borehole, such as a borehole, casing, or other borehole) is large. More specifically, this disclosure acknowledges that such sealing elements often encounter difficulties in open-hole conditions with large expansion gaps. For example, due to the large extrusion gap in open-hole conditions, when the sealing element buckles, it often loses a significant portion of its axial stiffness and escapes the intended load path.Consequently, the sealing element does not efficiently transfer the load to the support shoes and often tends to extrude over the support shoe, which can in turn lead to insufficient deployment. In the case of multi-part sealing element designs, the sealing elements may also have... tendency to overlap in an uncontrolled and chaotic manner, resulting in insufficient deployment of the support shoe and, consequently, a weak seal from the sealing elements.

[0019] This disclosure also acknowledges that the above problem is less significant when the sealing assembly is used in a fixed-diameter casing with small to medium expansion gaps, for example, because when the sealing element buckles, the casing imposes effective lateral confinement on the sealing elements. Consequently, effective lateral confinement prevents the total loss of axial stiffness of the sealing element, so that the support shoe can continue to expand after the sealing element buckles.

[0020] In light of the foregoing findings, this disclosure proposes inserting a new deployable spacer between some of the sealing elements. In one example, the deployable spacer improves the axial stiffness of the sealing elements and the load transfer mechanism by controlling the deployment of the sealing elements. Thus, the use of the deployable spacer can ensure the complete deployment of the support shoe with little or no risk of sealing element extrusion.

[0021] [Fig. 1] is a schematic view of a well system 100 designed, manufactured, and operated according to one or more embodiments disclosed herein. The well system 100 includes a platform 120 positioned above a subsurface formation 110 located below the Earth's surface 115. The platform 120, in at least one embodiment, includes a hoist 125 and a derrick 130 for raising and lowering one or more downhole tools, including pipe stacks, such as the drill string 140. Although an onshore oil and gas platform 120 is illustrated in [Fig. 1], the scope of this disclosure is not thereby limited and could therefore potentially apply to offshore applications. It is possible to apply the teachings of this disclosure to other onshore well systems, different from the one illustrated.

[0022] As shown, a main borehole 150 has been drilled through the various Earth strata, including the subsurface formation 110. The term "main" borehole is used here to refer to a borehole from which another borehole is drilled. It should be noted, however, that a main borehole 150 does not necessarily extend directly to the Earth's surface, but may instead be a branch of another borehole. A casing column 160 may be at least partially cemented inside the main borehole 150. The term "casing" is used here to refer to a tubular column used to line a borehole. The casing may, in fact, be of the type known to man The term "liner" is used in the trade and can be made of any material, such as steel or a composite material, and can be segmented or continuous, such as a spiral tube. The term "lateral" borehole is used here to refer to a borehole that is drilled outward from its intersection with another borehole, such as a main borehole. Furthermore, a lateral borehole may have another lateral borehole drilled outward from it.

[0023] In the embodiment of [Fig. 1], a deflector whistle assembly 170 according to one or more embodiments of this disclosure is positioned at a location in the main borehole 150. More specifically, the deflector whistle assembly 170 could be placed at a location in the main borehole 150 where it is desirable for a side borehole 190 to exit. Thus, the deflector whistle assembly 170 can be used to support a milling tool used to penetrate a window in the main borehole 150, and once the window has been milled and a side borehole 190 has been formed, in some embodiments, the deflector whistle assembly 170 can be retrieved and returned to the top of the hole using a retrieval tool.

[0024] In at least one embodiment, the deflector whistle assembly 170 comprises a deflector whistle element section 175, as well as a sealing / anchoring assembly 180 coupled to a bottom end of the hole thereof. The sealing / anchoring assembly 180, in one or more embodiments, comprises a set of orientation receptacle tools 182, a sealing assembly 184, and an anchoring assembly 186. In at least one embodiment, the anchoring assembly 186 axially, and optionally rotatably, fixes the deflector whistle assembly 170 inside the casing column 160. The sealing assembly 184, in at least one embodiment, seals (e.g., provides a pressure-tight seal) a ring between the deflector whistle assembly 170 and the casing column 160.In one or more embodiments, the orientation receptacle tool set 182, with a collar and one or more orientation keys, can be used to place and position a guided milling assembly and / or the diverter whistle element section 175 inside the casing column 160.

[0025] The components of the deflector whistle assembly 170 can be positioned in the main borehole 150 in one or more separate steps. For example, in at least one embodiment, the sealing / anchoring assembly 180, including the orientation receptacle tool assembly 182, the sealing assembly 184, and the anchoring assembly 186 are first inserted into the hole and then secured inside the casing column 160. In the illustrated embodiment, the sealing assembly 184 is located inside an open-hole section of the borehole 150. In other embodiments, however, the sealing assembly 184 could be located inside the casing 160. Then, the sealing assembly 184 can be pressure tested. Next, the diverter whistle element section 175 can be inserted into the hole and coupled to the sealing assembly 180, for example using the orientation receptacle tool set 182. The resulting diverter whistle assembly 170 is illustrated in [Fig. 1].

[0026] Turning now to [Figs. 2A] to [Figs. 2F], these illustrate various cross-sectional views of different deployment states of a sealing assembly 200 designed, manufactured, and / or operated according to one or more embodiments of the disclosure. The sealing assembly 200, in the embodiment shown in [Figs. 2A] to [Figs. 2F], includes a mandrel 210. In the illustrated embodiment, the mandrel 210 can be centered around a centerline (CL). The sealing assembly 200, at least in the embodiment of [Figs. 2A] to [Figs. 2F], further includes a hole 290 positioned around the mandrel 210. In at least one embodiment, the hole 290 is a borehole, such as an open borehole. Hole 290, in at least one other embodiment, is a tube positioned inside a borehole, such as casing, production tubing, etc. According to one aspect of the disclosure, the mandrel 210 and hole 290 form a ring 280.

[0027] According to one embodiment of the invention, the sealing assembly 200 comprises a sealing element 220 (for example, an elastomeric sealing element). The sealing element 220, according to at least one embodiment, comprises a first portion of a sealing element 220a and a second portion of a sealing element 220b. In one or more other embodiments, the sealing element 220 further comprises a third portion of a sealing element 220c, as well as optionally one or more additional portions of a sealing element. The sealing element 220, including the first portion of sealing element 220a, the second portion of sealing element 220b and the third portion of sealing element 220c, can move between a radially retracted state, such as that illustrated in [Fig.2A] and 2B, and a radially expanded state, such as that illustrated in [Fig.2C] to 2D (e.g.(partially radially expanded state) and [Fig. 2E] to 2F (e.g., fully radially expanded state). While a single sealing element 220 is shown in [Fig. 2A] to 2F, there are other embodiments in which several sealing elements 220 are used, either together or spaced in series along the mandrel 210. In the embodiment of [Fig. 2A] to 2F, the sealing element 220 comprises a non-inflatable elastomer, among other types and materials. According to the embodiment of [Fig. 2A] to 2F, the sealing element 220 may alternatively include a single portion of a sealing element 220a, only two portions of a sealing element 220a, 220b, or both. other embodiments than the three portions of sealing element 220a, 220b, 220c, shown.

[0028] In the illustrated embodiment of [Fig. 2A] to [Fig. 2F], the first and second support lugs 240a, 240b overlap the first and second ends 225a, 225b, respectively, of the sealing element 220. According to the embodiment of [Fig. 2A] to [Fig. 2F], the first and second collar sleeves 250a, 250b overlap the first and second support lugs 240a, 240b, respectively. In the embodiment of [Fig. 2A] to [Fig. 2F], a fixing sleeve 260 (e.g., an axially positioned fixing sleeve) is coupled to the first end 225a of the sealing element 220 (e.g., through the first support lug 240a and the first collar sleeve 250a). In one or more other embodiments, the first collar sleeve 250a and the fixing sleeve 260 are a single combined element, as opposed to the two separate elements illustrated in [Fig.2A] to 2F.

[0029] The person skilled in the art understands and appreciates the desire and / or need for the first and second support shoes 240a, 240b, in particular to prevent the extrusion of the sealing element 220 around the first and second collar sleeves 250a, 250b. Likewise, the person skilled in the art appreciates the desire and / or need for the first and second collar sleeves 250a, 250b. For example, in the embodiment illustrated in [Fig.2A] to 2F, the first and second sleeves 250a, 250b are configured to slide axially relative to each other in order to move the sealing element 220 between the radially retracted state, as illustrated in [Fig.2A] and 2B, and a radially expanded state, as illustrated in [Fig.2C] to 2D (e.g., partially radially expanded state) and [Fig.2E] to 2F (e.g., fully radially expanded state).

[0030] In the embodiment of [Fig. 2A] to 2F, the sealing element 200 further comprises a deployable spacer 230. In the illustrated embodiment, the sealing element 200 comprises a first deployable spacer 230a positioned between the first portion of the sealing element 220a and the second portion of the sealing element 220b, and a second deployable spacer 230b positioned between the second portion of the sealing element 220b and the third portion of the sealing element 220c. In at least one embodiment, each adjacent pair of sealing element portions comprises its own deployable spacer. Thus, as shown here, three sealing element portions comprise two deployable spacers. Thus, if the sealing element 200 comprised five sealing element portions, it would probably also include four deployable spacers positioned between them.In at least one embodiment, deployable spacers 230a, 230b are configured to deploy from a non-state. deployed (e.g. as shown in [Fig.2A] and 2B) to a deployed state (e.g. as shown in [Fig.2C] to 2F).

[0031] In at least one embodiment, each of the deployable spacers 230a, 230b comprises two flanges. In at least one embodiment, one of the two flanges 232a is configured to control the deployment of an adjacent sealing element portion, and a second of the two flanges 232b is configured to control the deployment of another adjacent sealing element portion. For example, the first of the two flanges 232a of the first deployable spacer 230a would control the deployment of the first adjacent sealing element portion 220a, and the second of the two flanges 232b of the first deployable spacer 230a would also control the deployment of the second adjacent sealing element portion 220b.Similarly, the first of the two flanges 232a of the second deployable spacer 230b would control the deployment of the second adjacent sealing element portion 220b, and the second of the two flanges 232b of the second deployable spacer 230a would also control the deployment of the third adjacent sealing element portion 220c. In at least one embodiment, the flanges 232 could have structural features (e.g., weakened points, removed sections (e.g., holes, slots, etc.)) that would allow them to deploy more easily.

[0032] According to one or more of the embodiments disclosed herein, in at least one embodiment, the first of the two flanges 232a and the second of the two flanges 232b (e.g., for a given deployable spacer 230) are configured to deploy separately, for example, sequentially. In at least one embodiment, the axial interior of the two flanges (e.g., the first flange 232a of the second deployable spacer 230b and the second flange 232b of the first deployable spacer 230a) is configured to deploy before the axial exterior of the two flanges. This may occur naturally during compression of the sealing element 220, or may be intentionally created by using different sizes, shapes, and / or materials between the two flanges.For example, in at least one embodiment, sequential deployment is achieved by manufacturing the sealing elements 220a, 220b, 220c from different materials whose rigidity, modulus of elasticity, etc., vary, or in another embodiment by having grooves of different sizes in the DI which allow the sealing elements 220a, 220b, 220c (and therefore the flanges 232) to deploy sequentially.

[0033] In one or more embodiments, as shown, each of the deployable spacers 230a, 230b comprises a base member 234 to which the two flanges are connected, the base member being positioned near the mandrel 210. According to this embodiment, the base member 234 may have a wide portion 236 near the mandrel 210 and a narrow distal portion 238 of the mandrel 210. In at least this embodiment, the wide portion 236 is configured to resist lifting or overturning of the deployable spacers 230a, 230b when the sealing element portions 220a, 220b, 220c move between their radially retracted and radially extended states. In at least one other embodiment, the base member 234 comprises a first base member portion coupled to one of the flanges 232 and a separate second base member portion coupled to the other flange 232.

[0034] In at least one embodiment, the deployable spacers 230a, 230b are designed in several parts, the multiple parts of the deployable spacers being connected using one or more assembly techniques, including screws, welds, etc. For example, in at least one embodiment, the base element(s) 234 could be physically attached to the mandrel 210, and the flanges 232 mechanically connected to the base element(s) 234 at a later time (e.g., when the sealing assembly 200 is on the platform). Such an embodiment, for example, using segmented flanges 232 attached later, would allow the use of different types of flanges 232 depending on the wellbore conditions (e.g., hole size, temperatures, etc.).

[0035] The deployable spacers 230a, 230b can comprise many different materials and remain within the scope of disclosure. In at least one embodiment, however, the deployable spacers 230a, 230b comprise a deployable ductile metal, such as AISI 1018 steel or SAE 316L stainless steel. In yet another embodiment, the deployable spacers 230a, 230b comprise a deployable plastic or polymer. For example, in at least one embodiment, at least a portion of the deployable spacers 230a, 230b comprises a material having a yield strength of 40 ksi or less, or even 30 ksi or less.

[0036] [Fig. 2A] and 2B illustrate the sealing assembly 200 in a break-in state, and therefore its sealing element 220 is in a radially retracted state. For example, each of the first, second, and third sealing element portions 220a, 220b, 220c is in its radially retracted state. Furthermore, each of the deployable spacers 230a, 230b, and their associated flanges 232a, 232b, is in its undeployed state. Similarly, the first and second support shoes 240a, 240b are in their undeployed state. In at least one embodiment, the sealing assembly 200, including the deployable spacers 230a, 230b and their associated flanges 232a, 232b, would potentially have better resistance to swabbing than conventional sealing assemblies without the deployable spacers 230a, 230b, thus allowing the sealing assembly 200 to be broken in at a higher speed.

[0037] [Fig. 2C] and 2D illustrate the sealing assembly 200 when the first and second sleeves 250a, 250b begin to move axially relative to each other. As shown in this embodiment, the axial translation results in compression and radial expansion of the second sealing element portion 220b (for example, the more central sealing element portion). In one or more embodiments, the second sealing element portion 220b buckles to expand radially. In at least this first embodiment, the axial inner flanges of the first deployable spacer 230a and the second deployable spacer 230b gradually deploy to control the deployment of the second sealing element portion 220b.For example, the axial inner flanges of the first deployable spacer 230a and the second deployable spacer 230b considerably prevent the second portion of the sealing element 220b from tilting, which greatly improves the rigidity after deployment (e.g. after buckling) of the second portion of the sealing element 220b.

[0038] [Fig. 2E] and 2F illustrate the sealing assembly 200 when the first and second sleeves 250a, 250b have finished moving axially relative to each other. As shown in this embodiment, the final axial translation results in the compression and radial expansion of the first and third sealing element portions 220a, 220c (e.g., the outermost sealing element portions). In one or more embodiments, the first and third sealing element portions 220a, 220c buckle to expand radially. In at least this first embodiment, the axial outer flanges of the first deployable spacer 230a and the second deployable spacer 230b gradually deploy to control the deployment of the first and third sealing element portions 220a, 220c.For example, the axial outer flanges of the first deployable spacer 230a and the second deployable spacer 230b considerably prevent the first and third sealing element portions 220a, 220c from tilting, which significantly improves the rigidity after deployment (e.g., after buckling) of the first and third sealing element portions 220a, 220c. In at least one embodiment, the flanges of the first and second deployable spacers 230a, 230b can ultimately be folded into a fully deployed position (e.g., as illustrated with the flanges oriented vertically), which allows the sealing assembly 200 to be completely fixed.

[0039] In the illustrated embodiment, the first and second support lugs 240a, 240b also deploy progressively to control the deployment of the first and third sealing element portions 220a, 220c. For example, the first and second support lugs 240a, 240b also help to prevent the first and third sealing element portions 220a, 220c from tipping over, which significantly improves the rigidity after deployment (e.g. after buckling) of the first and third portions of sealing element 220a, 220c.

[0040] Thus, according to this first embodiment, the first deployable spacer 230a and the second deployable spacer 230b deploy progressively to control the deployment of the sealing element in an orderly (e.g., as opposed to random) manner. This significantly improves the post-buckling rigidity of the sealing elements and efficiently transfers the load to the support shoes with minimal risk of rubber extrusion. Consequently, the performance of the support shoes 240a, 240b is greatly improved, and if there is a good balance between the strength and flexibility of the support shoes 240a, 240b, their successful deployment is also ensured.

[0041] Turning now to [Fig. 2G] to [Fig. 2H], these illustrate various cross-sectional views of different deployment states of a 200g sealing assembly designed, manufactured, and / or operated according to one or more alternative embodiments of the disclosure. The 200g sealing assembly of [Fig. 2G] to [Fig. 2H] is similar in several respects to the 200 sealing assembly of [Fig. 2A] to [Fig. 2B]. Thus, similar reference numbers have been used to indicate similar, or even identical, features. The 200g sealing assembly differs, in large part, from the 200 sealing assembly in that the 200g sealing assembly uses a basic element 234g which includes a first portion of basic element 234g' coupled to one of the flanges 232 (e.g. the first flange 232a) and a separate second portion of basic element 234g" coupled to the other of the flanges 232 (e.g. the second flange 232b).

[0042] Turning now to [Fig. 3A] to [Fig. 3F], these illustrate various cross-sectional views of different deployment states of a sealing assembly 300 designed, manufactured, and / or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 300 of [Fig. 3A] to [Fig. 3F] is similar in several respects to the sealing assembly 200 of [Fig. 2A] to [Fig. 2F]. Thus, similar reference numbers have been used to indicate similar, or even identical, features. The sealing assembly 300 differs, in large part, from the sealing assembly 200 in that the sealing assembly 300 uses one or more two-part support brackets 340.For example, in one or more embodiments, a first two-part support shoe 340a is located near the first end 225a of the sealing element 220 and a second two-part support shoe 340b is located near the second end 225b of the sealing element 220.

[0043] In at least one embodiment, the first two-part support shoe 340a and the second two-part support shoe 340b each comprise a first support shoe portion 342 and a second support shoe portion distinct 344. In at least one embodiment, the first portion of the support shoe 342 is located near the collar sleeve 250a, 250b, and the second portion of the support shoe 344 is located between the first portion of the support shoe 342 and the sealing element 220. In at least one other embodiment, the first portion of the support shoe 342 comprises a substantially vertical section 342a and an inclined section 342b. In one or more embodiments, the inclined section 342b is located near the mandrel 210, while the substantially vertical section 342a is located at a distance from the mandrel 210. Furthermore, in one of the disclosed embodiments, the inclined section 342b is inclined towards the sealing element 220.

[0044] In at least one embodiment, the first support shoe portion 342 and the second support shoe portion 344 (e.g., which may include a substantially vertical section 344b (up to 15 degrees from the vertical)) are configured to move independently of each other. According to this embodiment, the first support shoe portion 342 and the second support shoe portion 344 may be made of a similar material. In at least one other embodiment, the first support shoe portion 342, the separate second support shoe portion 344, and the deployable spacers 230a, 230b are made of a similar material. For example, in at least one embodiment, the first support shoe portion 342, the second support shoe portion 344 and the deployable spacers 230a, 230b each have a yield strength of 40 ksi or less.

[0045] [Fig. 3A] and 3B illustrate the sealing assembly 300 in a break-in state, and therefore its sealing element 220 is in a radially retracted state. For example, each of the first, second, and third sealing element portions 220a, 220b, 220c is in its radially retracted state. In addition, each of the deployable spacers 230a, 230b, and their associated flanges 232a, 232b, is in the undeployed state. Similarly, the first and second two-part support shoes 340a, 340b are in the undeployed state.

[0046] [Fig. 3C] and 3D illustrate the sealing assembly 300 when the first and second sleeves 250a, 250b begin to move axially relative to each other. The first and second two-part support shoes 340a, 340b are still in the undeployed state.

[0047] [Fig. 3E] and 3F illustrate the sealing assembly when the first and second sleeves 250a, 250b have finished moving axially relative to each other. As this embodiment shows, the final axial translation results in the compression and radial expansion of the first and third sealing element portions 220a, 220c (e.g., the outermost sealing element portions). external). In at least this first embodiment, the axial external flanges of the first deployable spacer 230a and the second deployable spacer 230b deploy progressively to control the deployment of the first and third portions of sealing elements 220a, 220b. For example, the axial external flanges of the first deployable spacer 230a and the second deployable spacer 230b considerably prevent the first and third portions of sealing elements 220a, 220c from tilting, which considerably improves the rigidity after deployment (e.g., after buckling) of the first and third portions of sealing elements 220a, 220c. In at least one embodiment, the flanges of the first and second deployable spacers 230a, 230b can finally be folded into a fully deployed position (e.g. as illustrated with the flanges oriented vertically) which allows the sealing assembly 200 to be completely fixed.The first and second two-part support shoes 340a, 340b also deploy progressively to control the deployment of the first and third sealing element portions 220a, 220b. Thus, the second support shoe portions 344 deploy radially outwards relative to the first support shoe portions 342. For example, the second support shoe portions 344 can control a radial outer edge of the first and third sealing element portions 220a, 220c, while the first support shoe portions 342 can control the radial inner edge of the first and third sealing element portions 220a, 220c.

[0048] Turning now to [Fig. 4A] to [Fig. 4F], these illustrate various cross-sectional views of different deployment states of a sealing assembly 400 designed, manufactured, and / or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 400 of [Fig. 4A] to [Fig. 4F] is similar in several respects to the sealing assembly 200 of [Fig. 2A] to [Fig. 2F]. Thus, similar reference numbers have been used to indicate similar, or even identical, elements. The sealing assembly 400 differs, in large part, from the sealing assembly 200 in that the sealing assembly 400 does not use a deployable spacer 230, but instead uses a deployable control strip 430 positioned radially outside a radial inner surface of its sealing element 420.In the illustrated embodiment, the deployable control strip is positioned radially outside a radial outer surface of the sealing element 420. The deployable control strip 430, in one or more embodiments, is configured to deploy from a non-deployed state to a deployed state when the sealing element 420 moves from the radially retracted state to the radially expanded state. The embodiment of [Fig. 4A] to 4F illustrates that the sealing element 420 comprises only a single portion of the sealing element. However, . There may be other embodiments in which the sealing element 420 comprises several portions of a sealing element, as indicated above.

[0049] In the illustrated embodiment, the sealing assembly 400 comprises first and second deployable control strips 430a, 430b. The first and second deployable control strips 430a, 430b are both positioned around the radial outer surface of the sealing element 420, but are equally spaced from each other. In at least one embodiment, the first and second deployable control strips 430a, 430b are substantially equally spaced between the first end 225a and the second end 225b of the sealing element 420. The term "substantially equally spaced," as used here, means that the first and second deployable control strips 430a, 430b are within 20 percent of being exactly equally spaced.Thus, in the illustrated embodiment, the first and second deployable control strips 430a, 430b would separate the sealing element 420 into three spaced sections 420a, 420b, 420c (e.g., three substantially equal sections (e.g., 20 percent exactly equal)). Although two deployable control strips 430a, 430b are used in the illustrated embodiment, more than two deployable control strips can be used and remain within the scope of disclosure.

[0050] In at least one embodiment, the first and second deployable control strips 430a, 430b have a control strip stiffness greater than the stiffness of the sealing element 420. The term "stiffness," as used here, refers to the amount of force required to cause a given amount of deformation in a given component. The greater the force required to cause a given amount of deformation, the stiffer the component. In at least one embodiment, the stiffness and strength of the deployable control strips are designed so that they break once the sealing elements have been deployed in an acceptable controlled manner. In at least one other embodiment, the deployable control strips do not buckle because they are not in compression, but rather in tension, and will eventually break as expected.

[0051] The rigidity of each of the first and second deployable control strips 430a, 430b is designed so that each spaced section 420a, 420b, 420c between the first and second deployable control strips 430a, 430b and the first and second support shoes 240a, 240b buckles at approximately the same time, allowing for good load transfer from one side to the other. This will also allow the buckled portions of the sections to support each other, thus preventing them from tipping to one side or the other. Therefore, in at least one embodiment, the first and second deployable control strips 430a, 430b (e.g., pairs of strips) associated control strips) would have similar rigidity. In at least one embodiment, the sealing assembly 400, including the deployable control strips 430a, 430b, would potentially have better swabbing resistance than conventional sealing assemblies without the deployable control strips 430a, 430b, thus allowing the sealing assembly 400 to be broken in at a higher speed.

[0052] [Fig. 4A] and 4B illustrate the sealing assembly 400 in a break-in state, and therefore its sealing element 420 is in a radially retracted state. For example, each of the spaced sections 420a, 420b, 420 of the sealing element 420 is in its radially retracted state. In addition, the first and second deployable control strips 430a, 430b are in the undeployed state. Similarly, the first and second support shoes 240a, 240b are in their undeployed state.

[0053] [Fig. 4C] and 4D illustrate the sealing assembly 400 when the first and second sleeves 250a, 250b begin to move axially relative to each other. As shown in this embodiment, the combination of the axial translation of the first and second collar sleeves 250a, 250b and the first and second deployable control strips 430a, 430b results in the compression and radial expansion of the spaced central section 420b. In one or more embodiments, the spaced central section 420b buckles to expand radially, thus forming two buckled sections, as illustrated.

[0054] [Fig. 4E] and 4F illustrate the sealing assembly 400 when the first and second sleeves 250a, 250b complete their axial movement relative to each other. As shown in this embodiment, the final axial translation results in the compression and radial expansion of the first and third spaced sections 420a, 420c (e.g., the outermost spaced sections). In one or more embodiments, the first and third spaced sections 420a, 420c buckle to expand radially, each again forming two buckled sections, as illustrated. Furthermore, in at least one embodiment, the first and second deployable control strips 430a, 430b deploy from their undeployed state to their deployed state, as illustrated. In the illustrated embodiment, the first and second deployable control strips 430a, 430b remain intact after the sealing element 420 passes into the radially expanded state.

[0055] As shown in [Fig. 4E] and 4F, the first and second support cleats 240a, 240b deploy progressively to control the deployment of the first and third spaced sections 420a, 420b. For example, the first and second support cleats 240a, 240b also help to prevent the first and third spaced sections 420a, 420c from tipping, which greatly improves rigidity after deployment (e.g. after buckling) of the first and third sections spaced 420a, 420c.

[0056] Turning now to [Fig. 5A] to [Fig. 5F], these illustrate various cross-sectional views of different deployment states of a sealing assembly 500 designed, manufactured, and / or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 500 of [Fig. 5A] to [Fig. 5F] is similar in several respects to the sealing assembly 400 of [Fig. 4A] to [Fig. 4F]. Thus, similar reference numbers have been used to indicate similar, or even identical, elements. The sealing assembly 500 differs, in large part, from the sealing assembly 400 in that the deployable control strips 530a, 530b of the sealing assembly 500 are configured to break and release after the sealing element 420 moves to the radially expanded state.

[0057] Turning now to [Fig. 6A] to [Fig. 6H], these illustrate various cross-sectional views of different deployment states of a sealing assembly 600 designed, manufactured, and / or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 600 of [Fig. 6A] to [Fig. 6H] is similar in several respects to the sealing assembly 400 of [Fig. 4A] to [Fig. 4F]. Thus, similar reference numbers have been used to indicate similar, or even identical, features. The 600 sealing assembly differs, in large part, from the 400 sealing assembly in that the 600 sealing assembly further includes third and fourth deployable control strips 630c, 630d positioned around the outer surface, the third and fourth deployable control strips 630c, 630d being positioned on the opposite axial sides of the first and second deployable control strips 430a, 430b.Thus, in the illustrated embodiment, the first, second, third and fourth deployable control strips 430a, 430b, 630c, 630d separate the sealing element 620 into first, second, third, fourth and fifth spaced sections 620a, 620b, 620c, 620d, 620e.

[0058] In at least one embodiment, the first and second deployable control strips 430a, 430b have a first control strip stiffness, and the third and fourth deployable control strips 630c, 630d have a second control strip stiffness. In at least one other embodiment, the second control strip stiffness differs from the first control strip stiffness. For example, in at least one embodiment, the second control strip stiffness is greater than the first control strip stiffness, for example, in order to cause the third spaced section 620c (e.g., the central section) to buckle first, followed by the second and fourth spaced sections 620b, 620d to buckle second, and the first and fifth spaced sections 620a, 620e to buckle last. For example, the stiffness and strength of the strip Deployable controls are designed to achieve a desirable sequence of deployment of sealing elements.

[0059] The different stiffnesses can be created using a number of different methods. For example, in at least one embodiment, the first and second deployable control strips 430a, 430b comprise a material having the first control strip stiffness, and the third and fourth deployable control strips 630c, 630d comprise a different material having a different second control strip stiffness. In another embodiment, the materials may be the same, but the size and / or shape are modified to modulate the stiffness.

[0060] Turning now to [Fig. 7A] to [Fig. 7H], these illustrate various cross-sectional views of different deployment states of a sealing assembly 700 designed, manufactured, and / or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 700 of [Fig. 7A] to [Fig. 7H] is similar in several respects to the sealing assembly 600 of [Fig. 6A] to [Fig. 6H]. Thus, similar reference numbers have been used to indicate similar, or even identical, elements. The sealing assembly 700 differs, in large part, from the sealing assembly 600 in that the deployable control strips 430a, 430b, 630c, 630d of the sealing assembly 700 are configured to break and release after the sealing element 420 moves to the radially expanded state.

[0061] Turning now to [Fig. 8A] to [Fig. 8F], they illustrate different cross-sectional views cross-section of various deployment states of a sealing assembly 800 designed, manufactured, and / or operated according to one or more alternative embodiments of disclosure. The sealing assembly 800 of [Fig. 8A] to 8F is similar in several respects to the sealing assembly 400 of [Fig. 4A] to 4F. Thus, similar reference numbers have been used to indicate similar, or even identical, elements. The sealing assembly 800 differs, in large part, from the sealing assembly 400 in that the deployable control strips 830a, 830b of the sealing assembly 800 are embedded in the sealing element 820.

[0062] In an alternative embodiment, during the break-in operations, the packing element bundle is exposed to the well environment, in particular to the velocity of the fluid flowing along the element bundle. Depending on the fluid velocity around the packing, the fluid can cause premature deployment or damage to the packing element.

[0063] In light of this finding, the present disclosure has developed an improved sealing assembly that includes a cylindrical protective sleeve having a controlled breaking point and an actuation mechanism on the gasket element. The cylindrical protective sleeve protects the element from The packing is broken during the break-in operation, then moved once the sealing assembly has reached the desired depth. This breaking and movement of the cylindrical protective sleeve allows the packing element to expand in the borehole, creating the desired seal. In at least one embodiment, the cylindrical protective sleeve (e.g., or at least the remaining portions thereof) moves axially to expose the packing element (e.g., as opposed to rotating). Such axial movement allows the cylindrical protective sleeve to be used with hydraulic and / or hydrostatic packing elements, as opposed to mechanically fastened packing elements only.Similarly, in at least one embodiment, the cylindrical protective sleeve does not require a soluble material or other chemical reaction to separate, as such processes have problems with the time it takes to dissolve, with determining whether it is completely dissolved, and problems that may arise if the lining element deploys while all or at least a portion of the protective sleeve remains undissolved.

[0064] The aforementioned cylindrical protective sleeve allows the operator to increase the flow rate in the wellbore before attaching the packing element, for example, to increase the injection rate. Increasing the injection rate reduces the cost per barrel, which is quite advantageous.

[0065] Turning now to [Fig. 9A] to [Fig. 9D], these illustrate various cross-sectional views of different deployment states of a sealing assembly 900 designed, manufactured, and / or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 900 of [Fig. 9A] to [Fig. 9D] is similar in several respects to the sealing assembly 200 of [Fig. 2A] to [Fig. 2H]. Thus, similar reference numbers have been used to indicate similar, or even identical, features.

[0066] The sealing assembly 900 differs, in large part, from the sealing assembly 200, in that the sealing assembly 900 includes a cylindrical protective sleeve 910 positioned around the sealing element 220. The sealing assembly 900, in the illustrated embodiment, includes the cylindrical protective sleeve 910 positioned radially around a central point of the sealing element 220. According to one or more embodiments, the cylindrical protective sleeve 910 is configured to break and deploy from an undeployed state (e.g. that illustrated in [Fig. 9A]) to a deployed state (e.g. that illustrated in [Fig. 9B] to [Fig. 9D]) when the sealing element 220 moves from the radially retracted state to the radially expanded state.

[0067] In at least one embodiment, the cylindrical protective sleeve 910 comprises a body 915 with a weakened region 930, the weakened region 930 defining the first and second portions of cylindrical protective sleeve 920a, 920b. In one or more embodiments, the weakened region 930 is located substantially near a midpoint of the sealing element 220. The expression "substantially near," as used here with reference to the midpoint of the sealing element 220, means that the weakened region 930 is located within 20% of the midpoint of the sealing element 220. In another embodiment, the weakened region 930 is ideally located near its midpoint, the expression "ideally near" meaning that the weakened region 930 is located within 5% of the midpoint of the sealing element 220. In yet another embodiment, the weakened region 930 is located exactly at the midpoint, meaning that the weakened region 930 is located within 1% of the midpoint of the sealing element 220.

[0068] The weakened region 930 can take many different sizes, shapes, and / or styles and remain within the scope of this disclosure. However, in the embodiment illustrated in [Fig. 9A] to [Fig. 9D], the weakened region 930 is a circumferential notch located around an inner radial surface of the cylindrical protective sleeve 910. The circumferential notch, in the illustrated embodiment, may not extend entirely through the thickness of the cylindrical protective sleeve 910. While the embodiment of [Fig. 9A] to [Fig. 9D] illustrates that a weakened region 930 extends circumferentially around an entire inner radial surface of the cylindrical protective sleeve 910, other embodiments may exist in which one or more circumferential notches extend around only a portion of the inner radial surface of the cylindrical protective sleeve 910.Furthermore, while the embodiment of [Fig.9A] to 9D illustrates that the weakened region 930 is located around an inner radial surface, in one or more other embodiments, the weakened region 930 is one or more circumferential notches located around an outer radial surface of the cylindrical protective sleeve 910.

[0069] The cylindrical protective sleeve 910 can comprise many different materials and remain within the scope of disclosure. In at least one embodiment, however, the cylindrical protective sleeve 910 comprises a deployable ductile metal, such as AISI 1018 steel or SAE 316L stainless steel. In another embodiment, the cylindrical protective sleeve 910 comprises a deployable plastic, polymer, or composite. For example, in at least one embodiment, at least a portion of the cylindrical protective sleeve 910 comprises a material having a yield strength of 40 ksi or less, or even 30 ksi or less. In yet another embodiment, the sleeve cylindrical protection 910 includes a plastic, polymer or corrodible material.

[0070] The cylindrical protective sleeve 910, according to the design of the sealing assembly 900, can cover varying amounts of the sealing element 220. For example, in at least one embodiment, the cylindrical protective sleeve 910 is located radially around at least 60 percent of the sealing element 220. In yet another embodiment, the cylindrical protective sleeve 910 is located radially around at least 80 percent of the sealing element 220, or even at least 90 percent, or at least 95 percent. In another embodiment, the cylindrical protective sleeve 910 is located radially around the entire sealing element 220, as illustrated in [Fig. 9A] to [Fig. 9D].

[0071] The sealing assembly 900, in the illustrated embodiment, may further include one or more actuating mechanisms 940. In at least one embodiment, the actuating mechanisms 940 are configured to retract the first and second portions of the cylindrical protective sleeve 920a, 920b around the sealing element 220 after the weakened region 930 has yielded, thereby allowing the sealing element 220 to move from its undeployed state to its deployed state. In the embodiment illustrated in [Fig. 9A] to 9D, the actuating mechanism 940 is a spring-loaded mechanism. Nevertheless, any other actuation mechanism 940 known or discovered later, configured to remove the first and second portions of cylindrical protective sleeve 920a, 920b around the sealing element 220 after the weakened region 930 has yielded, may be used and remain within the scope of this disclosure.

[0072] The sealing assembly 900 may further differ from the sealing assembly 200 in that it uses a standard spacer 950 (e.g., a non-deployable spacer). In the illustrated embodiment, the sealing element 200 comprises a first spacer 950a positioned between the first sealing element portion 220a and the second sealing element portion 220b, and a second spacer 950b positioned between the second sealing element portion 220b and the third sealing element portion 220c. In at least one embodiment, each adjacent pair of sealing element portions comprises its own spacer. Thus, as shown here, the three sealing element portions 920a, 920b, 920c each comprise two spacers 950a, 950b. Thus, if the sealing element 200 comprised five sealing element portions, it would probably also include four spacers positioned between them. Whereas the embodiment of [Fig.Figures 9A to 9D use standard 950 spacers; other embodiments exist in which the deployable spacers of Figures 2A to 2H are used instead. In at least this embodiment, the deployable spacers are configured to deploy. from a non-deployed state (e.g. as shown in [Fig.2A] and 2B) to a deployed state (e.g. as shown in [Fig.2C] to 2F).

[0073] In view of the above, [Fig. 9A] illustrates the sealing assembly 900 with its cylindrical protective sleeve 910 in the break-in state, and thus the weakened region 930 remains intact, and the first and second portions of the cylindrical protective sleeve 920a, 920b protect the sealing element 220. [Fig. 9B] illustrates the sealing assembly 900 shortly after the weakened region 930 has given way and thus the actuation mechanisms 940 begin to remove the first and second portions of the cylindrical protective sleeve 920a, 920b around the sealing element 220. In at least one embodiment, the weakened region 930 gives way when the actuation mechanism 940 pulls axially on it.In another embodiment, the weakened region 930 fails when the first and second collar sleeves 250a, 250b begin to move axially relative to each other, and thus, in one embodiment, when the sealing element begins to transition from its radially contracted state to its radially expanded state. In another embodiment, the weakened region 930 fails when the protective sleeve corrodes. [Fig.9C] illustrates the sealing assembly 900 a little longer after the weakened region 930 has given way and so the actuation mechanisms 940 have completely withdrawn the first and second portions of cylindrical protective sleeve 920a, 920b around the sealing element 220. [Fig.9D] illustrates the sealing assembly 900 after the sealing element 220 has deployed radially to engage in the hole 290.

[0074] The aspects disclosed here include:

[0075] A. A sealing assembly, the sealing assembly comprising: 1) a mandrel; 2) a sealing element positioned around the mandrel, the sealing element comprising: a) a first portion of the sealing element and a second portion of the sealing element; and b) a deployable spacer positioned between the first portion of the sealing element and the second portion of the sealing element; 3) a first collar sleeve coupled near a first end of the sealing element;and 4) a second collar sleeve coupled near a second end of the sealing element, wherein the first and second collar sleeves are configured to move axially relative to each other along the mandrel to move the sealing element between a radially retracted state and a radially expanded state, and wherein the deployable spacer is configured to deploy from a non-deployed state to a deployed state when the sealing element moves from the radially retracted state to the radially expanded state.

[0076] B. A well system, the well system comprising: 1) a borehole located in an underground formation; and 2) a sealing assembly positioned in the borehole, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned around the mandrel, the sealing element comprising: i) a first portion of the sealing element and a second portion of the sealing element; and ii) a deployable spacer positioned between the first portion of the sealing element and the second portion of the sealing element; c) a first collar sleeve coupled near a first end of the sealing element;and c) a second collar sleeve coupled near a second end of the sealing element, wherein the first and second collar sleeves are configured to move axially relative to each other along the mandrel to move the sealing element between a radially retracted state and a radially expanded state, and wherein the deployable spacer is configured to deploy from a non-deployed state to a deployed state when the sealing element moves from the radially retracted state to the radially expanded state.

[0077] C. A method, the method comprising: 1) positioning a sealing assembly in a borehole located in an underground formation, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned around the mandrel, the sealing element comprising: i) a first portion of the sealing element and a second portion of the sealing element; and ii) a deployable spacer positioned between the first portion of the sealing element and the second portion of the sealing element; c) a first collar sleeve coupled near a first end of the sealing element;and d) a second collar sleeve coupled near a second end of the sealing element, wherein the first and second collar sleeves are configured to move axially relative to each other along the mandrel to move the sealing element between a radially retracted state and a radially expanded state, and wherein the deployable spacer is configured to deploy from a non-deployed state to a deployed state when the sealing element moves from the radially retracted state to the radially expanded state; and 2) movement of the sealing element from the radially retracted state to the radially expanded state, the movement causing the deployable spacer to deploy from the non-deployed state to the deployed state.

[0078] D. A sealing assembly, the sealing assembly comprising: 1) a mandrel; 2) a sealing element positioned around the mandrel, the sealing element having a radial inner surface and a radial outer surface; 3) a deployable control strip positioned radially outside the radial inner surface; 4) a first collar sleeve coupled near a first end of the sealing element; and 5) a second collar sleeve coupled near a second end of the sealing element, wherein the first and second collar sleeves are configured to move axially relative to each other. relation to the other along the mandrel to move the sealing element between a radially retracted state and a radially expanded state, and wherein the deployable control strip is configured to deploy from a non-deployed state to a deployed state when the sealing element moves from the radially retracted state to the radially expanded state.

[0079] E. A well system, the well system comprising: 1) a borehole located in an underground formation; and 2) a sealing assembly positioned in the borehole, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned around the mandrel, the sealing element having a radial inner surface and a radial outer surface; c) a deployable control strip positioned radially outside the radial inner surface; d) a first collar sleeve coupled near a first end of the sealing element;and 3) a second collar sleeve coupled near a second end of the sealing element, wherein the first and second collar sleeves are configured to move axially relative to each other along the mandrel to move the sealing element between a radially retracted state and a radially expanded state, and wherein the deployable control strip is configured to deploy from a non-deployed state to a deployed state when the sealing element moves from the radially retracted state to the radially expanded state.

[0080] F. A method, the method comprising: 1) positioning a sealing assembly in a borehole located in an underground formation, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned around the mandrel, the sealing element having a radial inner surface and a radial outer surface; c) a deployable control strip positioned radially outside the radial inner surface; d) a first collar sleeve coupled near a first end of the sealing element;and 3) a second collar sleeve coupled near a second end of the sealing element, wherein the first and second collar sleeves are configured to move axially relative to each other along the mandrel to move the sealing element between a radially retracted state and a radially expanded state, and wherein the deployable control strip is configured to deploy from a non-deployed state to a deployed state when the sealing element moves from the radially retracted state to the radially expanded state; and 2) movement of the sealing element from the radially retracted state to the radially expanded state, the movement causing the deployable control strip to deploy from the non-deployed state to the deployed state.

[0081] G. A sealing assembly, the sealing assembly comprising: 1) a mandrel; 2) a sealing element positioned around the chuck; 3) a protective sleeve cylindrical positioned around the sealing element, the cylindrical protective sleeve being configured to break to deploy from a non-deployed state to a deployed state according to an axial or radial stress imposed upon it.

[0082] H. A well system, the well system comprising: 1) a borehole situated in an underground formation; and 2) a sealing assembly positioned in the borehole, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned around the mandrel; c) a cylindrical protective sleeve positioned around the sealing element, the cylindrical protective sleeve being configured to break to deploy from an undeployed state to a deployed state as a function of an axial or radial stress imposed upon it.

[0083] I. A method, the method comprising: 1) positioning a sealing assembly in a borehole located in an underground formation, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned around the mandrel; c) a cylindrical protective sleeve positioned around the sealing element, the cylindrical protective sleeve being configured to break to deploy from an undeployed state to a deployed state according to an axial or radial stress imposed upon it; 2) breaking of the cylindrical protective sleeve, thereby enabling the cylindrical protective sleeve to move from the undeployed state to the deployed state; and 3) according to the axial or radial stress imposed upon it.

[0084] Aspects A, B, C, D, E, F, G, H, and I may comprise one or more of the following additional elements in combination: Element 1: wherein the deployable spacer comprises two flanges, and wherein one of the two flanges is configured to control the deployment of the first portion of the sealing element and the second of the two flanges is configured to control the deployment of the second portion of the sealing element. Element 2: wherein the first of the two flanges and the second of the two flanges are configured to deploy separately. Element 3: wherein the deployable spacer comprises a base member to which the two flanges are connected, the base member being positioned near the mandrel.Element 4: wherein the base member has a wide portion near the mandrel and a narrow portion away from the mandrel, the wide portion being configured to resist lifting or overturning of the deployable spacer when the sealing element moves between the radially retracted and radially expanded states. Element 5: wherein the base member comprises a first base member portion coupled to the first of two flanges and a separate second base member portion coupled to the second of two flanges. Element 6: wherein both flanges have one or more weakened locations, the weakened locations being configured to permit the two flanges to deploy more easily. Element 7: wherein the weakened locations are removed sections. Component 8: wherein at least a portion of the deployable spacer comprises a material having a yield strength less than or equal to 40 ksi. Component 9: further comprising a first support shoe positioned between the first collar sleeve and the first end of the sealing element, and a second support shoe positioned between the second collar sleeve and the second end of the sealing element. Component 10: wherein the first support shoe comprises a first support shoe portion and a separate second support shoe portion, the first support shoe portion being located near the first collar sleeve and the second support shoe portion being located between the first support shoe portion and the first portion of the sealing element.Component 11: wherein the first support shoe portion, the second support shoe portion, and the deployable spacer are made of a similar material. Component 12: wherein the first support shoe portion, the second support shoe portion, and the deployable spacer each have a yield strength less than or equal to 40 ksi. Component 13: wherein the deployable control strip is a first deployable control strip, and further comprising a second deployable control strip positioned around the outer radial surface. Component 14: further comprising third and fourth deployable control strips positioned around the outer surface, the third and fourth deployable control strips being positioned on the opposite axial sides of the first and second deployable control strips.Element 15: wherein the first and second deployable control strips have a first control strip stiffness, and wherein the third and fourth deployable control strips have a second control strip stiffness. Element 16: wherein the second control strip stiffness is different from the first control strip stiffness. Element 17: wherein the second control strip stiffness is higher than the first control strip stiffness. Element 18: wherein the first and second deployable control strips comprise a material having the first control strip stiffness, and the third and fourth deployable control strips comprise a different material having a different second control strip stiffness.Element 19: wherein the first and second control strips have similar stiffness, the similar stiffness being configured to cause the simultaneous buckling of a portion of the sealing element relative to each other. Element 20: wherein the first and second deployable control strips are configured to remain intact after the sealing element moves into the radially expanded state. Element 21: wherein the first and second deployable control strips are configured to break after the sealing element moves into the radially expanded state. Element 22: wherein the control strip. The deployable control strip is positioned radially outside the radial outer surface. Element 23: wherein the deployable control strip is embedded in the sealing element. Element 24: wherein the cylindrical protective sleeve comprises a body with a weakened region, the weakened region defining the first and second portions of the cylindrical protective sleeve. Element 25: wherein the weakened region is located substantially near a midpoint of the sealing element. Element 26: wherein the weakened region is ideally located near a midpoint of the sealing element. Element 27: wherein the weakened region is a circumferential notch located around an inner radial surface of the cylindrical protective sleeve. Element 28: wherein the circumferential notch does not extend entirely through the thickness of the cylindrical protective sleeve.Component 28: wherein the circumferential notch extends entirely through the thickness of the cylindrical protective sleeve. Component 29: wherein the weakened region is a circumferential notch located around an outer radial surface of the cylindrical protective sleeve. Component 30: wherein the weakened region comprises a plurality of removed sections. Component 31: wherein at least a portion of the cylindrical protective sleeve comprises a corrodible material providing the weakened region. Component 32: further comprising one or more actuating mechanisms coupled to the cylindrical protective sleeve, the actuating mechanism(s) being configured to remove the first or second portion of the cylindrical protective sleeve around the sealing element after the weakened region has ruptured.Component 33: wherein the actuation mechanism(s) are configured to retract the first and second portions of the cylindrical protective sleeve around the sealing element once the weakened region has failed. Component 34: wherein the actuation mechanism(s) are one or more spring-loaded mechanisms. Component 35: wherein the cylindrical protective sleeve is located radially around at least 80 percent of the sealing element. Component 36: wherein the cylindrical protective sleeve is located radially around at least 95 percent of the sealing element. Component 38: wherein the cylindrical protective sleeve is located radially around the entire sealing element.Element 39: further comprising: a first collar sleeve coupled near a first end of the sealing element; and a second collar sleeve coupled near a second end of the sealing element, wherein the first and second collar sleeves are configured to move axially relative to each other along the mandrel in order to move the sealing element between a radially retracted state and a radially expanded state. Element 40: wherein the cylindrical protective sleeve is configured to break upon deployment. from the undeployed state to the deployed state before the first and second collar sleeves move axially relative to each other, or when the first and second collar sleeves move axially relative to each other. Component 41: wherein the cylindrical protective sleeve is configured to break and deploy from the undeployed state to the deployed state when the sealing element deploys from its radially retracted state to its radially expanded state in response to contact with downhole fluid. Component 42: wherein the cylindrical protective sleeve is configured to prevent wellbore fluid from contacting the sealing element before the cylindrical protective sleeve breaks. Component 43: wherein the break occurs before axial displacement. Component 44: wherein the break occurs during axial displacement.Element 45: in which the breakage occurs when the sealing element moves from its radially retracted state to its radially expanded state.

[0085] Those skilled in the art to which this application relates will understand that other additions, deletions, substitutions, and modifications may be made to the embodiments described.

Claims

Claims

1. A sealing assembly (200), comprising: a mandrel (210); a sealing member (220) positioned around the mandrel; and a cylindrical protective sleeve (910) positioned around the sealing member, the cylindrical protective sleeve being configured to break to expand from an unexpanded state to an expanded state in response to an axial or radial stress imposed thereon.

2. The sealing assembly of claim 1, wherein the cylindrical protective sleeve comprises a body (915) with a weakened region (930), the weakened region defining the first and second cylindrical protective sleeve portions (920a, 920b).

3. The sealing assembly of claim 2, wherein the weakened region is located substantially near a midpoint of the sealing member or optionally wherein the weakened region is located ideally near a midpoint of the sealing member.

4. The sealing assembly of claim 2, wherein the weakened region is a circumferential notch located around an inner radial surface of the cylindrical protective sleeve or optionally wherein the circumferential notch does not extend entirely through the thickness of the cylindrical protective sleeve, or optionally wherein the circumferential notch extends entirely through the thickness of the cylindrical protective sleeve.

5. The sealing assembly of claim 2, wherein the weakened region is a circumferential notch located around an outer radial surface of the cylindrical protective sleeve.

6. The sealing assembly of claim 4, wherein the weakened region comprises a plurality of removed sections.

7. The sealing assembly of claim 2, wherein at least a portion of the cylindrical protective sleeve comprises a corrodible material providing the weakened region.

8. The sealing assembly of claim 2, further comprising one or more actuating mechanisms (940) coupled to the cylindrical protective sleeve, the one or more actuating mechanisms being configured to withdraw the first or second portion of the cylindrical protective sleeve from around the sealing element after the weakened region has broken or optionally wherein the one or more actuating mechanisms are configured to withdraw the first and second portions of cylindrical protective sleeve from around the sealing element after the weakened region has broken, or optionally wherein the one or more actuating mechanisms are one or more spring mechanisms.

9. The sealing assembly of claim 1, wherein the cylindrical protective sleeve is located radially around at least 80 percent of the sealing member or optionally wherein the cylindrical protective sleeve is located radially around at least 80 percent of the sealing member, or optionally wherein the cylindrical protective sleeve is located radially around the entire sealing member.

10. The sealing assembly of claim 1, further comprising: a first collar sleeve (250a) coupled proximate a first end of the sealing member; and a second collar sleeve (250b) coupled proximate a second end of the sealing member, wherein the first and second collar sleeves are configured to move axially relative to each other along the mandrel to move the sealing member between a radially retracted state and a radially expanded state or optionally wherein the cylindrical protective sleeve is configured to break to expand from the unexpanded state to the expanded state before the first and second collar sleeves move axially relative to each other or when the first and second collar sleeves move axially relative to each other.

11. The sealing assembly of claim 1, wherein the cylindrical protective sleeve is configured to rupture and expand from the unexpanded state to the expanded state when the sealing member expands from its radially retracted state to its radially expanded state in response to contacting a downhole fluid or optionally wherein the protective sleeve cylindrical is configured to prevent wellbore fluid from contacting the sealing element before the cylindrical protective sleeve ruptures.

12. A well system (100), comprising: a wellbore (150) located in a subterranean formation (110); and a sealing assembly (200) positioned in the wellbore, the sealing assembly comprising: a mandrel (210); a sealing member (220) positioned about the mandrel; and a cylindrical protective sleeve (910) positioned about the sealing member, the cylindrical protective sleeve being configured to rupture to expand from an unexpanded state to an expanded state in response to an axial or radial stress imposed thereon.

13. The well system of claim 12, wherein the cylindrical protective sleeve comprises a body (915) with a weakened region (930), the weakened region defining the first and second cylindrical protective sleeve portions (920a, 920b).

14. The well system of claim 13, further comprising one or more actuation mechanisms (940) coupled to the cylindrical protective sleeve, the one or more actuation mechanisms being configured to withdraw the first or second portion of the cylindrical protective sleeve from around the sealing member after the weakened region has failed or optionally wherein the one or more actuation mechanisms are configured to withdraw the first and second portions of cylindrical protective sleeve from around the sealing member after the weakened region has failed, or optionally wherein the one or more actuation mechanisms are one or more spring mechanisms.

15. A method, comprising: positioning a sealing assembly (200) in a wellbore (150) located in a subterranean formation (110), the sealing assembly comprising: a mandrel (210); a sealing element (220) positioned around the mandrel; and a cylindrical protective sleeve (910) positioned around the sealing member, the cylindrical protective sleeve being configured to rupture to expand from an unexpanded state to an expanded state based on an axial or radial stress imposed thereon; breaking the cylindrical protective sleeve, thereby allowing the cylindrical protective sleeve to transition from the undeployed state to the deployed state; and securing the sealing element, the securing causing the sealing element to move from its radially retracted state to its radially expanded state.

Images