A SEALING ASSEMBLY USING A DEPLOYABLE CONTROL STRIP

Abstract

A sealing assembly (200), a well system (100) and a method are shown. The sealing assembly, in one aspect, comprises a mandrel (210) and a sealing element (220) positioned around the mandrel, the sealing element having a radial inner and outer surface.The sealing assembly, according to this aspect, further comprises a deployable control strip (430) positioned radially outside the radial inner surface, a first collar sleeve (250a) coupled near a first end of the sealing element, and a second collar sleeve (250b) 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 to move the sealing element between a radially retracted state and a radially extended state, and wherein the deployable control strip is configured to extend from a non-extended state to an extended state when the sealing element moves from the radially retracted state to the radially extended state. Figure 1.

Description

Title of the invention: A SEALING ASSEMBLY USING A DEPLOYABLE CONTROL STRIP REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 516,912, filed August 1, 2023, entitled “SEALING ASSEMBLY EMPLOYING A DEPLOYABLE SPACER,” and also claims the benefit of U.S. Provisional Application Serial No. 63 / 516,934, filed August 1, 2023, entitled “SEALING ASSEMBLY EMPLOYING A DEPLOYABLE CONTROL BAND.” CONTEXT

[0002] A typical sealing tool (e.g., packer, bridge plug, frac plug, etc.) generally includes one or more sealing elements or "rubbers" that are used to provide a radially fluid-tight seal between a mandrel of the sealing tool and the casing or wellbore in which the sealing tool is disposed. Such a sealing tool is generally carried in a subterranean wellbore, suspended from a casing extending to the earth's surface.

[0003] To prevent damage to the sealing tool elements while the sealing tool is being transported in the wellbore, the sealing elements may be carried on the mandrel in a retracted or uncompressed state, in which they are spaced radially inward of the casing. When the sealing tool is secured, the sealing elements expand radially, thereby sealing against the mandrel and the casing and / or the wellbore. In some embodiments, the sealing elements are axially compressed between the retaining elements which overlap them and 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.l] 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 in cross-section of various deployment states of a sealing assembly designed, manufactured and / or operated according to one or more embodiments of the disclosure;

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

[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 in accordance with one or more alternative embodiments of the 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 in accordance with one or more alternative embodiments of the 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 in accordance with one or more alternative embodiments of the disclosure;

[0011] [Fig.ôA], [Fig.ôB], [Fig.ôC], [Fig.ôD], [Fig.ôE], [Fig.ôF], [Fig.ôG] and [Fig.ôH] 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 the disclosure;

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

[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 in accordance with one or more alternative embodiments of the disclosure. DETAILED DESCRIPTION

[0014] In the following drawings and descriptions, similar parts are generally indicated in the specification and drawings by means of the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be presented on 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 conciseness. The present disclosure may be embodied in embodiments of various forms.

[0015] Specific embodiments are described in detail and illustrated in the drawings, it being understood that the present disclosure is to be considered an exemplification of the principles of the disclosure and is not intended to limit the disclosure to that which is illustrated and described herein. It is to be recognized that the various teachings of the embodiments discussed herein may be used separately or in any suitable combination to produce the desired results.

[0016] Unless otherwise indicated, the use of the terms "connect," "engage," "couple," "attach," or any other 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 elements described. Unless otherwise indicated, the use of the terms "top," "upper," "upward," "upstream," or other similar terms shall be interpreted as generally away from the bottom, terminal end of a well; likewise, the use of the terms "bottom," "lower," "downward," "downstream," "downstream," or other similar terms shall be interpreted as generally toward the bottom, terminal end of a well, regardless of the orientation of the wellbore.The use of one or more of the preceding terms should not be construed as referring to positions along a perfectly vertical axis. Unless otherwise specified, the use of the term "subsurface formation" should be construed as including both exposed underground areas and underground areas covered by water, such as ocean or fresh water.

[0017] Sealing elements have traditionally been an essential part of a sealing assembly. The present disclosure has recognized, however, that sealing elements tend to encounter difficulties when the expansion rate (e.g., the distance the sealing elements must travel between their radially retracted state and their radially expanded state to engage a hole, such as a wellbore, tubing, casing, etc.) is large. More specifically, the present disclosure has recognized 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 much of its axial stiffness and escapes the desired load path.As a result, the sealing element does not effectively transfer the load to the support shoes and often tends to extrude onto the support shoe, which in turn can lead to insufficient deployment. In the case of multi-part sealing element designs, the sealing elements can also tend to overlap in an uncontrolled and chaotic manner, resulting in a . insufficient deployment of the support shoe and, consequently, a weak seal from the sealing elements.

[0018] The present disclosure also recognizes that the above problem is less significant when the sealing assembly is used in a fixed ID 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. Accordingly, effective lateral confinement prevents total loss of axial stiffness of the sealing element, so that the support shoe can continue to expand after the sealing element buckles.

[0019] In view of the foregoing findings, the present disclosure proposes to insert a novel 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, use of the deployable spacer can ensure full deployment of the support shoe with little or no risk of extrusion of the sealing element.

[0020] [Fig.l] 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 subterranean formation 110 located below the earth's surface 115. The platform 120, in at least one embodiment, includes a hoisting apparatus 125 and a derrick 130 for raising and lowering one or more downhole tools, including pipe strings, such as the drill string 140. Although a land-based oil and gas platform 120 is illustrated in [Fig.l], the scope of this disclosure is not so limited, and thus could potentially be applied to offshore applications. It is possible to apply the teachings of the present disclosure to other land-based well systems, different from the one illustrated.

[0021] As shown, a main wellbore 150 has been drilled through the various earth strata, including the subterranean formation 110. The term "main" wellbore is used herein to refer to a wellbore from which another wellbore is drilled. It should be noted, however, that a main wellbore 150 does not necessarily extend directly to the earth's surface, but instead may be a branch of another wellbore. A casing string 160 may be at least partially cemented within the main wellbore 150. The term "casing" is used herein to refer to a tubular string that serves to line a wellbore. The casing may in fact be of the type known to those skilled in the art as a "liner" and may be made of any material, such as steel or a composite material, and may be segmented or continuous, such as a coiled tubing The term "lateral" wellbore is used here to refer to a wellbore that is drilled outward from its intersection with another wellbore, such as a main wellbore. Additionally, a lateral wellbore may have another lateral wellbore drilled outward from it.

[0022] In the embodiment of [Fig.l], a whipstock assembly 170 according to one or more embodiments of the present disclosure is positioned at a location in the main wellbore 150. More specifically, the whipstock assembly 170 could be placed at a location in the main wellbore 150 where it is desirable for a lateral wellbore 190 to exit. Thus, the whipstock assembly 170 may be used to support a milling tool used to penetrate a window of the main wellbore 150 and once the window has been milled and a lateral wellbore 190 has been formed, in some embodiments, the whipstock assembly 170 may be retrieved and returned uphole using a retrieval tool.

[0023] In at least one embodiment, the whipstock assembly 170 includes a whipstock element section 175, as well as a seal / anchor assembly 180 coupled to a downhole end thereof. The sealing / anchoring assembly 180, in one or more embodiments, includes an orientation receptacle tool assembly 182, a sealing assembly 184, and an anchoring assembly 186. In at least one embodiment, the anchoring assembly 186 axially, and optionally rotatably, secures the whipstock assembly 170 within the casing string 160. The sealing assembly 184, in at least one embodiment, seals (e.g., provides a pressure-tight seal) an annulus between the whipstock assembly 170 and the casing string 160.In one or more embodiments, the orientation receptacle tool assembly 182, with a collet and one or more orientation keys, may be used to install and position a guided milling assembly and / or the whipstock element section 175 within the casing string 160.

[0024] The elements of the whipstock assembly 170 may be positioned in the main wellbore 150 in one or more distinct steps. For example, in at least one embodiment, the seal / anchor assembly 180, including the orientation receptacle tool assembly 182, the seal assembly 184, and the anchor assembly 186 are first introduced into the hole and then secured within the casing string 160. In the illustrated embodiment, the seal assembly 184 is located within an open hole section of the wellbore 150. In other embodiments, however, the seal assembly 184 could be located within the casing 160. Then, the seal assembly 184 may be pressure tested. Next, the diverter whistle element section 175 may be inserted into the hole and coupled to the sealing assembly 180, for example using the orientation receptacle tool assembly 182. The result may be the whipstock assembly 170 shown in [Fig.l].

[0025] Turning now to [Fig. 2A]-2F, they illustrate various cross-sectional views of various 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 illustrated in [Fig. 2A]-2F, comprises a mandrel 210. In the illustrated embodiment, the mandrel 210 may be centered around a centerline (CL). The sealing assembly 200, at least in the embodiment of [Fig. 2A]-2F, further comprises a hole 290 positioned around the mandrel 210. In at least one embodiment, the hole 290 is a wellbore, such as an open wellbore. The hole 290, in at least one other embodiment, is a tubing positioned within a wellbore, such as a casing, a production tubing, etc. According to one aspect of the disclosure, the mandrel 210 and the hole 290 form an annulus 280.

[0026] According to one embodiment of the invention, the sealing assembly 200 comprises a sealing element 220 (e.g., an elastomeric sealing element). The sealing element 220, according to at least one embodiment, comprises a first sealing element portion 220a and a second sealing element portion 220b. In one or more other embodiments, the sealing element 220 further comprises a third sealing element portion 220c, as well as possibly one or more other additional sealing element portions. The sealing member 220, including the first sealing member portion 220a, the second sealing member portion 220b, and the third sealing member portion 220c, can move between a radially retracted state, such as that shown in [Fig. 2A] and 2B, and a radially expanded state, such as that shown 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 illustrated in [Fig. 2A] to 2F, there are other embodiments in which multiple 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-swellable elastomer, among other types and materials.

[0027] In the illustrated embodiment of [Fig. 2A] to 2F, the first and second support shoes 240a, 240b overlap the first and second ends 225a, 225b, respectively, of the sealing member 220. According to the embodiment of [Fig. 2A] to 2F, the first and second collar sleeves 250a, 250b overlap the first and second support shoes 240a, 240b, respectively. In the embodiment embodiments of [Fig. 2A] to 2F, a securing sleeve 260 (e.g., an axially established securing sleeve) is coupled to the first end 225a of the sealing member 220 (e.g., through the first support shoe 240a and the first collar sleeve 250a). In one or more other embodiments, the first collar sleeve 250a and the securing sleeve 260 are a single combined member, as opposed to the two separate members illustrated in [Fig. 2A] to 2F.

[0028] Those skilled in the art understand and appreciate the desire and / or need for the first and second support shoes 240a, 240b, particularly to prevent extrusion of the sealing element 220 around the first and second collar sleeves 250a, 250b. Similarly, those skilled in the art appreciate the desire and / or need for the first and second collar sleeves 250a, 250b. For example, in the illustrated embodiment of [Fig. 2A] to 2F, the first and second sleeves 250a, 250b are configured to slide axially relative to each other to move the sealing member 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).

[0029] 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 sealing element portion 220a and the second sealing element portion 220b, as well as a second deployable spacer 230b 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 deployable spacer. Thus, as shown here, three sealing element portions comprise two deployable spacers. Thus, if the sealing element 200 included five sealing element portions, it would likely also include four deployable spacers positioned between them.In at least one embodiment, the deployable spacers 230a, 230b are configured to deploy from an undeployed state (e.g., as shown in [Fig. 2A] and 2B) to a deployed state (e.g., as shown in [Fig. 2C] to 2F).

[0030] In at least one embodiment, each of the deployable spacers 230a, 230b comprises two flanges. In at least one embodiment, a first of the two flanges 232a is configured to control deployment of an adjacent sealing element portion and a second of the two flanges 232b is configured to control 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 230b 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.), etc.) that would allow them to deploy more easily.

[0031] 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, e.g., 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 upon compression of the sealing member 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 fabricating the sealing members 220a, 220b, 220c from different materials that vary in stiffness, modulus of elasticity, etc., or in another embodiment by having different sized grooves in the DI that allow the sealing members 220a, 220b, 220c (and thus the flanges 232) to deploy sequentially.

[0032] In one or more embodiments, as shown, each of the deployable spacers 230a, 230b includes a base member 234 to which the two flanges are connected, the base member being positioned proximate the mandrel 210. According to this embodiment, the base member 234 may have a wide portion 236 proximate the mandrel 210 and a narrow portion 238 distal to the mandrel 210. In at least this embodiment, the wide portion 236 is configured to resist lifting or tipping of the deployable spacers 230a, 230b as the sealing member portions 220a, 220b, 220c move between their radially retracted state and their radially expanded state. In at least one further embodiment, the base member 234 includes a first base member portion coupled to one of the flanges 232 and a separate second base member portion coupled to the other of the flanges 232.

[0033] In at least one embodiment, the deployable spacers 230a, 230b are designed in multiple pieces, with the multiple pieces of the deployable spacers being connected using one or more mounting techniques, including screws, welds, etc. For example, in at least one embodiment, the base member(s) 234 could be physically attached to the mandrel 210, and the flanges 232 mechanically connected to the base member(s) 234 at a later time (e.g., when the seal assembly 200 is on the platform). Such an embodiment, for example, using segmented flanges 232 attached later, would allow different types of flanges 232 to be used depending on wellbore conditions (e.g., hole size, temperatures, etc.).

[0034] The deployable spacers 230a, 230b may comprise many different materials and remain within the scope of the 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 grade 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.

[0035] [Fig.2A] and 2B illustrate the sealing assembly 200 in a lapping state, and thus 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. Further, each of the deployable spacers 230a, 230b, and their associated flanges 232a, 232b, is in the 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 swabbing resistance than conventional sealing assemblies without the deployable spacers 230a, 230b, thereby allowing the sealing assembly 200 to be lapped at a higher rate.

[0036] [Fig.2C] and 2D illustrate the sealing assembly 200 as the first and second sleeves 250a, 250b begin to move axially relative to each other. As shown in this embodiment, axial translation causes the second sealing member portion 220b (e.g., the centralmost sealing member portion) to compress and radially expand. In one or more embodiments, the second sealing member portion 220b buckles to radially expand. In at least this first embodiment, the axial inner flanges of the first deployable spacer 230a and the second spacer 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 significantly prevent the second sealing element portion 220b from tilting, which significantly improves the post-deployment (e.g., post-buckling) stiffness of the second sealing element portion 220b.

[0037] [Fig.2E] and 2F illustrate the sealing assembly 200 when the first and second sleeves 250a, 250b finish moving axially relative to each other. As shown in this embodiment, the final axial translation causes the first and third sealing element portions 220a, 220c (e.g., the outermost sealing element portions) to compress and radially expand. In one or more embodiments, the first and third sealing element portions 220a, 220c buckle to radially expand. In at least this first embodiment, the axial outer flanges of the first deployable spacer 230a and the second deployable spacer 230b gradually expand to control the expansion 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 substantially prevent the first and third sealing member portions 220a, 220c from tilting, thereby significantly improving the post-deployment (e.g., post-buckling) rigidity of the first and third sealing member portions 220a, 220c. In at least one embodiment, the flanges of the first and second deployable spacers 230a, 230b may ultimately be folded into a fully deployed position (e.g., as illustrated with the flanges oriented vertically), thereby allowing the sealing assembly 200 to fully secure.

[0038] In the illustrated embodiment, the first and second support shoes 240a, 240b also progressively deploy to control the deployment of the first and third sealing element portions 220a, 220c. For example, the first and second support shoes 240a, 240b also help prevent the first and third sealing element portions 220a, 220c from tilting, which significantly improves the post-deployment (e.g., post-buckling) rigidity of the first and third sealing element portions 220a, 220c.

[0039] Thus, according to this first embodiment, the first deployable spacer 230a and the second deployable spacer 230b deploy progressively to orderly (e.g., as opposed to random) control the deployment of the sealing element, which significantly improves the post-buckling stiffness of the sealing elements, and efficiently transfers the load to the support shoes with minimal risk of rubber extrusion. Accordingly, the performance of the support shoes support 240a, 240b is greatly improved, and if there is a good balance between the strength and flexibility of the support shoes 240a, 240b, the successful deployment of the support shoes 240a, 240b is also ensured.

[0040] Turning now to [Fig. 2G] to 2H, they illustrate various cross-sectional views of various deployment states of a sealing assembly 200g designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 200g of [Fig. 2G] to 2H is similar in several respects to the sealing assembly 200 of [Fig. 2A] to 2B. Thus, similar reference numerals have been used to indicate similar, or even identical, elements. The sealing assembly 200g differs, in large part, from the sealing assembly 200 in that the sealing assembly 200g uses a base member 234g that includes a first base member portion 234g' coupled to one of the flanges 232 (e.g., the first flange 232a) and a separate second base member portion 234g" coupled to the other of the flanges 232 (e.g., the second flange 232b).

[0041] Turning now to [Fig. 3A] through 3F, they illustrate various cross-sectional views of various deployment states of a sealing assembly 300 designed, manufactured, and / or operated in accordance with one or more alternative embodiments of the disclosure. The sealing assembly 300 of [Fig. 3A] through 3F is similar in several respects to the sealing assembly 200 of [Fig. 2A] through 2F. Thus, like reference numerals have been used to indicate like, or even identical, elements. The sealing assembly 300 differs, in substantial part, from the sealing assembly 200 in that the sealing assembly 300 utilizes one or more two-part support shoes 340.For example, in one or more embodiments, a first two-part support shoe 340a is located proximate the first end 225a of the sealing member 220 and a second two-part support shoe 340b is located proximate the second end 225b of the sealing member 220.

[0042] In at least one embodiment, the first two-part support shoe 340a and the second two-part support shoe 340b each include a first support shoe portion 342 and a separate second support shoe portion 344. In at least one embodiment, the first support shoe portion 342 is located proximate the collar sleeve 250a, 250b, and the second support shoe portion 344 is located between the first support shoe portion 342 and the sealing member 220. In at least one other embodiment, the first support shoe portion 342 includes a substantially vertical section 342a and an inclined section 342b. In one or more embodiments, the inclined section 342b is located proximate to the mandrel 210, while the substantially vertical section 342a is located spaced from the mandrel 210. Further, in a of embodiments of the disclosure, the inclined section 342b is inclined toward the sealing member 220.

[0043] 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 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.

[0044] [Fig. 3A] and 3B illustrate the sealing assembly 300 in a lapping state, and thus 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. Further, 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.

[0045] [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.

[0046] [Fig. 3E] and 3F illustrate the sealing assembly when the first and second sleeves 250a, 250b finish moving axially relative to each other. As shown in this embodiment, the final axial translation causes the first and third sealing element portions 220a, 220c (e.g., the outermost sealing element portions) to compress and radially expand. 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, 220b.For example, the axial outer flanges of the first deployable spacer 230a and the second deployable spacer 230b significantly prevent the first and third sealing element portions 220a, 220c from tilting, which significantly improves the post-deployment (e.g., post-buckling) stiffness of the first and third element portions. sealing elements 220a, 220c. In at least one embodiment, the flanges of the first and second deployable spacers 230a, 230b may ultimately be folded into a fully deployed position (e.g., as illustrated with the flanges oriented vertically) that allows the sealing assembly 200 to fully secure. The first and second two-part support shoes 340a, 340b also progressively deploy to control the deployment of the first and third sealing element portions 220a, 220b. Thus, the second support shoe portions 344 deploy radially outward relative to the first support shoe portions 342.For example, the second support shoe portions 344 may control a radial outer edge of the first and third sealing member portions 220a, 220c, while the first support shoe portions 342 may control the radial inner edge of the first and third sealing member portions 220a, 220c.

[0047] Turning now to [Fig. 4A] through 4F, they illustrate various cross-sectional views of various deployment states of a sealing assembly 400 designed, manufactured, and / or operated in accordance with one or more alternative embodiments of the disclosure. The sealing assembly 400 of [Fig. 4A] through 4F is similar in several respects to the sealing assembly 200 of [Fig. 2A] through 2F. Thus, like reference numerals have been used to indicate like, 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 utilize a deployable spacer 230, but instead utilizes a deployable control strip 430 positioned radially outwardly of a radially inner surface of its sealing member 420.In the illustrated embodiment, the deployable control band is positioned radially outward of a radial outer surface of the sealing element 420. The deployable control band 430, in one or more embodiments, is configured to deploy from an undeployed state to a deployed state as the sealing element 420 moves from the radially retracted state to the radially expanded state. The embodiment of [Fig. 4A] through 4F illustrates that the sealing element 420 comprises only a single sealing element portion. However, there may be other embodiments in which the sealing element 420 comprises multiple sealing element portions, as indicated above.

[0048] In the illustrated embodiment, the sealing assembly 400 includes first and second deployable control bands 430a, 430b. The first and second deployable control bands 430a, 430b are both positioned around the radial outer surface of the sealing member 420, but are also spaced apart from each other. In at least one embodiment, the first and second deployable control bands 430a, 430b are spaced apart from substantially equally between the first end 225a and the second end 225b of the sealing member 420. The term "substantially equally spaced," as used herein, means that the first and second deployable control bands 430a, 430b are 20 percent away from being exactly equally spaced. Thus, in the illustrated embodiment, the first and second deployable control bands 430a, 430b would separate the sealing member 420 into three spaced sections 420a, 420b, 420c (e.g., three substantially equally (e.g., 20 percent away from exactly equally) spaced sections). Although two deployable control strips 430a, 430b are used in the illustrated embodiment, more than two deployable control strips may be used and remain within the scope of the disclosure.

[0049] In at least one embodiment, the first and second deployable control bands 430a, 430b have a control band stiffness greater than the stiffness of the sealing member 420. The term "stiffness," as used herein, refers to the amount of force required to cause a given amount of deformation of a component of interest. 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 bands are designed such that they will break once the sealing members have been deployed in an acceptable controlled manner. In at least one other embodiment, the deployable control bands will not buckle, as they are not in compression, but rather in tension and will eventually break as expected.

[0050] The stiffness 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 portions of the buckled sections to support each other, thereby preventing tipping to one side or the other. Thus, in at least one embodiment, the first and second deployable control strips 430a, 430b (e.g., associated pairs of control strips) would have similar stiffness.In at least one embodiment, the seal assembly 400, including the deployable control strips 430a, 430b, would potentially have better swab resistance than conventional seal assemblies without the deployable control strips 430a, 430b, thereby allowing the seal assembly 400 to be lapped at a higher rate.

[0051] [Fig.4A] and 4B illustrate the sealing assembly 400 in a lapping state, and thus its sealing element 420 is in a radially retracted state. For example, each of the spaced sections 420a, 420b, 420 of the sealing member 420 is in its radially retracted state. Further, 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.

[0052] [Fig.4C] and 4D illustrate the sealing assembly 400 as the first and second sleeves 250a, 250b begin to move axially relative to each other. As shown in this embodiment, the combination of axial translation of the first and second collar sleeves 250a, 250b and the first and second deployable control bands 430a, 430b causes the spaced center section 420b to compress and radially expand. In one or more embodiments, the spaced center section 420b buckles to expand radially, thereby forming two buckled sections, as illustrated.

[0053] [Fig.4E] and 4F illustrate the sealing assembly 400 when the first and second sleeves 250a, 250b finish moving axially relative to each other. As shown in this embodiment, the final axial translation causes the first and third spaced sections 420a, 420c (e.g., the outermost spaced sections) to compress and radially expand. In one or more embodiments, the first and third spaced sections 420a, 420c buckle to radially expand, each again forming two buckled sections, as illustrated. Further, in at least one embodiment, the first and second deployable control bands 430a, 430b deploy from their undeployed state to their deployed state, as illustrated. In the illustrated embodiment, the first and second deployable control bands 430a, 430b remain intact after the sealing member 420 transitions into the radially expanded state.

[0054] As shown in [Fig.4E] and 4F, the first and second support shoes 240a, 240b gradually deploy to control the deployment of the first and third spaced sections 420a, 420b. For example, the first and second support shoes 240a, 240b also help prevent the first and third spaced sections 420a, 420c from tipping, which significantly improves the post-deployment (e.g., post-buckling) rigidity of the first and third spaced sections 420a, 420c.

[0055] Turning now to [Fig. 5A] through 5F, they illustrate various cross-sectional views of various deployment states of a sealing assembly 500 designed, manufactured and / or operated in accordance with one or more alternative embodiments of the disclosure. The sealing assembly 500 of [Fig. 5A] through 5F is similar in several respects to the sealing assembly 400 of [Fig. 4A] through 4F. Thus, similar reference numerals have been used to indicate similar, or even identical, elements. The sealing assembly 500 differs, in substantial part, from the assembly sealing element 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.

[0056] Turning now to [Fig. 6A] through 6H, they illustrate various cross-sectional views of various deployment states of a sealing assembly 600 designed, manufactured and / or operated in accordance with one or more alternative embodiments of the disclosure. The sealing assembly 600 of [Fig. 6A] through 6H is similar in several respects to the sealing assembly 400 of [Fig. 4A] through 4F. Thus, similar reference numerals have been used to indicate similar, or even identical, elements. The sealing assembly 600 differs, in substantial part, from the sealing assembly 400 in that the sealing assembly 600 further includes third and fourth deployable control bands 630c, 630d positioned around the outer surface, the third and fourth deployable control bands 630c, 630d being positioned on opposite axial sides of the first and second deployable control bands 430a, 430b.Thus, in the illustrated embodiment, the first, second, third, and fourth deployable control strips 430a, 430b, 630c, 630d separate the sealing member 620 into first, second, third, fourth, and fifth spaced sections 620a, 620b, 620c, 620d, 620e.

[0057] 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 is different 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, for the purpose of causing the third spaced section 620c (e.g., the center 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 deployable control strip are designed to achieve a desirable sequence of deployment of sealing elements.

[0058] The different stiffnesses may be created using a number of different methods. For example, in at least one embodiment, the first and second deployable control bands 430a, 430b comprise a material having the first control band stiffness and the third and fourth deployable control bands 630c, 630d comprise a different material having the different second control band stiffness. In another embodiment, the materials may be the same, but the size and / or shape are modified to modulate the rigidity.

[0059] Turning now to [Fig. 7A] through 7H, they illustrate various cross-sectional views of various deployment states of a sealing assembly 700 designed, manufactured, and / or operated in accordance with one or more alternative embodiments of the disclosure. The sealing assembly 700 of [Fig. 7A] through 7H is similar in several respects to the sealing assembly 600 of [Fig. 6A] through 6H. Thus, like reference numerals have been used to indicate like, or even identical, elements. The sealing assembly 700 differs, in substantial part, from the sealing assembly 600 in that the deployable control bands 430a, 430b, 630c, 630d of the sealing assembly 700 are configured to break and release after the sealing member 420 moves to the radially expanded state.

[0060] Turning now to [Fig.8A] to 8F, they illustrate different sectional views cross-section of various deployment states of a sealing assembly 800 designed, manufactured and / or operated in accordance with one or more alternative embodiments of the disclosure. The sealing assembly 800 of [Fig. 8A] through 8F is similar in several respects to the sealing assembly 400 of [Fig. 4A] through 4F. Thus, like reference numerals have been used to indicate like, or even identical, elements. The sealing assembly 800 differs, in substantial 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.

[0061] Aspects disclosed herein include:

[0062] 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 sealing element portion and a second sealing element portion; and b) an expandable spacer positioned between the first sealing element portion and the second sealing element portion; 3) a first collar sleeve coupled proximate a first end of the sealing element; and 4) a second collar sleeve coupled proximate 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 an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.

[0063] B. A well system, the well system comprising: 1) a wellbore located in a subterranean formation; and 2) a sealing assembly positioned in the wellbore, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned around the mandrel, the sealing element comprising: i) a first sealing element portion and a second sealing element portion; and ii) an expandable spacer positioned between the first sealing element portion and the second sealing element portion; c) a first collar sleeve coupled proximate a first end of the sealing element;and c) a second collar sleeve 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, and wherein the deployable spacer is configured to deploy from an undeployed state to a deployed state as the sealing member moves from the radially retracted state to the radially expanded state.;

[0064] C. A method, the method comprising: 1) positioning a sealing assembly in a wellbore located in a subterranean formation, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned around the mandrel, the sealing element comprising: i) a first sealing element portion and a second sealing element portion; and ii) an expandable spacer positioned between the first sealing element portion and the second sealing element portion; c) a first collar sleeve coupled proximate a first end of the sealing element;and d) a second collar sleeve 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, and wherein the deployable spacer is configured to deploy from an undeployed state to a deployed state as the sealing member moves from the radially retracted state to the radially expanded state; and 2) moving the sealing member from the radially retracted state to the radially expanded state, the movement causing the deployable spacer to deploy from the undeployed state to the deployed state. ;

[0065] D. A sealing assembly, the sealing assembly comprising: 1) a mandrel; 2) a sealing element positioned about the mandrel, the sealing element having a radial inner surface and a radial outer surface; 3) a deployable control band positioned radially outward of the radial inner surface; 4) a first collar sleeve coupled proximate a first end of the sealing member; and 5) a second collar sleeve 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 state radially retracted and a radially expanded state, and wherein the deployable control band is configured to deploy from an undeployed state to a deployed state as the sealing member moves from the radially retracted state to the radially expanded state.

[0066] E. A well system, the well system comprising: 1) a wellbore located in a subterranean formation; and 2) a sealing assembly positioned in the wellbore, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned about the mandrel, the sealing element having a radial inner surface and a radial outer surface; c) a deployable control band positioned radially outward of the radial inner surface; d) a first collar sleeve coupled proximate a first end of the sealing element;and 3) a second collar sleeve 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, and wherein the deployable control band is configured to deploy from an undeployed state to a deployed state as the sealing member moves from the radially retracted state to the radially expanded state.;

[0067] F. A method, the method comprising: 1) positioning a sealing assembly in a wellbore located in a subterranean formation, the sealing assembly comprising: a) a mandrel; b) a sealing element positioned about the mandrel, the sealing element having a radial inner surface and a radial outer surface; c) a deployable control band positioned radially outward of the radial inner surface; d) a first collar sleeve coupled proximate a first end of the sealing element;and 3) a second collar sleeve 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, and wherein the deployable control band is configured to deploy from an undeployed state to a deployed state as the sealing member moves from the radially retracted state to the radially expanded state; and 2) moving the sealing member from the radially retracted state to the radially expanded state, the movement causing the deployable control band to deploy from the undeployed state to the deployed state. ;

[0068] Aspects A, B, C, D, E and F may comprise one or more of the following additional elements in combination: Element 1: wherein the deployable spacer comprises two flanges, and wherein a first of the two flanges is configured to control deployment of the first sealing element portion and a second of the two flanges is configured to control deployment of the second sealing element portion. 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 proximate the mandrel. Element 4: wherein the base member has a wide portion proximate the mandrel and a narrow portion spaced from the mandrel, the wide portion being configured to resist lifting or tipping of the deployable spacer as the sealing element moves between the radially retracted state and the radially expanded state.Element 5: wherein the base member comprises a first base member portion coupled to the first of the two flanges and a separate second base member portion coupled to the second of the two flanges. Element 6: wherein the two flanges have one or more weakened locations, the weakened locations being configured to allow the two flanges to deploy more easily. Element 7: wherein the weakened locations are removed sections. Element 8: wherein at least a portion of the deployable spacer comprises a material having a yield strength of less than or equal to 40 ksi. Element 9: further comprising a first support shoe positioned between the first collar sleeve and the first end of the sealing member, and a second support shoe positioned between the second collar sleeve and the second end of the sealing member.Item 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 proximate the first collar sleeve and the second support shoe portion being located between the first support shoe portion and the first sealing member portion. Item 11: wherein the first support shoe portion, the second support shoe portion, and the deployable spacer are made of a similar material. Item 12: wherein the first support shoe portion, the second support shoe portion, and the deployable spacer each have a yield strength of less than or equal to 40 ksi. Item 13: wherein the deployable control band is a first deployable control band, and further comprising a second deployable control band positioned about the outer radial surface.Element 14: Further comprising third and fourth deployable control bands positioned about the outer surface, the third and fourth deployable control bands being positioned on opposite axial sides of the first and second deployable control bands. Element 15: Wherein the first and second deployable control bands have a first band stiffness of . control, and wherein the third and fourth deployable control bands have a second control band stiffness. Element 16: wherein the second control band stiffness is different from the first control band stiffness. Element 17: wherein the second control band stiffness is higher than the first control band stiffness. Element 18: wherein the first and second deployable control bands comprise a material having the first control band stiffness and the third and fourth deployable control bands comprise a different material having the different second control band stiffness. Element 19: wherein the first and second control bands have a similar stiffness, the similar stiffness being configured to cause a portion of the sealing member therebetween to buckle simultaneously.Element 20: wherein the first and second deployable control bands are configured to remain intact after the sealing member moves to the radially expanded state. Element 21: wherein the first and second deployable control bands are configured to break after the sealing member moves to the radially expanded state. Element 22: wherein the deployable control band is positioned radially outward of the radial outer surface. Element 23: wherein the deployable control band is embedded in the sealing member.

[0069] Those skilled in the art to which the present application relates will understand that other additions, deletions, substitutions and modifications may be made to the described embodiments.

Claims

Claims

1. A sealing assembly (200), comprising: a mandrel (210); a sealing member (220) positioned about the mandrel, the sealing member having a radial inner surface and a radial outer surface; a deployable control band (430) positioned radially outward of the radial inner surface; 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, and wherein the deployable control band is configured to deploy from an undeployed state to a deployed state as the sealing member moves from the radially retracted state to the radially expanded state.;

2. The sealing assembly of claim 1, wherein the deployable control strip is a first deployable control strip (430a), and further comprising a second deployable control strip (430b) positioned around the outer radial surface.

3. The sealing assembly of claim 2, further comprising third and fourth deployable control bands (630c, 630d) positioned around the outer surface, the third and fourth deployable control bands being positioned on opposite axial sides of the first and second deployable control bands.

4. The sealing assembly of claim 3, wherein the first and second deployable control bands have a first control band stiffness, and wherein the third and fourth deployable control bands have a second control band stiffness.

5. The sealing assembly of claim 4, wherein the second control band stiffness is different from the first control band stiffness, or optionally wherein the second control band stiffness is higher than the first control band stiffness, or optionally wherein the first and second deployable control bands comprise a material having the first control band stiffness and the third and fourth deployable control bands comprise a different material having the different second control band stiffness.

6. The sealing assembly of claim 2, wherein the first and second control bands have a similar stiffness, the similar stiffness being configured to cause a portion of the sealing member to buckle simultaneously therebetween, or optionally wherein the first and second deployable control bands are configured to remain intact after the sealing member moves to the radially expanded state, or optionally wherein the first and second deployable control bands are configured to break after the sealing member moves to the radially expanded state.

7. The sealing assembly of claim 1, wherein the deployable control strip is positioned radially outward of the radial outer surface.

8. The sealing assembly of claim 1, wherein the deployable control strip is embedded in the sealing member.

9. 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 element (220) positioned about the mandrel, the sealing element having a radial inner surface and a radial outer surface; a deployable control band (430) positioned radially outward of the radial inner surface; a first collar sleeve (250a) coupled proximate a first end of the sealing element; 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, and wherein the deployable control band is configured to deploy from an undeployed state to a deployed state as the sealing member moves from the radially retracted state to the radially expanded state.

10. The well system of claim 9, wherein the deployable control band is a first deployable control band (430a), and further comprising a second deployable control band (430b) positioned around the outer radial surface.

11. The well system of claim 10, further comprising third and fourth deployable control bands (630c, 630d) positioned around the exterior surface, the third and fourth deployable control bands being positioned on opposite axial sides of the first and second deployable control bands, or optionally wherein the first and second deployable control bands have a first control band stiffness, and wherein the third and fourth deployable control bands have a second control band stiffness, or optionally wherein the second control band stiffness is different from the first control band stiffness, or optionally wherein the second control band stiffness is higher than the first control band stiffness,or optionally wherein the first and second deployable control bands comprise a material having the first control band stiffness and the third and fourth deployable control bands comprise a different material having the different second control band stiffness.,

12. The well system of claim 10, wherein the first and second control bands have a similar stiffness, the similar stiffness being configured to cause a portion of the sealing member to buckle simultaneously therebetween, or optionally wherein the first and second deployable control bands are configured to remain intact after the sealing member moves to the radially expanded state,

13.

14.

15. or optionally wherein the first and second deployable control bands are configured to rupture after the sealing member moves to the radially expanded state. The well system of claim 9, wherein the deployable control strip is positioned radially outward of the radial outer surface. The well system of claim 9, wherein the deployable control strip is embedded in the sealing member. 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, the sealing element having a radial inner surface and a radial outer surface; a deployable control strip (430) positioned radially outward of the radial inner surface; 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, and wherein the deployable control band is configured to deploy from an undeployed state to a deployed state as the sealing member moves from the radially retracted state to the radially expanded state; and moving the sealing element from the radially retracted state to the radially expanded state, the moving causing the deployable control strip to deploy from the undeployed state to the deployed state.

Images