Radial stack next generation annular packing unit

Abstract

Blowout preventer (BOP) systems and methods for operating BOP systems. The BOP system includes an apparatus for isolating wellbore fluids having a packing unit and a piston, where the piston is located downhole of the packing unit, and a BOP housing radially surrounding the apparatus. The packing unit includes an elastomeric packer having a plurality of metal inserts. Methods include providing the BOP system to a wellbore, applying an opening pressure or a closing pressure to the apparatus in a series of stages, sealing a central circumference of the plurality of metal inserts when the closing pressure is applied by compressing the packing unit with the piston, where, upon compressing, the packing unit moves the plurality of metal inserts radially inward to form a seal.

Description

RADIAL STACK NEXT GENERATION ANNULAR PACKING UNIT BACKGROUND

[0001] Well control is an important aspect of oil and gas exploration. When drilling a well, for example, in oil and gas exploration applications, safety devices must be put in place to prevent injury to personnel and damage to equipment resulting from unexpected events associated with the drilling activities.

[0002] Drilling wells in oil and gas exploration involves penetrating a variety of subsurface geologic structures, or "layers." Occasionally, a wellbore will penetrate a layer having a formation pressure substantially higher than the pressure maintained in the wellbore. When this occurs, the well is said to have "taken a kick." The pressure increase associated with the kick is generally produced by an influx of formation fluids (which may be a liquid, a gas, or a combination thereof) into the wellbore. The relatively high pressure kick tends to propagate from a point of entry in the wellbore uphole (from a high pressure region to a low pressure region). If the kick is allowed to reach the surface, drilling fluid, well tools, and other drilling structures may be blown out of the wellbore. These "blowouts" may result in catastrophic destruction of the drilling equipment (including, for example, the drilling rig) and substantial injury or death of rig personnel.

[0003] Because of the risk of blowouts, blowout preventers ("BOPs") are typically installed at the surface or on the sea floor in deep water drilling arrangements to effectively seal a wellbore until active measures can be taken to control the kick. BOPs may be activated so that kicks are adequately controlled and "circulated out" of the system. There are several types of BOPs, one common type of which is an annular blowout preventer.

[0004] Annular BOPs typically comprise annular, elastomeric "packing units" that may be activated to encapsulate drill pipe and well tools to completely seal about a wellbore. In situations where no drill pipe or well tools are within the bore of the packing unit, the packing unit can be compressed to such an extent that the bore is essentially closed, acting as a valve on the wellbore. Typically, packing units are used in the case of sealing abouta drill pipe, in which the packing unit can be quickly compressed, either manually or by machine, to affect a seal about the pipe to prevent a well from blowing out.

[0005] Thus, a critical parameter for annular packing units is how much pressure the seal can handle because the pressure handling capacity determines the type of wellbore environment in which the packing unit may be safely implemented. While the pressure handling capacity of packing units depends on a number of parameters and conditions, the principle limiting factor is the “extrusion gap.” Factors which affect extrusion gap (and therefore pressure handling capacity of the packing unit) are seal design, seal type, and material.

[0006] In terms of sealing systems, the extrusion gap is defined as the clearance between one or more hardware components. For example, the radial clearance in the hardware that needs to be sealed is referred to as the extrusion gap. A seal extruding through the extrusion gap is a common failure mode for high-pressure systems. In an application where the extrusion gap is too large for the system pressure, the seal will begin to deform, and the material will begin to cold-flow into the gap, giving the appearance of the seal “extruding.” If enough extrusion of the seal takes place, the integrity of the seal will be compromised eventually leading to failure. The extrusion resistance of any seal may depend largely on the backup ring design. In general, the smaller the extrusion gap, the higher the pressure the seal can handle. Accordingly, there exists a need for improved annular BOP systems to minimize the extrusion gap.SUMMARY

[0007] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0008] In one aspect, embodiments disclosed herein relate to a blowout preventer (BOP) system including an apparatus configured to isolate wellbore fluids, the apparatus having a packing unit and a piston, where the piston is located downhole of and proximate to thepacking unit, where the packing unit includes an elastomeric packer having a plurality of metal inserts disposed axially through a plurality of insert portions in the elastomeric packer, and where the plurality of metal inserts includes a first metal insert and a second metal insert and each of the first metal insert and the second metal insert independently has an elongated portion extending between a first end having a first prong and a second end having a second prong. The BOP system also includes a BOP housing radially surrounding the apparatus, where the piston and the packing unit are axially stacked within the BOP housing.

[0009] In another aspect, embodiments disclosed herein relate to a method for operating a blowout prevention (BOP) system, the method including providing the BOP system to a wellbore. The BOP system includes an apparatus configured to isolate wellbore fluids and including a packing unit and a piston located downhole of and proximate to the packing unit, where the packing unit has an elastomeric packer having a plurality of metal inserts disposed axially through a plurality of insert portions in the elastomeric packer, and where the plurality of metal inserts include a first metal insert and a second metal insert and each of the first metal insert and the second metal insert independently has an elongated portion extending between a first end having a first prong and a second end having a second prong. The BOP system also includes a BOP housing radially surrounding the apparatus, where the piston and the packing unit are axially stacked within the BOP housing. The method further includes applying a pressure to the apparatus in a series of stages, where the applied pressure includes an opening pressure and a closing pressure, where the opening pressure moves the piston in a downhole direction and the closing pressure moves the piston in an uphole direction. The method further includes sealing a central circumference of the plurality of metal inserts when the closing pressure is applied by compressing the packing unit with the piston when the piston is moved uphole, where, upon compressing, the packing unit moves the plurality of metal inserts radially inward to form a seal, and unsealing the central circumference of the plurality of metal inserts when the opening pressure is applied by decompressing the packing unit when the piston is moved downhole, where, upon decompressing, the packing unit moves the plurality of metal inserts radially outward to release the seal.

[0010] Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.BRIEF DESCRIPTION OF DRAWINGS

[0011] FIG. 1 A illustrates an example BOP system according to one or more embodiments.

[0012] FIG. IB shows a zoomed in portion of an example BOP system according to one or more embodiments.

[0013] FIG. 2A shows a perspective view of a first piston according to one or more embodiments.

[0014] FIG. 2B shows a cutaway view of a first piston according to one or more embodiments.

[0015] FIG. 3A shows a perspective view of a first metal insert according to one or more embodiments.

[0016] FIG. 3B shows a second perspective view of a first metal insert according to one or more embodiments.

[0017] FIG. 3C shows a top view of a first metal insert according to one or more embodiments.

[0018] FIG. 3D shows a bottom view of a first metal insert according to one or embodiments.

[0019] FIG. 3E shows a side view of a first metal insert according to one or embodiments.

[0020] FIG. 4A shows a perspective view of a second metal insert according to one or more embodiments.

[0021] FIG. 4B shows a second perspective view of a second metal insert according to one or more embodiments.

[0022] FIG. 4C shows a top view of a second metal insert according to one or more embodiments.

[0023] FIG. 4D shows a bottom view of a second metal insert according to one or more embodiments.

[0024] FIG. 4E shows a side view of a second metal insert according to one or more embodiments.

[0025] FIG. 5A shows a perspective view of a first elastomeric packer according to one or more embodiments.

[0026] FIG. 5B shows a side view of a first elastomeric packer according to one or more embodiments.

[0027] FIG. 5C shows a top view of a first elastomeric packer according to one or more embodiments.

[0028] FIG. 5D shows a bottom view of a first elastomeric packer according to one or more embodiments.

[0029] FIG. 6A shows a perspective view of a first wear plate according to one or more embodiments.

[0030] FIG. 6B shows a side view of a first wear plate according to one or more embodiments.

[0031] FIG. 7 shows a cutaway view of a first apparatus for isolating wellbore fluids according to one or more embodiments.

[0032] FIG. 8A shows a perspective view of a second piston according to one or more embodiments.

[0033] FIG. 8B shows a cutaway view of a second piston according to one or more embodiments.

[0034] FIG. 9A shows a perspective view of a third metal insert according to one or more embodiments.

[0035] FIG. 9B shows a top view of a third metal insert according to one or more embodiments.

[0036] FIG. 9C shows a botom view of a third metal insert according to one or more embodiments.

[0037] FIG. 9D shows a side view of a third metal insert according to one or more embodiments.

[0038] FIG. 10A shows a perspective view of a fourth metal insert according to one or more embodiments.

[0039] FIG. 10B shows a second perspective view of a fourth metal insert according to one or more embodiments.

[0040] FIG. 10C shows a top view of a fourth metal insert according to one or more embodiments.

[0041] FIG. 10D shows a botom view of a fourth metal insert according to one or more embodiments.

[0042] FIG. 10E shows a side view of a fourth metal insert according to one or more embodiments.

[0043] FIG. 11A shows a perspective view of a second elastomeric packer according to one or more embodiments.

[0044] FIG. 11B shows a cutaway view of a second elastomeric packer according to one or more embodiments.

[0045] FIG. 11C shows a side view of a second elastomeric packer according to one or more embodiments.

[0046] FIG. 11D shows a top view of a second elastomeric packer according to one or more embodiments.

[0047] FIG. 1 IE shows a bottom view of a second elastomeric packer according to one or more embodiments.

[0048] FIG. 12A shows an isometric view of a second wear plate according to one or more embodiments.

[0049] FIG. 12B shows a side view of a second wear plate according to one or more embodiments.

[0050] FIG. 13A shows a second apparatus for isolating wellbore fluids according to one or more embodiments.

[0051] FIG. 13B shows a cutaway view of a second apparatus for isolating wellbore fluids according to one or more embodiments.

[0052] FIG. 14 shows a cross section of a third piston according to one or more embodiments.

[0053] FIG. 15A shows a perspective view of a fifth metal insert according to one or more embodiments.

[0054] FIG. 15B shows a second perspective view of a fifth metal insert according to one or more embodiments.

[0055] FIG. 16A shows a perspective view of a sixth metal insert according to one or more embodiments.

[0056] FIG. 16B shows a second perspective view of a sixth metal insert according to one or more embodiments.

[0057] FIG. 17A shows a perspective view of a third elastomeric packer according to one or more embodiments.

[0058] FIG. 17B shows a cutaway view of a third elastomeric packer according to one or more embodiments.

[0059] FIG. 17C shows a side view of a third elastomeric packer according to one or more embodiments.

[0060] FIG. 18A shows a third apparatus for isolating wellbore fluids according to one or more embodiments.

[0061] FIG. 18B shows a cutaway view of a third apparatus for isolating wellbore fluids according to one or more embodiments.

[0062] FIG. 19A is an initial position of an apparatus for isolating wellbore fluids prior to implementing a method for compressing a packing unit around a tubular according to one or more embodiments.

[0063] FIGs. 19B-E illustrate different stages of applying a closing pressure to an apparatus for isolating wellbore fluids according to one or more embodiments.

[0064] FIG. 19F is a final position of an apparatus for isolating wellbore fluids prior to implementing a method for compressing a packing unit around a tubular according to one or more embodiments.

[0065] FIG. 20A is an initial position of an apparatus for isolating wellbore fluids prior to implementing a method for compressing a packing unit around the apparatus according to one or more embodiments.

[0066] FIG. 20B is a final position of an apparatus for isolating wellbore fluids prior to implementing a method for compressing a packing unit around the apparatus according to one or more embodiments.DETAILED DESCRIPTION

[0067] Throughout the application, ordinal numbers (for example, first, second, third) may be used as an adjective for an element (that is, any noun in the application). The use of ordinal numbers does not imply or create a particular ordering of the elements or limit any element to being only a single element unless expressly disclosed, such as by the use of the terms “before,” “after,” “single,” and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.

[0068] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a horizontal beam” includes reference to one or more of such beams.

[0069] Terms such as “approximately” or “substantially” mean that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including, for example, tolerances, measurement error, measurement accuracy limitations, and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

[0070] It is to be understood that one or more of the steps shown in the flowcharts may be omitted, repeated, or performed in a different order than shown. Accordingly, the scope disclosed should not be considered limited to the specific arrangement of steps shown in the flowcharts.

[0071] Although multiple dependent claims are not introduced, it would be apparent to one of ordinary skill that the subject matter of the dependent claims of one or more embodiments may be combined with other dependent claims.

[0072] Embodiments disclosed herein generally relate to an apparatus for isolating wellbore fluids. Embodiments disclosed herein also relate to blowout preventer (BOP) systems including the apparatus for isolating wellbore fluids and methods for isolating a wellbore fluid using the BOP system disclosed herein.

[0073] As described above, sealing capacity of a seal is greatly improved as the extrusion gap decreases. An extrusion gap is defined herein as any free volume that material from the packer is able to flow into, particularly upon activation (i.e., application of pressure). In some embodiments, the extrusion gap includes a distance between two or more elements in an apparatus for sealing when the seal has been created. Specifically, according to embodiments disclosed herein, an “extrusion gap” may refer to a radial distance between a plurality of metal inserts disposed within the packing unit and a mandrel around which the BOP system is configured seal around. In addition, an “extrusion gap” according to one or more embodiments may refer to a radial diameter of a space within the central circumference of the metal inserts disposed within the packing unit when the BOP system is configured to seal around the packing unit itself (e.g., when a seal is created in the absence of a mandrel being inserted into the central circumferenceof the metal inserts). Sealing around the packing unit itself may also be referred to as “complete shut-off’ in the industry.

[0074] In general, an extrusion gap may be expressed in terms of radial or diametral clearance. Embodiments disclosed herein refer to an extrusion gas as a radial clearance. The radial clearance is equal to the diametral clearance divided by two.

[0075] A seal’s ability to withstand extrusion depends on numerous factors. The physical size of the seal plays an important role as a seal with a larger cross-section will handle higher pressures for a given extrusion gap. For example, a seal with a 1 / 16” cross-section can potentially hold the same amount of pressure as a seal with a %” cross-section, but the extrusion will need to be much smaller. The seal material also plays a critical role in resisting extrusion. Additives, such as fillers contained in the elastomer seal, may also affect the pressure handling capacity. Operating temperature of the system can also significantly affect a seal material’s pressure handling or extrusion requirements. Elevated temperatures make most materials softer and more compliant and therefore easier to extrude. Likewise, pressure ratings will be higher at cryogenic temperatures because the material is stiffer and more difficult to cold-flow.

[0076] The extrusion gas also varies with the size of hardware that the packing unit is sealing against. For example, a packing unit may seal against a tubular member. A tubular member according to one or more embodiments may be any tubular member known in the art, including but not limited to a mandrel, drill pipe, drill collars, pup joints, casing, production tubing, coiled tubing, and the like. The term “mandrel” will be used herein as the tubular member. A common mandrel size is a 5 inch mandrel. Accordingly, the BOP system 100 of one or more embodiments may have an optimized (e.g., lowest) extrusion gap size when sealing around a 5 inch mandrel. For example, sealing around a 5 inch diameter mandrel within the annular flow path of a BOP system 100 mandrel may lead to a smaller extrusion gap then sealing around mandrel having a diameter of other than 5 inches. Additionally, as hardware diameters increase, manufacturing tolerances also increase, making it impractical or cost-prohibitive to require extremely tighttolerances in large diameter hardware; thus, extrusion gaps may be inherently larger when sealing around larger diameter hardware.

[0077] Turning now to the Figures, FIG. 1 A shows a BOP system 100 according to one or more embodiments. The BOP system 100 of FIG. 1A includes an apparatus for isolating wellbore fluids 101 which includes an assembly of components that may be axially stacked within a BOP housing 110. Each component of the assembly of components within the apparatus may each contain a generally central hole such that, when stacked, an inner flow path is formed axially through the assembly of components. The BOP system may also include a BOP housing radially surrounding the apparatus, where the piston and the packing unit are axially stacked within the BOP housing. Although not explicitly shown in the Figures, it would be understood by one of ordinary skill in the art that the BOP system disclosed herein may include other components not depicted which are necessary for operation of the BOP system. Other components of the BOP system may include, but are not limited to, flow lines fluidly connected to the BOP system (such as choke and / or kill lines), one or more rams, an accumulator, a drilling spook, and the like.

[0078] The apparatus for isolating wellbore fluids 101 shown in FIG. 1A may include a wear plate 102, a sleeve 103, a packing unit 104, and a piston 106. As shown in FIG. 1 A, a wear plate 102 may be stacked on an uphole side of the packing unit 104 and a sleeve 103 may be placed on a downhole side of the packing unit 104. The sleeve 103 may therefore be located radially within the piston 106, where the piston 106 is located downhole of the packing unit 104. Example apparatuses are shown in FIG. 7, FIGs. 13A- B, and FIGs. 18A-B, as follows.

[0079] The term “piston” as used herein generally refers to a component of the blowout preventer which moves within a BOP housing and is driven by a hydraulic thrust. The piston 106 according to one or more embodiments will be described in more detail in FIGs.2A-B, FIGs. 8A-B, and FIG. 14.

[0080] A packing unit, often called a “packer” is a downhole tool with one or more elastic sealing elements used to seal an annular space between various sizes of tubing string anda wellbore, or between tubing strings. Packing units 104 according to one or more embodiments will be described in more detail in FIGs. 5A-D, FIGs. 11A-E, and FIGs.17A-C.

[0081] In general, a wear plate may be defined as a device used to prevent damage to main portions of machinery due to abrasion or impact and to increase the life of the machine. Wear plates may also be known as “liners” in the industry. Wear plates 102 according to one or more embodiments will be described in more detail in FIGs. 4A-B and FIGs. 12A- B.

[0082] Returning to FIG. 1A, in one or more embodiments, a mandrel 108 may extend through a central circumference (e.g., the central hole as described above) of the packing unit 104 and the piston 106, for example during drilling or production of a well. The mandrel may refer to any tubular member known in the art, including but not limited to a drill pipe, drill collars, pup joints, casing, production tubing, coiled tubing, and the like.

[0083] As will be described in further detail below, the BOP system 100 may be configured to dynamically adjust such that a seal is formed around the mandrel 108. In some embodiments, the apparatus for isolating wellbore fluids 101 may seal around itself (e.g., in the absence of a mandrel 108).

[0084] FIG. IB shows a zoomed in portion 150 of the BOP system 100 of FIG. 1A. FIG.IB illustrates how the components of the apparatus for isolating wellbore fluids 101 fit together and within a BOP system. The piston 106 may include a first tubular body 154 and a second tubular body 156. The second tubular body 156 may be located circumferentially around an outer surface of the first tubular body 154, where the second tubular body 156 protrudes a radial distance from the first tubular body 154 such that the second tubular body 156 has a larger outer diameter than the first tubular body 154. The larger outer diameter of the second tubular body 156 may be inserted into a portion of the BOP housing 110, as shown in FIG. IB. Additionally, the second tubular body may include a notched portion 158 configured to abut a BOP housing shoulder 160 when the components of the BOP system 100 are assembled together.

[0085] Additionally, the first tubular body 154 of the packing unit 104 may include a sloped profile 252 at an uphole location of the piston 106, proximate the packing unit 104. The sloped profile 252 is sloped such that various components of the packing unit 104 may sit within the sloped profile 252 portion of the piston 106. As will be described in more detail in the methods section, upon activation of the piston 106, the sloped profile 252 may advantageously stroke different portions of the packing unit 104 (for example, a plurality of metal inserts or an elastomeric packer, not shown in FIG. IB) to provide a sealing function around the mandrel 108 or provide sealing of the apparatus for isolating wellbore fluids 101 to itself.

[0086] Turning to FIG. 2A, a perspective view of a first piston 200 according to one or more embodiments disclosed herein is shown. As described above with reference to piston 106, the first piston 200 may include a first tubular body 254 and a second tubular body 256. The first tubular body 254 includes a first end 202 and a second end 201, where the first end 202 may be located uphole and proximate the packing unit 104. The second end 201 is located opposite the first end 202. An inner diameter of the first end 202 of the first tubular body 254 may have a sloped profile 252 configured to abut against a portion of a packing unit.

[0087] FIG. 2B is a cutaway view 220 of a first piston 200 according to one or more embodiments. As best shown in FIG. 2B, the sloped profile 252 may further include a first sloped portion 204 and a second sloped portion 206. The first sloped portion 204 and the second sloped portion 206 of sloped profile 252 may be separated by a vertical step 260. The vertical step 260 of one or more embodiments may advantageously prevent tipping of a plurality of metal inserts (e.g., a first metal insert 300 and a second metal insert 400) when the apparatus for isolating wellbore fluids is activated according to methods disclosed herein. Features of the metal inserts will be described in more detail in the following sections.

[0088] In one or more embodiments, the vertical step 260 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the vertical step 260 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limitof about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0089] Also shown in FIG. 2B, the second tubular body 256 includes a first end 202 and a second end 210, where the first end 202 may be located uphole of the second end 210. The second end 210 of the second tubular body 256 may have a notched portion 258 configured to abut a shoulder of a BOP housing (e.g., 160 shown in FIG. IB). The notched portion 258 on the second end 210 of the second tubular body 256 may extend circumferentially around a portion of the second tubular body 256 from an inner diameter of the second tubular body 256 towards an outer diameter of the second tubular body 256.

[0090] In one or more embodiments, the first sloped portion 204 of the first piston 200 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 206 of the first piston 200 may have an angle in a range of about 30° to 60°.

[0091] FIG. 3A shows a perspective view of a first metal insert 300 according to one or more embodiments. The first metal insert 300 may include an elongated portion 306 extending between a first end 302 and a second end 304, opposite the first end 302. In one or more embodiments, the elongated portion 306 of the first metal insert 300 includes a wing section 308 extending from the elongated portion 306. The wing section 308 may advantageously abut one or more portions of the piston during activation of the apparatus for isolating wellbore fluids, as will be described in more detail in the methods section.

[0092] While the plurality of metal inserts disclosed herein are labeled as “first,” “second,” “third,” etc., the numbering of metal inserts is merely for distinction and should not be taken as limiting. For example, any of the disclosed metal inserts may be substituted within the isolation apparatus 101 without departing from the present disclosure.

[0093] The first end 302 of the first metal insert 300 may include a first prong 310 and the second end 304 of the first metal insert 300 may include a second prong 312. FIG. 3B shows a second perspective view 320 of a first metal insert of one or more embodiments, illustrating the features of the first prong 310 located on the first end 302. The first prong 310 may include a base portion 314 and a protrusion portion 316. The protrusion portion316 may have a generally “T” shaped profile, as shown in the perspective views of FIGs.3A-B.

[0094] FIG. 3C shows a top down view 340 of a first metal insert, further illustrating the features of the first prong 310. In some embodiments, the first prong 310 may include a base portion 314 and a protrusion portion 316 extending from the base portion 314. The base portion 314 may be a three dimensional body comprising a generally wedge shaped profile, where the wedge shaped profile may include a tip side 342 and a base side 350, the tip side 342 opposite the base side 350 and the wing section 308. In one or more embodiments, a portion of the tip side 342 may be removed to form a notch 352 throughout the three dimensional body of the base portion 314. The notch 352 may advantageously have an arc length designed to seal around a mandrel 108 (described in FIGs. 1A-B) and / or to seal around other components of the apparatus for isolating wellbore fluids according to one or more embodiments.

[0095] The protrusion portion 316 of the first prong 310 may be coupled to and extend from an outer surface of the base portion 314. In one or more embodiments, the protrusion portion 316 may have a generally rectangular shaped profile when viewed from above, including a first side 354 axially aligned with the base side 350 of the base portion 314 and a second side 356 extending toward the notch 352 on the tip side 342 of the base portion 314.

[0096] FIG. 3D shows a bottom view of a first metal insert 360, illustrating the features of the second prong 312. In one or more embodiments, the second prong 312 may include a three dimensional body having a generally wedge shaped profile, where the wedge shaped profile includes a tip side 362 and a base side 364, the tip side 362 being opposite the base side 364 and the wing section 308. In some embodiments, a portion of the tip side 362 may be removed to form a notch 366. As described above, the notch 366 may also advantageously have an arc length designed to seal around a mandrel 108 (described in FIGs. 1 A-B) and / or to seal around other components of the apparatus for isolating wellbore fluids according to one or more embodiments. As would be understood by one of ordinary skill in the art, the dimensions of the first prong 310 and the second prong 312 may varydepending on the overall design of the apparatus for isolating wellbore fluids disclosed herein.

[0097] As best seen in FIG. 3E, which shows a side view 380 of the first metal insert 300, the wing section 308 may include a first sloped portion 382 on an outer surface of the wing section 308. The first sloped portion 382 may be located on a portion of the wing section 308 proximate the second prong 312. The second prong 312 may further include a second sloped portion 384 on an outer surface of the second prong 312, where the outer surface of the second prong 312 may be proximate the wing section 308. The first sloped portion 382 and the second sloped portion 384 of the first metal insert 300 may advantageously abut one or more portions of the piston during activation of the apparatus for isolating wellbore fluids as will be described in more detail in the following sections.

[0098] In one or more embodiments, the first sloped portion 382 on the outer surface of the wing section 308 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 384 on an outer surface of the second prong 312 may have an angle in a range of about 30° to 60°.

[0099] The first sloped portion 382 and the second sloped portion 384 of the first metal insert 300 may be separated by a first insert step 386. The first insert step 386 of one or more embodiments may advantageously prevent tipping of the first metal insert 300 when the apparatus for isolating wellbore fluids is activated according to methods disclosed herein. For example, during activation of the apparatus for isolating wellbore fluids, the first metal insert 300 and the second metal insert 400 are pulled toward the center of the apparatus for isolating wellbore fluids, creating a void between a back portion of the first metal insert 300 and the second metal insert 400 and the first elastomeric packer 500. The void causes a tensile force on the portion of the first elastomeric packer located on an outer surface of the apparatus, where the tensile force is higher at the top of the first elastomeric packer portion (e.g., proximate the first prong 310 of the first metal insert 300). To prevent said tipping phenomenon, steps (such as the first insert step 386, second insert step 486, the first sloped portion 204 and the second sloped portion 206 on the first piston 200) are machined into several components of the apparatus according to embodiments disclosedherein. The various steps allow for stroking of the first elastomeric packer 500 in some cases during activation of the apparatus for isolating wellbore fluids, rather than stroking the metal inserts themselves, therefore allowing for the first elastomeric packer 500 to fill the void as previously described and reduce the tipping force experienced by the first metal insert 300 and the second metal insert 400.

[0100] In one or more embodiments, the first insert step 386 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the first insert step 386 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limit of about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0101] FIG. 4A shows a perspective view of a second metal insert 400 according to one or more embodiments. The second metal insert 400 may include an elongated portion 406 extending between a first end 402 and a second end 404, opposite the first end 402. In one or more embodiments, the elongated portion 406 of the second metal insert 400 includes a wing section 408 extending from the elongated portion 406. The wing section 408 may advantageously abut one or more portions of the piston during activation of the apparatus for isolating wellbore fluids as will be described in more detail in the following sections.

[0102] The first end 402 of the second metal insert 400 may include a first prong 410 and the second end 404 of the second metal insert 400 may include a second prong 412. The first prong 410 may include a base portion 414, a first protrusion portion 416, and a second protrusion portion 418. The first protrusion portion 416 may have a generally tapered wedge shape and the second protrusion portion 418 may have a generally “T” shaped profile, as shown in the perspective view of FIG. 4A.

[0103] As best seen in the second perspective view 420 of the second metal insert depicted in FIG. 4B, the second prong 412 may include a base portion 422 and a protrusion portion 424. The protrusion portion 424 may have a generally tapered wedge shape. The base portion 422 may have a stepped wedge profile, as will be described in more detail below.

[0104] FIG. 4C shows a top down view 440 of a second metal insert, illustrating the features of the first prong 410. In some embodiments, the first prong 410 may include a base portion 414, a first protrusion portion 416, and a second protrusion portion 418.

[0105] The base portion 414 may be a three dimensional body comprising a generally wedge shaped profile, where the wedge shaped profile may include a tip side 442 and a base side 450, the tip side 442 opposite the base side 450 and the wing section 408. In one or more embodiments, a portion of the tip side 442 may be removed to form a notch 452 throughout the three dimensional body of the base portion 414. The notch 452 may advantageously have an arc length designed to seal around a mandrel 108 (described in FIGs. 1A-B) and / or to seal around other components of the apparatus for isolating wellbore fluids according to one or more embodiments.

[0106] In one or more embodiments, the wedge shaped profile of the base portion 414 may be stepped such that a first portion 444 of the base portion 414, proximate the tip side 442, has a wider dimension than a second portion 448 located opposite the first portion 444 and extending to the base side 450 of the base portion 414.

[0107] The first protrusion portion 416 of the first prong 410 may extend from an outer surface of the base portion 414. In one or more embodiments, the first protrusion portion 416 may have a generally tapered wedge shaped profile when viewed from above, including a first side 457 axially aligned with the base side 450 of the base portion 414 and a tapered side 458 extending to the notch 452 on the tip side 442 of the base portion 414.

[0108] The second protrusion portion 418 of the first prong 410 may extend from an outer surface of the first protrusion portion 416. In one or more embodiments, the second protrusion portion 418 may have a generally rectangular shaped profile when viewed from above, including a first side 454 axially aligned with the base side 450 of the base portion 414 and a second side 456 extending toward the notch 452 on the tip side 442 of the base portion 414.

[0109] FIG. 4D shows a bottom view 460 of a second metal insert, illustrating the features of the second prong 412. In some embodiments, the second prong 412 may include abase portion 422 and a protrusion portion 424 extending from an outer surface of the base portion 422.

[0110] The base portion 422 may be a three dimensional body comprising a generally wedge shaped profile, where the wedge shaped profile may include a tip side 462 and a base side 470, the tip side 462 opposite the base side 470 and the wing section 408. In one or more embodiments, a portion of the tip side 462 may be removed to form a notch 472 throughout the three dimensional body of the base portion 422. The notch 472 may advantageously have an arc length designed to seal around a mandrel 108 (described in FIGs. 1A-B) and / or to seal around other components of the apparatus for isolating wellbore fluids according to one or more embodiments. In one or more embodiments, the wedge shaped profile of the base portion 422 may be stepped such that a first portion 464 of the base portion 422, proximate the tip side 462, has a wider dimension than a second portion 468 located opposite the first portion 464 and extending to the base side 470 of the base portion 422.

[0111] The protrusion portion 424 of the second prong 412 may extend from an outer surface of the base portion 422. In one or more embodiments, the protrusion portion 424 may have a generally tapered wedge shaped profile, including a first side 478 axially aligned with the base side 470 of the base portion 422 and a tapered side 474 extending to the notch 472 on the tip side 462 of the base portion 422. As would be understood by one of ordinary skill in the art, the dimensions of the first prong 410 and the second prong 412 may vary depending on the overall design of the apparatus for isolating wellbore fluids disclosed herein.

[0112] As best seen in FIG. 4E, which shows a side view 480 of the second metal insert, the wing section 408 may include a first sloped portion 482 on an outer surface of the wing section 408. The first sloped portion 482 may be located on a portion of the wing section 408, proximate the second prong 412. The second prong 412 may further include a second sloped portion 484 on an outer surface of the second prong 412, where the outer surface of the second prong 412 may be proximate the wing section 408. The first sloped portion 482 and the second sloped portion 484 of the second metal insert 400 may advantageously abutone or more portions of the piston during activation of the apparatus for isolating wellbore fluids as will be described in more detail in the following sections.

[0113] In one or more embodiments, the first sloped portion 482 on the outer surface of the wing section 408 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 484 on an outer surface of the second prong 412 may have an angle in a range of about 30° to 60°.

[0114] The first sloped portion 482 and the second sloped portion 484 of the second metal insert 400 may be separated by a second insert step 486. The second insert step 486 of one or more embodiments may advantageously prevent tipping of the second metal insert 400 when the apparatus for isolating wellbore fluids is activated according to methods disclosed herein.

[0115] In one or more embodiments, the second insert step 486 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the second insert step 486 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limit of about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0116] The first metal insert 300 and the second metal insert 400 of one or more embodiments may advantageously be configured to stack upon each other when the isolation apparatus is activated according to methods disclosed herein. For example, a height of the first protrusion portion 416 located on the first prong 410 of the second metal insert 400 may advantageously be large enough such that a portion of the base portion 314 of the first prong 310 of the first metal insert 300 may slide over and stack upon a portion of the base portion 414 of the first prong 410 of the second metal insert 400. The ability for the first metal insert 300 and the second metal insert 400 of one or more embodiments to stack upon each other when the isolation apparatus is activated may allow for a reduced extrusion gap by allowing the metal inserts to become radially closer to each other during activation of the isolation apparatus.

[0117] FIG. 5A shows a perspective view of a first elastomeric packer 500 according to one or more embodiments. The first elastomeric packer 500 may be part of a first packingunit (e.g., packing unit 701 shown in FIG. 7). The first elastomeric packer 500 of FIG.5A includes a first side 502 located at an uphole location compared to a second side 504, opposite the first side 502. The first elastomeric packer 500 may also include a plurality of cutout portions 506 and a plurality of insert portions 508. The plurality of insert portions 508 may extend axially through a body of the elastomeric packer 500 and may be configured to hold a plurality of metal inserts (e.g., a first metal insert 300 and a second metal insert 400) in place. The first elastomeric packer 500 may also have a plurality of cutout portions 506, where material is removed from the first elastomeric packer 500 in a generally triangular prism shape, extending through a body of the first elastomeric packer 500. The exact dimension and shape of the cutout portion 508 may vary depending on the specific size of the elastomeric packer and the size and number of metal inserts. In one or more embodiments, the cutout portions 506 may advantageously allow for the plurality of metal inserts to move radially inward within the first elastomeric packer 500 when the apparatus for isolating wellbore fluids is activated according to methods disclosed herein. Methods will be described in more detail in the following sections.

[0118] FIG. 5B shows a side view of an elastomeric packer 520, including a first side 502 and a second side 504. In some embodiments, the first side 502 and the second side 504 are substantially flat, as shown in FIG. 5B.

[0119] FIGs. 5C and 5D show a view 540 of the first side 502 of the first elastomeric packer 500 and a view 560 of the second side 504 of the first elastomeric packer 500, respectively. Insert portions 508 can be seen spaced periodically around a circumference of the first side 502 and the second side 504. Cutout portions 506 may also be seen spaced periodically around a circumference of the first side 502 and the second side 504. In one or more embodiments, the insert portions may be configured to fit a first metal insert shown in FIGs. 3A-3E and a second metal insert shown in FIGs. 4A-4E.

[0120] The first elastomeric packer may be constructed of any suitable material known in the art. Examples of elastomeric packer material include but are not limited to elastomers including rubbers such as natural rubber, nitrile rubbers (nitrile butadiene rubber or nitrile rubber NBR, hydrogenated nitrile butadiene rubber HNBR, etc.) and the like.

[0121] Returning to the figures, FIG. 6 A shows a perspective view of a first wear plate 600 according to one or more embodiments. The first wear plate 600 includes a first side 601 and a second side 602. The first side 601 of the first wear plate 600 may include a plurality of cutout portions 604. The cutout portions 604 may be sized to fit, radially align with, and guide one or more prongs on a first metal insert or a second metal insert according to embodiments disclosed herein.

[0122] FIG. 6B shows a side view 620 of a first wear plate. As shown in FIG. 6B, a first side 601 of the first wear plate 600 may include cutout portions 604 as described above. The cutout portions 604 may have a T-shaped profile, as shown in FIGs. 6A-B. The second side 602 of the first wear plate 600, opposite the first side 601, may be substantially flat, as shown in FIG. 6B.

[0123] FIG. 7 shows a cutaway view of an example of a first apparatus 700 for isolating wellbore fluids according to one or more embodiments. In the first apparatus 700, a packing unit 701 may be axially stacked uphole of a piston (such as the first piston 200 described in FIGs. 2A-B). The packing unit 701 may include a first elastomeric packer 500 having a plurality of insert portions (not shown) and cutout portions 506. A plurality of metal inserts may be inserted into the insert portion, for example, a first metal insert 300 and a second metal insert 400. The first metal insert 300 and the second metal insert 400 may be coupled to the first elastomeric packer 500 as part of the packing unit 701. In some embodiments, the first metal insert 300 and the second metal insert 400 are arranged in an alternating pattern in the first elastomeric packer 500. While the first and second metal insert 300, 400 are shown in an alternating pattern, the arrangement depicted in FIG. 7 is merely an example and is not intended to be limiting. As would be understood by one of ordinary skill in the art, the metal insert type and arrangement may vary depending on the specific design of the system, wellbore conditions, and the like. Alternate metal insert designs will be described in FIGs. 9A-D, FIGs. 10A-E, FIGs. 15A- B, and FIGs. 16A-B.

[0124] In addition, in some embodiments, the plurality of metal inserts may be inserted into the insert portion of the packing unit 701 via molding of the first elastomeric packer500 around the plurality of metal inserts. In some embodiments, the plurality of metal inserts may be painted with a chemical adhesive, inserted into the insert portion of the packing unit 701, and chemically bonded to the first elastomeric packer 500. Chemically bonding the metal inserts into the first elastomeric packer 500 may occur by any method known in the art, including but not limited to curing or vulcanization of the chemical adhesive.

[0125] The number of metal inserts in the plurality of metal inserts included in the first apparatus 700 may also vary, however, according to one or more embodiments, the number of metal inserts may be in a range of between about 10 and 14 inserts. In some embodiments, the number of metal inserts included in the first apparatus 700 is 12. As would be understood by one of ordinary skill in the art, the number of metal inserts may be varied as necessary to comply with other requirements of the apparatus, including by not limited to a size of the metal insert(s) and diameter of the packing unit 701.

[0126] For simplicity, only a cutaway view of an upper piston portion 702 (e.g., an upper portion of the first tubular body 254 of the first piston 200 shown in FIG. 2A) is depicted in FIG. 7. A cutaway view of a second metal insert 400 is also shown, where the second metal insert 400 is inserted into the insert portion of the first elastomeric packer 500.

[0127] As shown in FIG. 7, a first end 202 of the upper piston portion 702 may be proximate the packing unit 701. The first end 202 of the upper piston portion 702 may include a sloped profile 252, including a first sloped portion 204 and a second sloped portion 206. Additionally, the second metal insert 400 includes a wing section 408 having a first sloped portion 482 and a second prong 412 having a second sloped portion 484. In some embodiments, the second sloped portion 484 of the second metal insert 400 may be sloped at the same angle as the second sloped portion 206 of the sloped profile 252 of the upper piston portion 702.

[0128] While the example shows how a second metal insert 400 fits within a packing unit 701 and abuts an upper piston portion 702 in the first apparatus 700 according to one or more embodiments, it is envisioned that any of the plurality of metal inserts described herein may be substituted for the second metal insert 400 in the example of FIG. 7.

[0129] The first apparatus 700 may also include a first wear plate 600 and a sleeve 640. As shown in FIG. 7, the first wear plate 600 may be located on an uphole side of the first apparatus 700, stacked on the packing unit 701. As described in FIGs. 6A-6B, the first wear plate 600 may include a plurality of cutout portions 604, which may be sized to fit, radially align with, and guide one or more prongs on a first metal insert 300 or a second metal insert 400 according to embodiments disclosed herein. In some embodiments, the first apparatus 700 may also include a sleeve 640. The sleeve 640 may be located on a downhole side of the first apparatus 700, radially within the upper piston portion 702. In one or more embodiments, the sleeve 640 may contact a downhole side of the packing unit 701. The inclusion of a first wear plate 600 and / or a sleeve 640 in first apparatus 700 may advantageously prevent tipping of the first metal insert 300 and the second metal insert 400 during activation of the first apparatus 700.

[0130] “Tipping” is defined herein as a lateral movement of one or more metal inserts within the isolation apparatus 101 disclosed herein. Specifically, tipping refers an angular deviation of a central longitudinal axis of the elongated portion of the metal inserts disclosed herein from the main the central longitudinal axis of the isolation apparatus 101, specifically during activation of the apparatus. Embodiments disclosed herein may advantageously reduce or eliminate tipping of the one or more metal inserts using systems and methods according to one or more embodiments.

[0131] In some embodiments, the first apparatus 700 may reach an extrusion gap having a size of less than approximately 4 inches. For example, the apparatus may reach an extrusion gap having a size of approximately less than 4 inches, less than 3 inches, less than 2 inches, less than 1 inch, less than 0.1 inches, or approximately 0 inches. In some embodiments, the isolation apparatus 101 may advantageously reach an extrusion gap having a size of approximately 0 inches upon sealing. For example, the apparatus may reach an extrusion gap having a size of approximately 0.1 inches, approximately 0.01 inches, approximately 0.001 inches, or approximately 0 inches. The extrusion gap size may depend on a variety of factors specific to the BOP system 100, including but not limited to a mandrel size, and whether the apparatus seals around the mandrel or around itself.

[0132] FIG. 8A shows a perspective view of a second piston 800 according to one or more embodiments disclosed herein. The second piston 800 may include a first tubular body 802 and a second tubular body 804. The second tubular body 804 includes a first end 806 and a second end 808, where the first end 806 may be located uphole and proximate the packing unit (e.g., 104 in FIG. 1 A). The first end 806 is located opposite the second end 808. An inner diameter of the first end 806 of the first tubular body 802 may have a sloped profile 810 configured to abut against a portion of the packing unit.

[0133] FIG. 8B is a cutaway view 850 of a second piston according to one or more embodiments. As best shown in FIG. 8B, the sloped profile 810 may further include a first sloped portion 812 and a second sloped portion 814. The first sloped portion 812 and the second sloped portion 814 of sloped profile 810 may be separated by a vertical step 860. The vertical step 860 of one or more embodiments may advantageously prevent tipping of a plurality of metal inserts (e.g., a third metal insert 900 and a fourth metal insert 1000) when the isolation apparatus 101 is activated according to methods disclosed herein. Features of the metal inserts will be described in more detail in the following sections.

[0134] In one or more embodiments, the vertical step 860 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the vertical step 860 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limit of about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0135] Also shown in FIG. 8B, the second tubular body 804 includes a first end 816 and a second end 818, where the first end 816 may be located uphole of the second end 818. The second end 818 of the second tubular body 804 may have a notched portion 820 configured to abut a shoulder of BOP housing (e.g., 160, as shown in FIG. IB). The notched portion 820 on the second end 818 of the second tubular body 804 may extend circumferentially around a portion of the second tubular body 804 from an inner diameter of the second tubular body 804 towards an outer diameter of the second tubular body 804.

[0136] The second piston 800 shown in FIGs. 8A-B may be substantially similar in design to the first piston as described in FIGs. 2A-B above. The second piston may advantageously have a different angle of the first sloped portion 812 and the second sloped portion 814 of the sloped profile 810 when compared to the corresponding sloped portions of the first piston. In one or more embodiments, the first sloped portion 812 of the second piston 800 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 814 of the second piston 800 may have an angle in a range of about 30° to 60°.

[0137] FIG. 9A shows a perspective view of a third metal insert 900 according to one or more embodiments. The third metal insert 900 may include an elongated portion 906 extending between a first end 902 and a second end 904, opposite the first end 902. In one or more embodiments, the elongated portion 906 of the third metal insert 900 includes a wing section 908 extending from the elongated portion 906. The wing section 908 may advantageously abut one or more portions of the piston during activation of the isolation apparatus 101 as will be described in more detail in the following sections.

[0138] The first end 902 of the third metal insert 900 may include a first prong 910 and the second end 904 of the third metal insert 900 may include a second prong 912. FIG. 9B shows a top down view 920 of a third metal insert, illustrating the features of the first prong 910. In one or more embodiments, the first prong 910 may include a three dimensional body having a generally wedge shaped profile, where the wedge shaped profile includes a tip side 922 and a base side 924, the tip side 922 being opposite the base side 924 and the wing section 908. In some embodiments, a portion of the tip side 922 may be removed to form a notch 926. The notch 926 may advantageously have an arc length designed to seal around a mandrel (e.g., 108 in FIGs. 20A-F) and / or to seal around other components of the isolation apparatus 101 according to one or more embodiments.

[0139] FIG. 9C shows a bottom view 940 of a third metal insert, illustrating the features of the second prong 912. In one or more embodiments, the second prong 912 may include a three dimensional body having a generally wedge shaped profile, where the wedgeshaped profile includes a tip side 942 and a base side 944, the tip side 942 being opposite the base side 944 and the wing section 908. In some embodiments, a portion of the tip side 942 may be removed to form a notch 946. As described above, the notch 946 may also advantageously have an arc length designed to seal around a mandrel (e.g., 108 in FIGs.20A-F) and / or to seal around other components of the isolation apparatus 101 according to one or more embodiments. As would be understood by one of ordinary skill in the art, the dimensions of the first prong 910 and the second prong 912 may vary depending on the overall design of the isolation apparatus 101 disclosed herein.

[0140] As best seen in FIG. 9D, which shows a side view 960 of the third metal insert, the wing section 908 may include a first sloped portion 962 on an outer surface of the wing section 908, proximate the second prong 912. The second prong 912 may include a second sloped portion 964 on an outer surface of the second prong 912, where the outer surface of the second prong 912 is proximate the wing section 908. The first sloped portion 962 and the second sloped portion 964 of the third metal insert 900 may advantageously abut one or more portions of the piston during activation of the isolation apparatus 101 as will be described in more detail in the following sections.

[0141] In one or more embodiments, the first sloped portion 962 on the outer surface of the wing section 908 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 964 on an outer surface of the second prong 912 may have an angle in a range of about 30° to 60°.

[0142] The first sloped portion 962 and the second sloped portion 964 of the third metal insert 900 may be separated by a third insert step 986. The third insert step 986 of one or more embodiments may advantageously prevent tipping of the third metal insert 900 when the isolation apparatus 101 is activated according to methods disclosed herein.

[0143] In one or more embodiments, the third insert step 986 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the third insert step 986 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limit of about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0144] FIG. 10A shows a perspective view of a fourth metal insert 1000 according to one or more embodiments. The fourth metal insert 1000 may include an elongated portion 1006 extending between a first end 1002 and a second end 1004, opposite the first end 1002. In one or more embodiments, the elongated portion 1006 of the fourth metal insert 1000 includes a wing section 1008 extending from the elongated portion 1006. The wing section 1008 may advantageously abut one or more portions of the piston 106 during activation of the isolation apparatus 101 as will be described in more detail in the following sections.

[0145] The first end 1002 of the fourth metal insert 1000 may include a first prong 1010 and the second end 1004 of the fourth metal insert 1000 may include a second prong 1012. FIG. 10B shows a second perspective view of a fourth metal insert 1020 of one or more embodiments, illustrating the features of the second prong 1012 located on the second end 1004. The second prong 1012 may be proximate the wing section 1008 and may include a base portion 1018 and a protrusion portion 1022.

[0146] FIG. 10C shows a top down view 1040 of a fourth metal insert, illustrating the features of the first prong 1010. In some embodiments, first prong 1010 may include a base portion 1054 and a protrusion portion 1056 extending from the base portion 1054.

[0147] The base portion 1054 may be a three dimensional body comprising a generally wedge shaped profile when viewed from above, where the wedge shaped profile may include a tip side 1042 and a base side 1050, the tip side 1042 opposite the base side 1050 and the wing section 1008. In one or more embodiments, a portion of the tip side 1042 may be removed to form a notch 1052 throughout the three dimensional body of the base portion 1054. The notch 1052 may advantageously have an arc length designed to seal around a mandrel (e.g., 108 in FIGs. 20A-F) and / or to seal around other components of the isolation apparatus 101 according to one or more embodiments. In one or more embodiments, the wedge shaped profile of the base portion 1054 may be stepped such that a first portion 1044 of the base portion 1054, proximate the tip side 1042, has a wider dimension than a second portion 1048 located opposite the first portion 1044 and extending to the base side 1050 of the base portion 1054.

[0148] The protrusion portion 1056 of the first prong 1010 may extend from an outer surface of the base portion 1054. In one or more embodiments, the protrusion portion 1056 may have a generally tapered wedge shaped profile when viewed from above, including a first side 1057 axially aligned with the base side 1050 of the base portion 1054 and a tapered side 1058 extending to the notch 1052 on the tip side 1042 of the base portion 1054.

[0149] FIG. 10D shows a bottom view 1060 of a fourth metal insert, illustrating the features of the second prong 1012. In some embodiments, the second prong 1012 may include a base portion 1074 and a protrusion portion 1076 extending from the base portion 1074.

[0150] The base portion 1074 may be a three dimensional body comprising a generally wedge shaped profile when viewed from below, where the wedge shaped profile may include a tip side 1062 and a base side 1070, the tip side 1062 opposite the base side 1070 and the wing section 1008. In one or more embodiments, a portion of the tip side 1062 may be removed to form a notch 1072 throughout the three dimensional body of the base portion 1074. The notch 1072 may advantageously have an arc length designed to seal around a mandrel (e.g., 108 in FIGs. 20A-F) and / or to seal around other components of the isolation apparatus 101 according to one or more embodiments. In one or more embodiments, the wedge shaped profile of the base portion 1074 may be stepped such that a first portion 1064 of the base portion 1074, proximate the tip side 1062, has a wider dimension than a second portion 1068 located opposite the first portion 1064 and extending to the base side 1070 of the base portion 1074.

[0151] The protrusion portion 1076 of the second prong 1012 may extend from an outer surface of the base portion 1074. In one or more embodiments, the protrusion portion 1076 may have a generally tapered wedge shaped profile, including a first side 1077 proximate the base side 1070 of the base portion 1074 and a tapered side 1078 extending to the notch 1052 on the tip side 1062 of the base portion 1074. As would be understood by one of ordinary skill in the art, the dimensions of the first prong 1010 and the second prong 1012 may vary depending on the overall design of the isolation apparatus 101 disclosed herein.

[0152] As best seen in FIG. 10E, which shows a side view 1080 of the fourth metal insert, the wing section 1008 may include a first sloped portion 1082 on an outer surface of the wing section 1008 proximate the second prong 1012. The second prong 1012 may include a second sloped portion 1084 on an outer surface of the second prong 1012, where the outer surface of the second prong 1012 is proximate the wing section 1008. The first sloped portion 1082 and the second sloped portion 1084 of the fourth metal insert 1000 may advantageously abut one or more portions of the piston during activation of the isolation apparatus 101 as will be described in more detail in the following sections.

[0153] In one or more embodiments, the first sloped portion 1082 on the outer surface of the wing section 1008 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 1084 on an outer surface of the second prong 1012 may have an angle in a range of about 30° to 60°.

[0154] The first sloped portion 1082 and the second sloped portion 1084 of the fourth metal insert 1000 may be separated by a fourth insert step 1086. The fourth insert step 1086 of one or more embodiments may advantageously prevent tipping of the fourth metal insert 1000 when the isolation apparatus 101 is activated according to methods disclosed herein.

[0155] In one or more embodiments, the fourth insert step 1086 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the fourth insert step 1086 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limit of about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0156] The third metal insert 900 and the fourth metal insert 1000 of one or more embodiments may advantageously be configured to stack upon each other when the isolation apparatus is activated according to methods disclosed herein. For example, a height of the protrusion portion 1056 located on the first prong 1010 of the fourth metal insert 1000 may advantageously be large enough such that a portion of the first prong 910 of the third metal insert 900 may slide over and stack upon a portion of the base portion 1054 of the first prong 1010 of the fourth metal insert 1000. The ability for the third metal insert 900 and the fourth metal insert 1000 of one or more embodiments to stack upon eachother when the isolation apparatus is activated may allow for a reduced extrusion gap by allowing the metal inserts to become radially closer to each other during activation of the isolation apparatus.

[0157] FIG. 11A shows a second elastomeric packer 1100 as part of the packing unit according to one or more embodiments. The second elastomeric packer 1100 includes a first side 1102 and a second side 1104. The first side 1102 of the second elastomeric packer 1100 may be oriented at an uphole location compared to the second side 1104, located opposite the first side 1102. The second elastomeric packer 1100 may include a plurality of insert portions 1106 configured to hold a plurality of metal inserts (e.g., a third metal insert 900 and a fourth metal insert 1000) in place. As shown in the cutaway view 1120 in FIG. 11B, the plurality of insert portions 1106 may extend axially throughout the second elastomeric packer 1100. The second elastomeric packer 1100 may also have cutout portions 1107, where material is removed from the second elastomeric packer 1100 in a generally triangular prism shape. The exact dimension and shape of the cutout portion 1107 may vary depending on the specific size of the elastomeric packer and the size and number of metal inserts. In one or more embodiments, the cutout portions 1107 may advantageously allow for the plurality of metal inserts to move radially inward within the second elastomeric packer 1100 when the isolation apparatus 101 is activated according to methods disclosed herein. Methods will be described in more detail in the following sections.

[0158] FIG. 11C shows a side view of a second elastomeric packer 1140, where wing cutouts 1108 are shown on the second side 1104 of the second elastomeric packer 1100. The wing cutouts 1108 prevent pinching between the material of the second elastomeric packer 1100 and the piston upon activation of the piston, as will be described in more detail in the methods sections below. The wing cutouts 1108 may match a geometry of a wing section 908, 1008 of the third metal insert 900 and the fourth metal insert 1000, respectively.

[0159] FIG. 1 ID shows a view 1160 of the first side 1102 of the second elastomeric packer 1100. Insert portions 1106 can be seen spaced periodically around a circumference of thefirst side 1102. In FIG. HE, a view 1180 of the second side 1104 of the second elastomeric packer 1100 is shown. On the second side 1104, insert portions 1106 can also be seen spaced periodically around a circumference of the second side 1104 in a pattern corresponding to the pattern shown in FIG. HD. The second side 1104 also includes cutout portions 1107, where material is removed from the second elastomeric packer 1100 in a generally triangular prism shape symmetrically to the first side 1102. Also shown in FIG. 1 IE are wing cutouts 1108, located on the second side 1104 of the second elastomeric packer 1100.

[0160] The second elastomeric packer may be constructed of the same materials as listed above with respect to the first elastomeric packer (shown in FIGs. 5A-D).

[0161] FIGs. 12A-B show a second wear plate 1200 in accordance with one or more embodiments. The second wear plate 1200 plate includes a second wear plate first side 1202, as best shown in FIG. 12A, and a second side wear plate second side 1206, as best shown in FIG. 12B. The second wear plate 1200 may also include a plurality if holes 1204 to secure the second wear plate 1200 to one or more components of the second apparatus 1300 for isolating wellbore fluids.

[0162] FIG. 13 A is a perspective view of a second apparatus 1300 for isolating wellbore fluids according to one or more embodiments. In the second apparatus 1300, a packing unit 1304 may be axially stacked uphole of a second piston 800 (such as the piston described in FIGs. 8A-B). The packing unit 1304 may include a second elastomeric packer 1100 (such as the elastomeric packer described in FIGs. 11 A-E) having a plurality of insert portions (1106 in FIG. 11 A) and cutout portions 1107. A plurality of metal inserts may be inserted into the insert portion, such as a third metal insert 900 and a fourth metal insert 1000 coupled to the second elastomeric packer 1100 as part of the packing unit 1304. In some embodiments, the third metal insert 900 and the fourth metal insert 1000 are arranged in an alternating pattern in the second elastomeric packer 1100. While the third and fourth metal insert 900, 1000 are shown in an alternating pattern, the arrangement depicted in FIGs. 13A and 13B are merely an example and is not intended to be limiting. As would be understood by one of ordinary skill in the art, the metal insert type, number, andarrangement may vary depending on the specific design of the system, wellbore conditions, and the like.

[0163] In addition, in some embodiments, the plurality of metal inserts may be inserted into the insert portion of the packing unit 1304 via molding of the second elastomeric packer 1100 around the plurality of metal inserts. In some embodiments, the plurality of metal inserts may be painted with a chemical adhesive, inserted into the insert portion of the packing unit 1304, and chemically bonded to the second elastomeric packer 1100. Chemically bonding the metal inserts into the second elastomeric packer 1100 may occur by any method known in the art, including but not limited to curing or vulcanization of the chemical adhesive.

[0164] The number of metal inserts in the plurality of metal inserts included in the second apparatus 1300 may also vary, however, according to one or more embodiments, the number of metal inserts may be in a range of between about 10 and 14 inserts. In some embodiments, the number of metal inserts included in the first apparatus 1300 is 12. As would be understood by one of ordinary skill in the art, the number of metal inserts may be varied as necessary to comply with other requirements of the apparatus, including by not limited to a size of the metal insert(s) and diameter of the packing unit 1304.

[0165] FIG. 13B shows a cutaway view 1350 of a second isolation apparatus 101. As described above, a packing unit 1304 may be stacked on a second piston 800. For simplicity, only a cutaway view of an upper portion of the piston 1352 (e.g., an upper portion of the first tubular body 802 of the second piston 800 shown in FIGs. 8A-B) is depicted in FIG. 13B. A cutaway view of a fourth metal insert 1000 is also shown, where the fourth metal insert 1000 is inserted into the insert portion of the second elastomeric packer 1100.

[0166] As shown in FIG. 13B, a first end 806 of the upper portion of the piston 1352 may be proximate the packing unit 1304. The first end 806 of the upper portion of the piston 1352 may include a sloped profile 810, including a first sloped portion 812 and a second sloped portion 814. Additionally, the fourth metal insert 1000 includes a wing section 1008 having a first sloped portion 1082 and a second prong 1012 having a second slopedportion 1084. In some embodiments, the first sloped portion 1082 of the fourth metal insert 1000 may be sloped at the same angle as the second sloped portion 814 of the sloped profile 810 of the portion of the piston 1352. In some embodiments, the second sloped portion 1084 of the fourth metal insert 1000 may be sloped at the same angle as the second sloped portion 814 of the sloped profile 810 of the portion of the piston 1352. While the example shows how a fourth metal insert 1000 fits within a packing unit 1304 and abuts an upper portion of a piston 1352 in the second apparatus 1300 according to one or more embodiments, it is envisioned that any of the plurality of metal inserts described herein may be substituted for the fourth metal insert 1000 in the example of FIG. 13B.

[0167] One or more systems disclosed herein may include a third piston. FIG. 14 is a cutaway view of a third piston 1400 according to one or more embodiments. The third piston 1400 may include a first tubular body 1402 and a second tubular body 1404. The second tubular body 1404 includes a first end 1406 and a second end 1408, where the first end 1406 may be located uphole and proximate the packing unit (e.g., 104 in FIG.1A). The first end 1406 is located opposite the second end 1408. An inner diameter of the first end 1406 of the first tubular body 802 may have a sloped profile 1410 configured to abut against a portion of the packing unit. The sloped profile 1410 may further include a first sloped portion 1412 and a second sloped portion 1414. The first sloped portion 1412 and the second sloped portion 1414 of sloped profile 1410 may be separated by a vertical step 1460. The vertical step 1460 of one or more embodiments may advantageously prevent tipping of a plurality of metal inserts (e.g., a fifth metal insert 1500 and a sixth metal insert 1600) when the isolation apparatus 101 is activated according to methods disclosed herein. Features of the metal inserts will be described in more detail in the following sections.

[0168] In one or more embodiments, the vertical step 1460 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the vertical step 1460 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limit of about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0169] In one or more embodiments, the second end 1418 of the second tubular body 1404 may have a notched portion 1420 configured to abut a BOP housing shoulder 160, as shown in FIG. IB. The notched portion 1420 on the second end 1418 of the second tubular body 1404 may extend circumferentially around a portion of the second tubular body 1404 from an inner diameter of the second tubular body 1404 towards an outer diameter of the second tubular body 1404.

[0170] The third piston 1400 shown in FIG. 14 may be substantially similar in design to the first piston and the second piston described above. The third piston 1400 may advantageously have a different angle of the first sloped portion 1412 and the second sloped portion 1414 of the sloped profile 1410 when compared to the corresponding sloped portions of the first piston and the second piston. In one or more embodiments, the first sloped portion 1412 of the third piston 1400 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 1414 of the third piston 1400 may have an angle in a range of about 30° to 60°.

[0171] FIG. 15A shows a perspective view of a fifth metal insert 1500 according to one or more embodiments. The fifth metal insert 1500 may include an elongated portion 1506 extending between a first end 1502 and a second end 1504, opposite the first end 1502. In one or more embodiments, the elongated portion 1506 of the fifth metal insert 1500 includes a wing section 1508 extending from the elongated portion 1506. The wing section 1508 may advantageously abut one or more portions of the piston during activation of the isolation apparatus 101 as will be described in more detail in the following sections.

[0172] The first end 1502 of the fifth metal insert 1500 may include a first prong 1510 and the second end 1504 of the fifth metal insert 1500 may include a second prong 1512. The shape of the first prong 1510 and the second prong 1512 may be substantially similar to the shape of the first prong 910 of the third metal insert 900 and the second prong 912 of the third metal insert 900. Thus, for the sake of brevity, the similar features will not be discussed in detail herein.

[0173] As best seen in FIG. 15B, which shows a side view 1560 of the fifth metal insert, the wing section 1508 may include a first sloped portion 1562 on an outer surface of the wing section 1508, proximate the second prong 1512. The second prong 1512 may include a second sloped portion 1564 on an outer surface of the second prong 1512, where the outer surface of the second prong 1512 is proximate the wing section 1508. The first sloped portion 1562 and the second sloped portion 1564 of the fifth metal insert 1500 may advantageously abut one or more portions of the piston during activation of the isolation apparatus 101 as will be described in more detail in the following sections.

[0174] In one or more embodiments, the first sloped portion 1562 on the outer surface of the wing section 1508 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 1564 on an outer surface of the second prong 1512 may have an angle in a range of about 30° to 60°.

[0175] The first sloped portion 1562 and the second sloped portion 1564 of the fifth metal insert 1500 may be separated by a fifth insert step 1586. The fifth insert step 1586 of one or more embodiments may advantageously prevent tipping of the fifth metal insert 1500 when the isolation apparatus 101 is activated according to methods disclosed herein.

[0176] In one or more embodiments, the fifth insert step 1586 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the fifth insert step 1586 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limit of about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0177] FIG. 16A shows a perspective view of a sixth metal insert 1600 according to one or more embodiments. The sixth metal insert 1600 may include an elongated portion 1606 extending between a first end 1602 and a second end 1604, opposite the first end 1602. In one or more embodiments, the elongated portion 1606 of the sixth metal insert 1600 includes a wing section 1608 extending from the elongated portion 1606. The wing section 1608 may advantageously abut one or more portions of the piston during activation of the isolation apparatus 101 as will be described in more detail in the following sections.

[0178] The first end 1602 of the sixth metal insert 1600 may include a first prong 1610 and the second end 1604 of the sixth metal insert 1600 may include a second prong 1612. The shape of the first prong 1610 and the second prong 1612 may be substantially similar to the shape of the first prong 1010 of the fourth metal insert 1000 and the second prong 1012 of the fourth metal insert 1000. Thus, for the sake of brevity, the similar features will not be discussed in detail herein.

[0179] As best seen in FIG. 16B, which shows a side view 1680 of the sixth metal insert, the wing section 1608 may include a first sloped portion 1682 on an outer surface of the wing section 1608. The first sloped portion 1682 may be located on a portion of the wing section 1608 proximate the second prong 1612. The second prong 1612 may further include a second sloped portion 1684 on an outer surface of the second prong 1612, where the outer surface of the second prong 1612 may be proximate the wing section 1608. The first sloped portion 1682 and the second sloped portion 1684 of the sixth metal insert 1600 may advantageously abut one or more portions of the piston during activation of the isolation apparatus 101 as will be described in more detail in the following sections.

[0180] In one or more embodiments, the first sloped portion 1682 on the outer surface of the wing section 1608 may have an angle in a range of about 30° to 60°. In one or more embodiments, the second sloped portion 1684 on an outer surface of the second prong 1612 may have an angle in a range of about 30° to 60°.

[0181] The first sloped portion 1682 and the second sloped portion 1684 of the sixth metal insert 1600 may be separated by a sixth insert step 1686. The sixth insert step 1686 of one or more embodiments may advantageously prevent tipping of the sixth metal insert 1600 when the isolation apparatus 101 is activated according to methods disclosed herein.

[0182] In one or more embodiments, the sixth insert step 1686 may have a length in a range of from about 0.5 inches to about 3 inches. For example, the length of the sixth insert step 1686 may be in a range having a lower limit of from about 0.5, 0.75, and 1 inch to an upper limit of about 1.5, 2, and 3 inches, where any lower limit may be paired with any mathematically compatible upper limit.

[0183] The fifth metal insert 1500 and the sixth metal insert 1600 of one or more embodiments may advantageously be configured to stack upon each other when the isolation apparatus is activated according to methods disclosed herein. For example, a height of the protrusion portion 1616 located on the first prong 1610 of the sixth metal insert 1600 may advantageously be large enough such that a portion of the first prong 1510 of the fifth metal insert 1500 may slide over and stack upon a portion of the base portion 1614 of the first prong 1610 of the sixth metal insert 1600. The ability for the fifth metal insert 1500 and the sixth metal insert 1600 of one or more embodiments to stack upon each other when the isolation apparatus is activated may allow for a reduced extrusion gap by allowing the metal inserts to become radially closer to each other during activation of the isolation apparatus.

[0184] FIG. 17A shows a third elastomeric packer 1700 as part of the packing unit 104 according to one or more embodiments. The third elastomeric packer 1700 includes a first side 1702 and a second side 1704. The first side 1702 of the third elastomeric packer 1700 may be oriented at an uphole location compared to the second side 1704, located opposite the first side 1702. The third elastomeric packer 1700 may include a plurality of insert portions 1106 configured to hold a plurality of metal inserts (e.g., a fifth metal insert 1500 and a sixth metal insert 1600) in place. As shown in the cutaway view 1720 in FIG. 17B, the plurality of insert portion 1706 may extend axially throughout the third elastomeric packer 1700. The third elastomeric packer 1700 may also have cutout portions 1707, where material is removed from the third elastomeric packer 1700 in a generally triangular prism shape. The exact dimension and shape of the cutout portion 1707 may vary depending on the specific size of the elastomeric packer and the size and number of metal inserts. In one or more embodiments, the cutout portions 1707 may advantageously allow for the plurality of metal inserts to move radially inward within the third elastomeric packer 1700 when the isolation apparatus 101 is activated according to methods disclosed herein. Methods will be described in more detail in the following sections.

[0185] FIG. 17C shows a side view 1740 of a third elastomeric packer, where wing cutouts 1708 are shown on the second side 1704 of the third elastomeric packer 1700. The wingcutouts 1708 may have a geometry matching the wing portions of the fifth and sixth metal inserts 1500, 1600, respectively. The wing cutouts 1708 prevent pinching between the material of the third elastomeric packer 1700 and the piston upon activation of the piston, as will be described in more detail in sections below. In some embodiments, the third elastomeric packer 1700 may be substantially similar to the second elastomeric packer 1100 as described above.

[0186] The third elastomeric packer may be constructed of the same materials as listed above with respect to the first elastomeric packer (shown in FIGs. 5A-D).

[0187] The third apparatus 1900 for isolating wellbore fluids may also include a wear plate, for example the second wear plate 1200 as described in FIGs. 12A-B, above.

[0188] FIG. 18A is a perspective view of a third apparatus 1900 for isolating wellbore fluids according to one or more embodiments. In the third apparatus 1900, a packing unit 1902 may be axially stacked uphole of a third piston 1400 (such as the piston described in FIG. 14). The packing unit 1902 may include a third elastomeric packer 1700 (such as the elastomeric packer described in FIGs. 17A-C) having a plurality of insert portions (1706 in FIG. 17A) and cutout portions 1707. A plurality of metal inserts may be inserted into the insert portion, such as a fifth metal insert 1500 and a sixth metal insert 1600 coupled to the third elastomeric packer 1700 as part of the packing unit 1902. In some embodiments, the fifth metal insert 1500 and the sixth metal insert 1600 are arranged in an alternating pattern in the third elastomeric packer 1700. While the fifth and sixth metal inserts 1500, 1600 are shown in an alternating pattern, the arrangement depicted in FIGs. 18A and 18B are merely an example and is not intended to be limiting. As would be understood by one of ordinary skill in the art, the metal insert type, number, and arrangement may vary depending on the specific design of the system, wellbore conditions, and the like.

[0189] In addition, in some embodiments, the plurality of metal inserts may be inserted into the insert portion of the packing unit 1902 via molding of the third elastomeric packer 1700 around the plurality of metal inserts. In some embodiments, the plurality of metal inserts may be painted with a chemical adhesive, inserted into the insert portion of the packing unit 1902, and chemically bonded to the third elastomeric packer 1700.Chemically bonding the metal inserts into the third elastomeric packer 1700 may occur by any method known in the art, including but not limited to curing or vulcanization of the chemical adhesive.

[0190] The number of metal inserts in the plurality of metal inserts included in the third apparatus may also vary, however, according to one or more embodiments, the number of metal inserts may be in a range of between about 10 and 14 inserts. In some embodiments, the number of metal inserts included in the third apparatus 900 is 12. As would be understood by one of ordinary skill in the art, the number of metal inserts may be varied as necessary to comply with other requirements of the apparatus, including by not limited to a size of the metal insert(s) and diameter of the packing unit 1902.

[0191] FIG. 18B shows a cutaway view 1950 of a second isolation apparatus. As described above, a packing unit 1902 may be stacked on a third piston 1400. For simplicity, only a cutaway view of an upper portion of the piston 1952 (e.g., an upper portion of the first tubular body 1402 of the third piston 1400 shown in FIG. 14) is depicted in FIG. 18B. A cutaway view of a sixth metal insert 1600 is also shown, where the sixth metal insert 1600 is inserted into the insert portion of the third elastomeric packer 1700.

[0192] As shown in FIG. 18B, a first end 1406 of the upper portion of the piston 1952 may be proximate the packing unit 1902. The first end 1406 of the upper portion of the piston 1952 may include a sloped profile 1410, including a first sloped portion 1412 and a second sloped portion 1414. Additionally, the sixth metal insert 1600 includes a wing section 1608 having a first sloped portion 1662 and a second prong 1612 having a second sloped portion 1664. In some embodiments, the first sloped portion 1662 of the sixth metal insert 1600 may be sloped at the same angle as the second sloped portion 1414 of the sloped profile 1410 of the portion of the piston 1952. In some embodiments, the second sloped portion 1664 of the sixth metal insert 1600 may be sloped at the same angle as the second sloped portion 1414 of the sloped profile 1410 of the portion of the piston 1952. While the example shows how a sixth metal insert 1600 fits within a packing unit 1902 and abuts an upper portion of a piston 1952 in the third apparatus 1900 according to one or more embodiments, it is envisioned that any of the plurality of metal insertsdescribed herein may be substituted for the sixth metal insert 1600 in the example of FIG.18B.

[0193] Embodiments disclosed herein also relate to methods for operating a blowout prevention (BOP) system to isolate wellbore fluids. In one or more embodiments, methods include providing the BOP system to a wellbore, applying a pressure to the apparatus in a series of stages, sealing a central circumference of the metal inserts when a closing pressure is applied, and unsealing the central circumference of the metal inserts when an opening pressure is applied.

[0194] In one or more embodiments, the method for operating a BOP system to isolate wellbore fluids includes providing the BOP system to a wellbore. The BOP system used in methods disclosed herein may include any of the components described in the above sections. For example, the BOP system may include an isolation apparatus 101, where the apparatus includes a packing unit, having a plurality of metal inserts, including one or more of a first metal insert and one or more of a second metal insert, disposed in an elastomeric packer, and a piston located downhole of and proximate to the packing unit. The BOP system may also include a BOP housing radially surrounding the apparatus, where the piston and the packing unit are axially stacked within the BOP housing.

[0195] In one or more embodiments, the method for operating a BOP system to isolate wellbore fluids further includes applying a pressure to the apparatus in a series of stages. The applied pressure may include an opening pressure and a closing pressure, where the opening pressure moves the piston in a downhole direction and the closing pressure moves the piston in an uphole direction. The phrase “series of stages” as used herein refers to arbitrary units of closing or opening pressure applied to the apparatus. The phrase “series of stages” does not specifically refer to a concrete number of stages; the phrase is used only to help illustrate movement of components within the apparatus when a closing or opening pressure is applied to the apparatus and is in no way intended to be limiting. The series of stages will be described in more detail in the sections below. The series of stages will be described in more detail in the sections below.

[0196] In one or more embodiments, the method for operating a BOP system to isolate wellbore fluids further includes sealing a central circumference of the metal inserts when the closing pressure is applied by compressing the packing unit with the piston when the piston is moved uphole, where upon compressing, the packing unit moves the plurality of metal inserts radially inward to form a seal. In one or more embodiments, the method for operating a BOP system to isolate wellbore fluids further includes unsealing the central circumference of the metal inserts when the opening pressure is applied by decompressing the packing unit when the piston is moved downhole, where upon decompressing, the packing unit moves the plurality of metal seals radially outward to release the seal. In one or more embodiments, upon sealing the central circumference of the metal inserts when the closing pressure is applied to form the seal, an extrusion gap within the apparatus has a size of less than approximately four inches. In one or more embodiments, the BOP system further includes a mandrel extending through a central circumference of the packing unit and the piston, and, upon sealing the central circumference of the metal inserts when the closing pressure is applied to form the seal, the seal is formed around the mandrel and an extrusion gas within the apparatus has a size of approximately zero.

[0197] A description of methods disclosed herein will now be made in reference to FIGs.19A-F. FIGs. 19A-F show how the apparatus for isolating fluids in a wellbore (700 as shown in FIG. 7) is operated to provide a seal around a mandrel after applying a closing pressure to the apparatus in a series of stages. While the apparatus shown in FIG. 7 is used to illustrate the method, other systems and components as disclosed herein may be substituted in the method without departing from the present disclosure.

[0198] FIG. 19A shows an initial position 2000 of the apparatus for isolating fluids in a wellbore. The elements in FIG. 19A correspond to those shown and described in FIG. 7, except that a first metal insert 300 is shown in a cutaway view (instead of a second metal insert 400 shown in a cutaway view in FIG. 7). For example, a packing unit 701 is shown axially stacked at an uphole position from an upper piston portion 702. The packing unit 701 and the upper piston portion 702 each include a generally central hole such that, whenstacked, an inner flow path is formed axially throughout. A mandrel 108 is shown inserted into said inner flow path.

[0199] In FIG. 19 A, a first metal insert 300 is inserted into a first elastomeric packer 500 as part of the packing unit 701. The first metal insert 300 includes a wing section 308 having a first sloped portion 382 and a second prong 312 having a second sloped portion 384. The upper piston portion 702 includes a first sloped portion 204 and a second sloped portion 206. As shown in FIG. 19A, the upper piston portion 702 is located at an initial position 2002 and will move axially uphole a first distance 2004 to a first position 2006. Although not shown in FIG. 19A, note that, when the piston is in the initial position 2002, no pressure is applied to the piston and a second tubular body of the piston (256 in FIG.2A) having a notched portion (258 in FIG. 2B) abuts a shoulder of a BOP housing (160 in FIG. IB).

[0200] When a first applied pressure is applied to the system in the initial position 2000 shown in FIG. 19A, a first stroke causes the piston portion 704 to move the first distance 2004 to a first position 2006, and the system moves to the first position 2010, shown in FIG. 19B. In moving from FIG. 19A to FIG. 19B, a first stroke as a part of the series of stages of applied closing pressure has occurred. During the first stroke, upper piston portion 702 moves the first distance 2004 and the first end 202 of the upper piston portion 702 contacts a first portion 2018 of the elastomeric packer, compressing the elastomeric packer in a first compression 2012.

[0201] When a second applied pressure is applied to the system in the first position 2010 shown in FIG. 19B, a second stroke causes the upper piston portion 702 to move a second distance 2014 to a second position 2016 and the system moves to the second position 2016, shown in FIG. 19C. In moving from FIG. 19B to FIG. 19C, a second stroke as a part of the series of stages of applied closing pressure has occurred. During the second stroke, upper piston portion 702 moves the second distance 2014 and the second sloped portion 206 of upper piston portion 702 contacts the second sloped portion 384 of the first metal insert 300. Movement of the first metal insert responsive to the second stroke alsocontacts a second portion 2028 the elastomeric packer, compressing the elastomeric packer in a second compression 2022, as shown in FIG. 19C.

[0202] When a third applied pressure is applied to the system in the second position 2020 shown in FIG. 19C, a third stroke causes the upper piston portion 702 to move a third distance 2024 to a third position 2026 and the system moves to the third position 2030, shown in FIG. 19D. In moving from FIG. 19C to FIG. 19D, a third stroke as a part of the series of stages of applied closing pressure has occurred. During the third stroke, upper piston portion 702 moves the third distance 2024 and the first end 202 of the upper piston portion 702 contacts a third portion 2038 of the elastomeric packer, compressing the elastomeric packer in a third compression 2032, as shown in FIG. 19D.

[0203] When a fourth applied pressure is applied to the system in the third position 2030 shown in FIG. 19D, a fourth stroke causes the piston portion 704 to move a fourth distance 2034 to a fourth position 2036 and the system moves to the fourth position 2040, shown in FIG. 19E. In moving from FIG. 19D to FIG. 19E, a fourth stroke as a part of the series of stages of applied closing pressure has occurred. During the fourth stroke, upper piston portion 702 moves the fourth distance 2034 and the first sloped portion 204 of piston portion 704 contacts the first sloped portion 382 of the first metal insert 300. Movement of the first metal insert 300 responsive to the fourth stroke also contacts a fourth portion 2048 of the elastomeric packer, compressing the elastomeric packer in a fourth compression 2042, as shown in FIG. 19E.

[0204] Finally, when a fifth applied pressure is applied to the system in the fourth position 2040 shown in FIG. 19E, a fifth stroke causes the upper piston portion 702 to move a fifth distance 2044 to a fifth position 2046 and the system moves to the fifth position 2050, shown in FIG. 19F. In moving from FIG. 19E to FIG. 19F, a fifth stroke as a part of the series of stages of applied closing pressure has occurred. During the fifth stroke, upper piston portion 702 moves the fifth distance 2044 and the first end 202 of the piston portion 704 contacts a fifth portion 2058 of the elastomeric packer, compressing the elastomeric packer in a fifth compression to produce a fifth compressed elastomeric packer 2052, as shown in FIG. 19F.

[0205] FIG. 19F shows the system in the final position 2050. In FIG. 19F, piston portion 704 has moved from the initial position 2002 shown in FIG. 19A to the fifth position (or final position) 2054. When in the fifth position 2054, the first prong 310 and the second prong 312 of the first metal insert 300 and the compressed elastomeric packer 2052 provide a seal around mandrel 108 by moving radially inward to close a central circumference of the isolation apparatus 101 when the closing pressure is applied. Upon sealing the central circumference of the metal inserts when the closing pressure is applied to form the seal, an extrusion gap 2056 (e.g., radial distance between the first metal insert 300 and the mandrel 108) within the apparatus has a size of approximately zero inches.

[0206] As would be understood by one of ordinary skill in the art, though not explicitly shown, the methods and procedures described in the above sections may be reversed. For example, moving from FIG. 19E to FIG. 19A illustrates a method for decompressing a packing unit according to one or more embodiments. Decompressing the packing unit may occur when an opening pressure is applied to the isolation apparatus 101, whereby the central circumference of the metal inserts is unsealed when the piston is moved downhole. Upon decompressing, the packing unit moves the plurality of metal inserts radially outward to release the seal.

[0207] A description of methods disclosed herein will now be made in reference to FIGs.20A-B. FIGs. 20A-B show an initial position (in FIG. 20 A) and a final position (in FIG.20B) of the apparatus for isolating fluids in a wellbore (700 as shown in FIG. 7) is operated to provide a seal around itself after applying a closing pressure to the apparatus in a series of stages. While the apparatus shown in FIG. 7 is used to illustrate the method, other systems and components as disclosed herein may be substituted in the method without departing from the present disclosure.

[0208] The methods and procedures described above with regard to FIGs. 19A-F may be the same as applied to the system 2100 in FIG. 20A. FIG. 20A shows an initial position of the system 2100 for isolating fluids in a wellbore. The elements in FIG. 20 A correspond to those shown and described in FIG. 7, except that a first metal insert 300 is shown in a cutaway view (instead of a second metal insert 400 shown in a cutaway viewin FIG. 7). In the system 2100 of FIG. 20A, a packing unit 701 is shown axially stacked at an uphole position from an upper piston portion 702. The packing unit 701 and the upper piston portion 702 each include a generally central hole such that, when stacked, an inner flow path 2104 is formed axially throughout. The first elastomeric packer 500 is in an uncompressed state and the upper piston portion 702 in an initial position 2102.

[0209] In moving from FIG. 20A to FIG. 20B, applying a closing pressure to the isolation apparatus 101 in a series of stages causes the apparatus to seal around itself. In one or more embodiments, the series of stages includes a first stroke, a second stroke, a third stroke, a fourth stroke, and a fifth stroke, as described in regard to FIGs. 19A-F, above. For brevity, the stages will not be described in detail herein. FIG. 20B shows the system in the final position 2120, where upper piston portion 702 has moved from the initial position 2102 shown in FIG. 20A to the final position 2122. When in the final position 2122, the first prong 310 and the second prong 312 of the first metal insert 300 and the first elastomeric packer 500 provide a seal around itself by moving radially inward to close a central circumference of the metal inserts for isolating wellbore fluids (700 in FIG. 7) when the closing pressure is applied. In the final position, the elastomeric packer is compressed to a final position 2126 and the central circumference is in a final, closed position 2124. Upon sealing the central circumference of the metal inserts when the closing pressure is applied to form the seal, an extrusion gap 2128 (e.g., radial distance between the prongs of the first metal insert 300 and a radially opposite first / second metal insert 300, 400) within the apparatus has a size of less than approximately four inches, as described above.

[0210] Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.

Claims

CLAIMSWhat is claimed:

1. A blowout preventer (BOP) system comprising:an apparatus configured to isolate wellbore fluids and comprising a packing unit and a piston, wherein the piston is located downhole of and proximate to the packing unit,wherein the packing unit comprises an elastomeric packer having a plurality of metal inserts disposed axially through a plurality of insert portions in the elastomeric packer, andwherein the plurality of metal inserts comprises a first metal insert and a second metal insert and each of the first metal insert and the second metal insert independently comprises an elongated portion extending between a first end having a first prong and a second end having a second prong; anda BOP housing radially surrounding the apparatus, wherein the piston and the packing unit are axially stacked within the BOP housing.

2. The BOP system of claim 1, further comprising a mandrel extending through a central circumference of the packing unit and the piston, wherein the BOP system is configured to dynamically adjust such that a seal is formed around the mandrel when the apparatus is activated.

3. The BOP system of claim 1 or 2, wherein the plurality of first metal inserts and the plurality of second metal inserts are arranged in an alternating pattern in the elastomeric packer.

4. The BOP system of claim 1 or 2, further comprising a sleeve located radially within the piston on a downhole side of the packing unit.

5. The BOP system of claim 1 or 2, further comprising a wear plate located on an uphole side of the packing unit, wherein the uphole side of the packing unit is opposite the piston.

6. The BOP system of claim 6, wherein a first side of the wear plate comprises a plurality of cutout portions configured to radially align with and guide the first prong of the first metal insert and the first prong of the second metal insert.

7. The BOP system of claim 1 or 2, wherein the piston comprises:a first tubular body having a first end and a second end, wherein the first end is located uphole and proximate the packing unit,wherein an inner diameter of the first end comprises a sloped profile configured to abut against a portion of the packing unit, wherein the sloped profile comprises a first sloped portion and a second sloped portion, the second sloped portion positioned to contact a sloped portion of an outer surface of the first metal insert and the second metal insert upon activation of the piston, and wherein the first sloped portion and the second sloped portion of sloped profile are separated by a vertical step configured to prevent tipping; anda second tubular body located circumferentially around an outer surface of the first tubular body,wherein the second tubular body protrudes a radial distance from the first tubular body such that the second tubular body has a larger outer diameter than the first tubular body,wherein the second tubular body comprises a first end and a second end, the first end located uphole of the second end, andwherein the second end of the second tubular body comprises a notched portion extending circumferentially around a portion of the second tubular body from an inner diameter of the second tubular body towards an outer diameter of the second tubular body, the notched portion configured to abut a shoulder of the BOP housing.

8. The BOP system of claim 1 or 2, wherein:the elongated portion of the first metal insert and the second metal insert comprises a wing section extending from the elongated portion;the wing section comprises a first sloped portion located on an outer surface of the wing section proximate the second prong;the second prong comprises a second sloped portion on an outer surface of the second prong proximate the wing section; andthe first sloped portion and the second sloped portion are separated by an insert step configured to prevent tipping.

9. The BOP system of claim 8, wherein the first prong and the second prong of the first metal insert comprise a base portion having a three dimensional body comprising a wedge shaped profile, the wedge shaped profile having a tip side and a base side, the tip side opposite the base side and the wing section,wherein a portion of the tip side is removed to form a notch, andwherein the first prong further comprises a protrusion portion, extending from the base portion, the protrusion portion having a first side and a second side and a “T” shaped profile, wherein the first side of the protrusion portion is axially aligned with the base side of the base portion.

10. The BOP system of claim 8, wherein the first prong and the second prong of the second metal insert comprise:a base portion having a three dimensional body comprising a wedge shaped profile, the wedge shaped profile including a tip side and a base side, the tip side opposite the base side and the wing section,wherein a portion of the tip side is removed to form a notch through the three dimensional body,wherein the wedge shaped profile is stepped such that a first portion of the base portion proximate the tip side has a wider dimension than a second portion located opposite the first portion and extending to the base side of the base portion; anda first protrusion portion extending from an outer surface of the base portion, the first protrusion portion comprising a tapered wedge shaped profile including a first side axially aligned with the base side of the base portion and a tapered side extending to the notch on the tip side of the base portion, wherein the first prong further comprises a second protrusion portion, extending from an outer surface of the first protrusion portion, the second protrusion portion having a first side and a second side and a “T” shaped profile, wherein the first side of the second protrusion portion is axially aligned with the first side of the first protrusion portion.

11. A method for operating a blowout prevention (BOP) system, the method comprising:providing the BOP system to a wellbore, the BOP system comprising;an apparatus configured to isolate wellbore fluids and comprising a packing unit and a piston located downhole of and proximate to the packing unit,wherein the packing unit comprises an elastomeric packer having a plurality of metal inserts disposed axially through a plurality of insert portions in the elastomeric packer, and wherein the plurality of metal inserts comprises a first metal insert and a second metal insert and each of the first metal insert and the second metal insert independently comprises an elongated portion extending between a first end having a first prong and a second end having a second prong; and a BOP housing radially surrounding the apparatus, wherein the piston and the packing unit are axially stacked within the BOP housing; applying a pressure to the apparatus in a series of stages, wherein the applied pressure comprises an opening pressure and a closing pressure, wherein the opening pressure moves the piston in a downhole direction and the closing pressure moves the piston in an uphole direction;sealing a central circumference of the plurality of metal inserts when the closing pressure is applied by compressing the packing unit with the piston when the piston is moved uphole, wherein, upon compressing, the packing unit moves the plurality of metal inserts radially inward to form a seal; and unsealing the central circumference of the plurality of metal inserts when the opening pressure is applied by decompressing the packing unit when the piston is moved downhole, wherein, upon decompressing, the packing unit moves the plurality of metal inserts radially outward to release the seal.

12. The method of claim 11, wherein the BOP system further comprises:a sleeve located radially within the piston; anda wear plate located on a first side of the packing unit, wherein the first side of the packing unit is opposite the piston, wherein a first side of the wear plate comprises a plurality of cutout portions configured to radially align with and guide the first prong of the first metal insert and the first prong of the second metal insert.

13. The method of claim 11 or 12, wherein the piston comprises:a first tubular body having a first end and a second end, the first end located uphole and proximate the packing unit,wherein an inner diameter of the first end comprises a sloped profile configured to abut against a portion of the packing unit, and wherein the sloped profile comprises a first sloped portion and a second sloped portion, the second sloped portion positioned to contact a sloped portion of an outer surface of the first metal insert and the second metal insert upon activation of the piston, and wherein the first sloped portion and the second sloped portion of sloped profile are separated by a vertical step configured to prevent tipping; anda second tubular body located circumferentially around an outer surface of the first tubular body,wherein the second tubular body protrudes a radial distance from the first tubular body such that the second tubular body has a larger outer diameter than the first tubular body,wherein the second tubular body comprises a first end and a second end, the first end located uphole of the second end, andwherein the second end of the second tubular body comprises a notched portion extending circumferentially around a portion of the second tubular body from an inner diameter of the second tubular body towards an outer diameter of the second tubular body, the notched portion configured to abut a shoulder of the BOP housing.

14. The method of claim 11 or 12, wherein the elongated portion of the first metal insert and the second metal insert comprises a wing section extending from the elongated portion; the wing section comprises a first sloped portion located on an outer surface of the wing section proximate the second prong;the second prong comprises a second sloped portion on an outer surface of the second prong proximate the wing section; andthe first sloped portion and the second sloped portion are separated by an insert step configured to prevent tipping.

15. The method of claim 14, wherein the first prong and the second prong of the first metal insert comprise:a base portion having a three dimensional body comprising a wedge shaped profile, the wedge shaped profile having a tip side and a base side, the tip side opposite the base side and the wing section,wherein a portion of the tip side is removed to form a notch, andwherein the first prong further comprises a protrusion portion, extending from the base portion, the protrusion portion having a first side and a second side and a “T” shaped profile, wherein the first side of the protrusion portion is axially aligned with the base side of the base portion.

16. The method of claim 14, wherein the first prong and the second prong of the second metal insert comprise:a base portion having a three dimensional body comprising a wedge shaped profile, the wedge shaped profile including a tip side and a base side, the tip side opposite the base side and the wing section,wherein a portion of the tip side is removed to form a notch through the three dimensional body,wherein the wedge shaped profile is stepped such that a first portion of the base portion proximate the tip side has a wider dimension than a second portion located opposite the first portion and extending to the base side of the base portion; anda first protrusion portion extending from an outer surface of the base portion, the first protrusion portion comprising a tapered wedge shaped profile including a first side axially aligned with the base side of the base portion and a tapered side extending to the notch on the tip side of the base portion, wherein the first prong further comprises a second protrusion portion, extending from an outer surface of the first protrusion portion, the second protrusion portion having a first side and a second side and a “T” shaped profile, wherein the first side of the second protrusion portion is axially aligned with the first side of the first protrusion portion.

17. The method of claim 14, wherein when the applied pressure is the closing pressure, the series of stages comprises:a first stroke, wherein the first stroke is responsive to a first applied pressure and the first stroke moves the piston a first distance such that the piston contacts a first portion of the elastomeric packer;a second stroke, wherein the second stroke is responsive to a second applied pressure and the second stroke moves the piston a second distance such that the piston contacts the second sloped portion of the second prong of the plurality of metal inserts and a second portion of the elastomeric packer;a third stroke, wherein the third stroke is responsive to a third applied pressure and the third stroke moves the piston a third distance such that the piston contacts a third portion of the elastomeric packer;a fourth stroke, wherein the fourth stroke is responsive to a fourth applied pressure and the fourth stroke moves the piston a fourth distance such that the piston contacts the first sloped portion of the wing section of the plurality of metal inserts and a fourth portion of the elastomeric packer; and a fifth stroke, wherein the fifth stroke is responsive to a third applied pressure and the third stroke moves the piston a fifth distance such that the piston contacts a fifth portion of the elastomeric packer.

18. The method of claim 17, wherein, upon sealing the central circumference of the plurality of metal inserts when the closing pressure is applied to form the seal, an extrusion gap within the apparatus has a size of less than four inches.

19. The method of claim 17, wherein the BOP system further comprises a mandrel extending through a central circumference of the packing unit and the piston, wherein, upon sealing the central circumference of the plurality of metal inserts when the closing pressure is applied to form the seal, the seal is formed around the mandrel and an extrusion gap within the apparatus has a size of approximately zero.

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