Device and method to seal boreholes

• US 7,578,354 B2
• Filed: 06/11/2007
• Issued: 08/25/2009
• Est. Priority Date: 01/26/2001
• Status: Expired due to Term

• Current Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Original Assignee: E2tech Limited
• Inventors: Thomson, Neil
• Primary Examiner(s): THOMPSON, KENNETH L
• Application Number:
  US11/761,283
• Publication Number:
  US 20080000646A1
• Time in Patent Office: 806 Days
• Field of Search: 166/387, 166/207, 166/191, 166/297, 166/384, 166/55, 166/179, 166/187, 277/322, 277944-946, 277/934
• US Class Current: 166/387
• CPC Class Codes: E21B 33/1208 characterised by the construction of the sealing or packing means E21B33/1277 takes precedence
• CPC Class Codes: E21B 33/14 for cementing casings into boreholes
• CPC Class Codes: E21B 43/103 of expandable casings, screens, liners, or the like
• CPC Class Codes: Y10S 277/934 Seal swells when wet
• CPC Class Codes: Y10S 277/944 Elastomer or plastic

Abstract

Apparatus and methods are described that are particularly suited for creating a seal in a borehole annulus. In one embodiment, an outer surface 10s of an expandable conduit 10 is provided with a formation 20 that includes an elastomeric material (e.g. a rubber) that can expand and/or swell when the material comes into contact with an actuating agent (e.g. water, brine, drilling fluid etc.). The expandable conduit 10 is located inside a second conduit (e.g. a pre-installed casing, liner or open borehole) and radially expanded. The actuating agent can be naturally occurring in the borehole or can be injected or pumped therein to expand or swell the elastomeric material to create the seal.

Claims

1. A seal for use in a borehole, the seal comprising:

an elastomeric material that is capable of expanding or swelling upon contact with an actuating agent, wherein the elastomeric material is applied to an outer surface of a conduit and wherein the conduit has a first diameter prior to expansion and a second larger diameter after expansion; and

a soluble material disposed around the elastomeric material, wherein the soluble material is configured to at least partially dissolve upon contact with a fluid.

2. The seal according to claim 1, wherein the elastomeric material comprises a rubber.

3. The seal according to claim 1, wherein the elastomeric material is selected from the group consisting of NITRILE™

, VITON™

, AFLAS™

, Ethylene-propylene rubbers and KALREZ™

.

4. The seal according to claim 1, wherein the actuating agent is selected from the group consisting of a water-based oil, a water, a mineral-based oil and a mineral-based water.

5. The seal according to claim 1, wherein the actuating agent is naturally occurring downhole.

6. The seal according to claim 1, wherein the elastomeric material is applied at at least two axially spaced-apart locations on the conduit.

7. The seal according to claim 1, wherein the elastomeric material can expand through chemical attack resulting in a breakdown of cross-linked bonds.

8. A method of creating a seal in a borehole, the method comprising:

providing an elastomeric material in the borehole;

exposing the material to an actuating agent that causes the elastomeric material to expand; and

controlling the direction of expansion of the elastomeric material, wherein the direction is controlled by an outer cover that covers a portion of the elastomeric material and wherein the cover is a non-swelling elastomeric material band that encases a top portion and a side portion of the elastomeric material.

9. The method according to claim 8, including the additional step of applying the elastomeric material to an outer surface of a conduit.

10. The method according to claim 9, including the additional step of locating the conduit within a second conduit.

11. The method according to claim 9, wherein the method includes the additional step of applying a radial expansion force to the conduit.

12. The method according to claim 8, wherein the method includes the additional step of injecting the actuating agent into the borehole.

13. The method according to claim 8, wherein the direction is controlled by a pair of non-swelling elastomeric material bands disposed on each side of the elastomeric material.

14. A sealing apparatus for isolating a tubular, comprising:

an expandable tubular body;

one or more swelling elastomers disposed around an outer surface of the expandable tubular body; and

an outer cover disposed on a portion of each swelling elastomer, wherein the outer cover is configured to control the direction of swelling as the swelling elastomer expands and wherein the outer cover is a non-swelling elastomeric material band that encases a top portion and a side portion of the elastomeric material.

15. The apparatus according to claim 14, wherein the one or more swelling elastomers are activated by a wellbore fluid.

16. The apparatus according to claim 14, wherein the one or more swelling elastomers include at least one hydrocarbon activated swelling elastomer and at least one water activated swelling elastomer.

17. The apparatus according to claim 14, wherein the outer cover is a non-swelling elastomer.

18. A method for isolating a well, comprising:

running a sealing apparatus into the wellbore, the sealing apparatus including;

a tubular body; and

a swelling element disposed around an outer surface of the tubular body; and

expanding the sealing apparatus to allow the swelling element to contact the wellbore as the swelling element swells.

19. The method according to claim 18, including the additional step of controlling the direction of swelling.

20. The method according to claim 19, wherein the direction of swelling is controlled by a cover disposed on a side of the swelling element.

21. A sealing apparatus for isolating a tubular, comprising:

a tubular body;

one or more swelling elastomers disposed around an outer surface of the tubular body, wherein each elastomer is a band having an outer surface, an inner surface, a first end surface and a second end surface and wherein the inner surface of the band is in contact with the tubular body; and

a lip-type seal disposed adjacent each swelling elastomer, wherein the lip-type seal is configured to control the direction of swelling as the swelling elastomer expands and wherein the lip-type seal is positioned adjacent the first end surface and not the second end surface.

22. The apparatus according to claim 21, wherein the lip-type seal is an elastomer.

23. A seal for use in a borehole, the seal comprising:

an elastomeric material that is capable of expanding or swelling upon contact with an actuating agent, wherein the elastomeric material is applied to an outer surface of a conduit and wherein a container of the actuating agent is located near the elastomeric material such that the container bursts upon radial expansion of the conduit; and

a soluble material disposed around the elastomeric material, wherein the soluble material is configured to at least partially dissolve upon contact with a fluid.

24. A seal for use in a borehole, the seal comprising:

an elastomeric material that is capable of expanding or swelling upon contact with an actuating agent, wherein the elastomeric material is applied to an outer surface of a conduit and wherein the conduit is radially expanded; and

a soluble material disposed around the elastomeric material, wherein the soluble material is configured to at least partially dissolve upon contact with a fluid.

25. The seal according to claim 24, wherein the conduit is located in a second conduit before being radially expanded.

26. A method of creating a seal in a borehole, the method comprising:

positioning a tubular body having a swelling elastomer in the borehole, wherein the swelling elastomer is a band having an outer surface, an inner surface, a first end surface and a second end surface and wherein the inner surface of the band is in contact with the tubular body;

exposing the swelling elastomer to an actuating agent that causes the swelling elastomer to expand; and

controlling the direction of expansion of the swelling elastomer by a lip-type seal disposed adjacent the swelling elastomer, wherein the lip-type seal is positioned adjacent the first end surface and not the second end surface.

27. A sealing apparatus for isolating a tubular, comprising:

a tubular body;

a swelling elastomer disposed around the tubular body, wherein the elastomer is a band having an outer surface, an inner surface, a first end surface and a second end surface and wherein the inner surface of the band is in contact with the tubular body; and

a lip-type seal disposed adjacent the swelling elastomer, wherein the lip-type seal is configured to control the direction of swelling as the swelling elastomer expands and wherein the lip-type seal is positioned adjacent the first end surface and not the second end surface.

28. The apparatus according to claim 27, wherein the lip-type seal is an elastomer.