High expansion packer

• US 20040069502A1
• Filed: 10/09/2002
• Published: 04/15/2004
• Est. Priority Date: 10/09/2002
• Status: Active Grant

• Current Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Original Assignee: Weatherford/Lamb Incorporated (Weatherford International PLC)
• Inventors: Luke, Mike A.
• Granted Patent: US 6,827,150 B2
• Time in Patent Office: Days
• 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 33/1216 Anti-extrusion means, e.g. means to prevent cold flow of rubber packing
• CPC Class Codes: E21B 33/1293 with means for anchoring against downward and upward movement E21B33/1291, E21B33/1295 take precedence
• CPC Class Codes: E21B 33/134 Bridging plugs

Abstract

The present invention generally relates to a method and apparatus for sealing a tubular. In one aspect, the apparatus is sealing apparatus for a downhole tool such as a bridge plug, packer, or frac-plug. In one embodiment, the present invention provides for a sealing apparatus having a body and a sealing system disposed about the body. The sealing apparatus further includes one or more extrusion rings disposed at each end of the sealing system. The sealing apparatus may also have a first cone to support the one or more extrusion rings and a second cone expandable over the first cone. A slip member is disposed adjacent the second cone at each end of the sealing system. Upon actuation, the sealing apparatus expands the sealing system and causes the slip member to fold outward and engage the tubular. The sealing apparatus is functionally expandable to at least 25% diametrically to seal the tubular.

Claims

1. A sealing apparatus for engaging a tubular, comprising:

a body;

a sealing system disposed about the body;

one or more extrusion rings disposed at each end of the sealing system;

a cone for supporting the one or more extrusion rings; and

a slip member disposed adjacent to the a cone at each end of the sealing system, whereby actuating the sealing apparatus expands the sealing system and causes the slip member to fold outward and engage the tubular.

2. The sealing apparatus of claim 1, wherein the sealing system comprises one or more sealing elements.

3. The sealing apparatus of claim 2, wherein the sealing system comprises a center seal element, a middle seal element, and an end seal element.

4. The sealing apparatus of claim 3, wherein the center seal element folds outward and cam the middle seal element outward upon actuation.

5. The sealing apparatus of claim 3, wherein the middle seal element comprises a material that is harder than the end seal element.

6. The sealing apparatus of claim 3, wherein at least one of the seal elements of the sealing system comprises an elastomeric material.

7. The sealing apparatus of claim 1, further comprising a backup ring disposed between the one or more extrusion rings and the cone.

8. The sealing apparatus of claim 7, further comprising an expansion member disposed between the cone and the slip member.

9. The sealing apparatus of claim 8, wherein the expansion member is connected to the cone using a first shearable member.

10. The sealing apparatus of claim 9, wherein the slip member is connected to the expansion member using a second shearable member.

11. The sealing apparatus of claim 10, wherein the first shearable member shears at a lower force than the second shearable member.

12. The sealing apparatus of claim 1, wherein each of the one or more extrusion rings includes a plurality of slots.

13. The sealing apparatus of claim 12, wherein the plurality of slots are staggered relative to each of the one or more extrusion rings.

14. The sealing apparatus of claim 13, further comprising a backup ring disposed between the one or more extrusion rings and the slip member.

15. The sealing apparatus of claim 14, wherein the backup ring includes a plurality of slots.

16. The sealing apparatus of claim 15, wherein the one or more extrusion rings and the backup ring pivots about a cone.

17. The sealing apparatus of claim 16, wherein the cone cams an expansion member outward.

18. The sealing apparatus of claim 1, wherein a first slip member at one end of the sealing apparatus is substantially fixed against the body and a second slip member at another end of the sealing apparatus is movable relative to the body.

19. The sealing apparatus of claim 18, wherein the second slip member has teeth that engage one or more teeth formed on the body to provide one way movement of the second slip member.

20. The sealing apparatus of claim 1, wherein the sealing apparatus is functionally expandable to at least 15% diametrically.

21. The sealing apparatus of claim 1, wherein the sealing apparatus is functionally expandable to at least 20% diametrically.

22. The sealing apparatus of claim 1, wherein the sealing apparatus is functionally expandable to at least 25% diametrically.

23. The sealing apparatus of claim 1, wherein the sealing apparatus is functionally expandable to at least 33% diametrically.

24. A sealing apparatus for engaging a tubular, comprising:

a body;

a sealing system disposed about the body;

one or more extrusion rings disposed at each end of the sealing system;

a first cone for supporting the one or more extrusion rings;

a second cone expandable over the first cone; and

a slip member disposed adjacent to the a cone at each end of the sealing system, whereby actuating the sealing apparatus expands the sealing system and causes the slip member to fold outward and engage the tubular.

25. The sealing apparatus of claim 24, wherein the expansion member includes a finger attached to a base, wherein the finger is expandable toward the tubular.

26. The sealing apparatus of claim 24, wherein the sealing system comprises one or more sealing elements.

27. The sealing apparatus of claim 26, wherein at least one of the one or more seal elements comprises an elastomeric material.

28. The sealing apparatus of claim 24, further comprising a backup ring disposed between the one or more extrusion rings and the first cone.

29. The sealing apparatus of claim 28, wherein the backup ring is connected to the first cone.

30. The sealing apparatus of claim 24, wherein the second cone is connected to the first cone using a first shearable member.

31. The sealing apparatus of claim 30, wherein the slip member is connected to the second cone using a second shearable member.

32. The sealing apparatus of claim 31, wherein the first shearable member shears at a lower force than the second shearable member.

33. The sealing apparatus of claim 24, wherein the one or more extrusion rings comprises a plurality of slots.

34. The sealing apparatus of claim 33, wherein the plurality of slots are staggered relative to each of the one or more extrusion rings.

35. A method of sealing a tubular, comprising:

running a tool into the tubular, the tool comprising;

a body;

a sealing system disposed about the body;

an extrusion ring disposed adjacent each end of the sealing system;

a cone disposed adjacent each extrusion ring; and

a slip member disposed adjacent each cone;

applying a force to the slip member at one end of the tool;

expanding the sealing system into contact with an area of the tubular;

causing the extrusion ring to fold outward and plastically deform; and

causing the slip member to engage the tubular, wherein the sealing member, extrusion ring, and the slip member are set in a predetermined sequence.

36. The method of claim 35, wherein the tool further comprises an expansion member disposed between the cone and the slip member.

37. The method of claim 35, wherein the slip member includes a serrated portion for frictional engagement with the tubular.

38. The method of claim 35, wherein sealing system comprises a plurality of seal elements.

39. The method of claim 35, wherein the expanded sealing system provides a bi-directional, self-energizing cup type seal system.

40. The method of claim 35, wherein the sealing system is expanded to at least 15% diametrically.

41. The method of claim 35, wherein the sealing system is expanded to at least 20% diametrically.

42. The method of claim 35, wherein the sealing system is expanded to at least 25% diametrically.

43. The method of claim 35, wherein the sealing system is expanded to at least 44% diametrically.

44. A slip and cone assembly functionally expandable to at least 25% diametrically.