PACKER ASSEMBLY WITH AN ANTI-EXTRUSION ASSEMBLY

A packer assembly for use within a wellbore. The packer assembly may include a mandrel, a seal assembly disposed about the mandrel, an anti-extrusion assembly disposed about the mandrel proximate the seal assembly to prevent extrusion of the seal assembly, and a deployment system. The anti-extrusion assembly may include a cradle cone that may include a plurality of arcuate surfaces on an exterior of the cradle cone and a plurality of cradle arms. Each cradle arm may include a flexible tip and be positioned on a respective arcuate surface of the cradle cone. The deployment system may be operable to compress the seal assembly such that the seal assembly seals against a wellbore wall and to rotate the plurality of cradle arms such that the flexible tips of the cradle arms contact the wellbore wall to prevent extrusion of the seal assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Indian Patent Application No. 202121057236 entitled “High Expansion Cradle Shaped Anti-Extrusion Ring and Ax Type Elastomeric Seal for Bridge Plugs, Packer or Frac Plug,” filed Dec. 9, 2021, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

Hydrocarbons produced from a subterranean formation oftentimes have sand or other particulates disposed therein. As the sand is undesirable to produce, many techniques exist for reducing the sand content in the hydrocarbons. Gravel packing is one technique used to filter and separate the sand from the hydrocarbons in a wellbore. Gravel packing generally involves pumping a gravel slurry, including gravel dispersed within a carrier fluid, down a work string and into the annulus formed between a completion assembly and the wall of the wellbore. The gravel is used to filter and separate the sand from the hydrocarbons as the hydrocarbons flow from the formation, into a completion assembly, and up to the surface.

One or more packers are oftentimes set or actuated prior to gravel packing. Upon actuation, the packers expand radially outward into contact with the wall of the wellbore to isolate different layers or zones of the formation. Isolating the different zones prevents the cross-flow of fluids (e.g., hydrocarbon fluids such as oil or gas) between the different zones and reduces the amount of water produced from the formation.

SUMMARY

A packer assembly for use within a wellbore according to one or more embodiments of the present disclosure includes a mandrel, a seal assembly disposed about the mandrel, an anti-extrusion assembly disposed about the mandrel proximate the seal assembly to prevent extrusion of the seal assembly, and a deployment system. The anti-extrusion assembly includes a cradle cone including a plurality of arcuate surfaces on an exterior of the cradle cone and a plurality of cradle arms. Each cradle arm includes a flexible tip and be positioned on a respective arcuate surface of the cradle cone. The deployment system is operable to compress the seal assembly such that the seal assembly seals against a wellbore wall and to rotate the plurality of cradle arms such that the flexible tips of the cradle arms contact the wellbore wall to prevent extrusion of the seal assembly.

A completion system according to one or more embodiments of the present disclosure includes a tubing string positionable within the wellbore and a packer assembly coupled to the tubing string. The packer assembly includes a mandrel, a seal assembly disposed about the mandrel, an anti-extrusion assembly disposed about the mandrel proximate the seal assembly to prevent extrusion of the seal assembly, and a deployment system. The anti-extrusion assembly includes a cradle cone including a plurality of arcuate surfaces on an exterior of the cradle cone and a plurality of cradle arms. Each cradle arm includes a flexible tip and be positioned on a respective arcuate surface of the cradle cone. The deployment system is operable to compress the seal assembly such that the seal assembly seals against a wellbore wall and to rotate the plurality of cradle arms such that the flexible tips of the cradle arms contact the wellbore wall to prevent extrusion of the seal assembly.

A method of completing a wellbore according to one or more embodiments of the present disclosure includes positioning a packer assembly within a wellbore. The method also includes compressing a seal assembly of the packer assembly via a deployment system of the packer assembly such that the seal assembly seals against a wellbore wall. The method further includes rotating a plurality of cradle arms of an anti-extrusion assembly of the packer assembly via the deployment system such that flexible tips of the cradle arms contact the wellbore wall to prevent extrusion of the seal assembly.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that that embodiments of the present disclosure may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

In the specification and appended claims: the terms “connect,” “connection,” “connected,” “in connection with,” “connecting,” “couple,” “coupled,” “coupled with,” and “coupling” are used to mean “in direct connection with” or “in connection with via another element.” As used herein, the terms “up” and “down,” “upper” and “lower,” “upwardly” and “downwardly,” “upstream” and “downstream,” “uphole” and “downhole,” “above” and “below,” and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the disclosure.

Referring now toFIG.1,FIG.1is a well system100that includes a wellbore102having a deviated wellbore section104extending into a formation106containing hydrocarbon fluids. Depending on the application, the wellbore102may comprise one or more deviated wellbore sections104, e.g. horizontal wellbore sections, which may be cased or un-cased. In the example illustrated, a tubing string108is deployed downhole into wellbore102and comprises a downhole well completion system110deployed in the deviated, e.g. horizontal, wellbore section104.

The downhole well completion110system may be constructed to facilitate production of well fluids and/or injection of fluids. By way of example, the downhole well completion110system may comprise at least one sand screen joint112, e.g. a plurality of screen assemblies112. Each sand screen joint112may include a shroud, e.g. a sand screen,114that cover a screen filter through which fluid may enter the corresponding sand screen joint112for production to a suitable location, e.g. a surface location. For example, hydrocarbon well fluids may flow from formation106, into wellbore102, and into the screen assemblies112via the shrouds114. In some embodiments, the downhole well completion system110also may comprise a plurality of packers116which may be used to isolate sections or zones118along the wellbore102.

Turning now toFIG.2,FIG.2is a packer assembly216that includes a tubular mandrel200, a seal assembly202positioned around the mandrel200, and anti-extrusion assemblys204positioned on either side of the element system. The anti-extrusion assemblys204are activated via a piston206of a deployment system208, which also compresses the seal assembly202. The seal assembly202, when compressed, expands in radial direction to seal an annular space between the packer assembly216and a casing or a formation. The deployment system208can be actuated via hydrostatic pressure in the well, applying hydraulic pressure from the surface, using a mechanical tool, or any combination thereof.

Turning now toFIG.3,FIG.3is an enlarged view of the seal assembly202ofFIG.2. The seal assembly202includes multiple sealing elements300,304,306,308that are retained via two sets of foldback rings310,312. In one or more embodiments, the center sealing element300comprises a soft durometer elastomer (e.g., an elastomer having a durometer between approximately 60 and approximately 70) having a cylindrical groove314formed on the inner surface adjacent the mandrel200. The groove314is sized and positioned such that the center sealing element300will buckle radially outward when compression force is applied to the seal assembly202, as shown inFIG.5. An inner sealing element304comprises a soft durometer elastomer and is positioned within the groove314to reduce or prevent the formation of air or fluid pockets within the seal assembly202once the system is set.

In one or more embodiments, wedge elements306comprising a hard durometer elastomer (e.g., an elastomer having a durometer of between approximately 80 and approximately 90) are positioned on either side of the center sealing element300. In other embodiments, the wedge elements306may be made of metal, polyether ether ketone (“PEEK”), or any other similar polymer. The wedge elements306each include an angled surface316on the surface opposite the center sealing element300and an arcuate surface318contacting the center sealing element300.

A pair of end elements308is positioned adjacent to the angled surface316of the wedge elements. In one or more embodiments, the end elements308comprise a soft durometer elastomer to allow the end elements308to deform within the annular gap between the center sealing element300and a tubular or wellbore wall when the seal assembly202is compressed and create a seal. The pair of foldback rings310,312are formed from a ductile metal or polymer and partially cover portions of the end elements308opposite the wedge elements306. The foldback rings310,312may deform such that the foldback rings310,312remain in contact with the end elements308as the seal assembly202is compressed. Further, the foldback rings310,312may each include slots or gaps and be aligned with each other in such a way that one foldback ring310,312covers the slots or gaps in the adjacent foldback ring310,312to reduce or prevent extrusion of the end elements308.

Turning now toFIG.4,FIG.4is an enlarged view of the anti-extrusion assembly204ofFIG.2. The anti-extrusion assembly includes arcuate cradle arms400and a cradle cone402that includes plurality of arcuate surfaces404on the exterior of the cradle cone. Each cradle arm400includes a flexible tip406that can deform against a casing or wellbore wall. This allows the anti-extrusion assembly204to account for ovality and irregularity of the wellbore. The cradle arms400are each positioned an arcuate surface404of the cradle cone402and are retained on the arcuate surface404via guides408and support members410, such as leaf springs. Additionally, the support members410help to retain the cradle arms400in position against a casing or borehole wall once the anti-extrusion assembly204has been deployed, as described in more detail below. In one or more embodiments, the anti-extrusion assembly204also includes a foldback ring414to prevent the premature actuation of the anti-extrusion assembly204.

In one embodiment, the anti-extrusion assembly204includes 20 cradle arms400positioned about a cradle cone402that includes twenty arcuate surfaces404. In other embodiments, the anti-extrusion assembly may include less than twenty cradle arms400and respective arcuate surfaces404or more than twenty cradle arms400and respective arcuate surfaces404.

As discussed above, the anti-extrusion assembly204is deployed along with the seal assembly202via the deployment system208. When actuated via the deployment system208, the cradle arms400rotate to contact the casing or wellbore wall, as shown inFIG.5. Further, the deployment system208includes an angled or curved contact surface412that is positioned adjacent to the cradle arms400to ensure that the deployment system208remains in contact with the cradle arms as the cradle arms400are actuated.

As used herein, a range that includes the term between is intended to include the upper and lower limits of the range; e.g., between 50 and 150 includes both50and150. Additionally, the term “approximately” includes all values within 5% of the target value; e.g., approximately 100 includes all values from 95 to 105, including 95 and 105. Further, approximately between includes all values within 5% of the target value for both the upper and lower limits; e.g., approximately between 50 and 150 includes all values from 47.5 to 157.5, including 47.5 and 157.5.