INFLATABLE PACKER ELEMENT

Abstract: An inflatable packer is described comprising an elastomeric tubular core (18), an outer cover (20), an annular reinforcement sheath (22) sandwiched between the core and cover comprising a strength zone (24) composed of strain-resisting elements of high modulus (25) extending helically at alternate lay angles of less than 40° with respect to the packer axis, and sleeve means (28) to which the reinforcement is securely attached at each end of the packer. In one embodiment a transition reinforcement zone (26) is interposed between the tubular core and strength zone to improve the flex properties and increase the life of the packer. In another embodiment an improved anchor means formed of a frustro-conical matrix (32) encapsulates embedded reinforcement members.

Description: This invention relates to an inflatable packer for sealing an annular space in a wellbore about a supporting element to which the packer is attached. Reference is made to co-pending patent European Patent Application No. 8330ll36.4. An inflatable packer is a downhole tool which is inflatable with a fluid to seal off an annular space in the well, for example between the casing and the wellbore, or between a drill string or other retrievable tool and an outer well casing. Although not so limited, the packer of the invention is particularly suited for isolating zones within a well for such purposes as cementing, fracturing, treating, testing, preventing gas migration to the surface, and for gravel pack operations. With reference to Patent Application GB-A-2099541 and corresponding applications, the applicant has voluntarily limited the scope of the present application, and submitted separate claims for France, Great Britain and The Netherlands. Inflatable packers normally include an elastomeric body within which is disposed or embedded a reinforcement sheath. Examples of such prior art include U.S. Patent Nos. 2,643,722 to Lynes et al., 2,872,230 to Desbrandes, 3,028,9l5 to Jennings, and 4,l9l,383 to Baker et al. Typically, these prior publications provide an inflatable packer having an inflatable portion and terminal end portions, comprising: an elastomeric tubular core; an outer cover; an annular reinforcement sheath sandwiched between the core and cover and comprising a strength zone composed of strain-resisting elements having a first elastic modulus, said elements being helically disposed alternately in opposite lay sense within the sheath annulus at lead angle(s) to the longitudinal axis of the packet of less than 40° in the deflated condition; and sleeve means to which at least a portion of the reinforcement sheath is attached at a respective end of the packer. Significant problems in practice include the tendency of the body of the packer to rupture or develop pinhole leaks, and the failure of the body to return substantially to its original uninflated configuration, after repeated inflation/deflation cycles. According to the present invention, an inflatable packer is provided according to the pre-characterising part of claim l, characterised by a transition zone disposed radially inwardly of the strength zone, composed of a plurality of layers of strain-resisting elements having a second elastic modulus lower than the first elastic modulus, portions of the lower modulus elements being helically disposed respectively in opposite lay sense within the sheath annulus at lead angle(s) to the longitudinal axis of the packer of less than 40° in the deflated condition. By this means, the packer of the present invention is better able to overcome the problems of the prior art and to withstand high internal inflation pressures and external differential pressures across the packer element. The invention also comprehends the inflatable packer described above, in assembly with a tubular supporting element such as a mandrel to which the packer is attached. The invention in its preferred embodiment will be more particularly described by reference to the accompanying drawings, in which like numerals designate like parts, and in which: Figure l is a vertical sectional view, partially cutaway, of an inflatable packer and associated tool assembly therefor, the packer being shown deflated; Figure 2 is a vertical sectional view, partially broken away, of the packer and tool assembly of Figure l, shown inflated against a wellbore; Figure 3 depicts a vertical sectional, broken away view showing the detailed construction of the packer body and end termination arrangement; and Figure 4 is a broken, transverse sectional view of an alternative embodiment of the packer element assembly of the invention. Referring to the drawings and particularly Figures l and 2, there is shown an inflatable packer assembly generally at l0 including an inner cylindrical mandrel l2 connected to a casing string ll, ll′ and the inflatable annular packer element l4 (shown in detail in Figure 3) supported on mandrel l2. Although this detailed description describes a casing type packer to seal between the well casing and wellbore l6 of a subterranean formation, the packer can alternatively be installed on a drill string (corresponding to mandrel l2) located inside of a well casing, for sealing the annular space therebetween. The packer element l4 includes an elastomeric tubular core l8, an outer abrasion resistant elastomeric cover 20, and an annular reinforcement sheath 22 (Figure 3) sandwiched between the core l8 and cover 20. In the preferred embodiment the reinforcement sheath is formed of multiple reinforcement zones including a strength zone 24 and a transition zone 26, which will be discussed in more detail hereinafter. The packer element further includes respective end sleeves 28, 30 to which at least a portion of the reinforcement is attached by anchoring in matrix 32. Lower end sleeve 30 is internally threaded for coupling engagement with externally threaded lower end shoe 34 which in turn is securely attached by way of threaded connection to mandrel l2 and casing segment ll′. The upper end of the packer assembly, on the other hand, is slidably connected with respect to mandrel l2 by way of sliding upper shoe means 36, which is threadedly connected to upper packer end sleeve 28. Shoe means 36 slidingly engages the radially outer cylindrical surface of mandrel l2 and is sealed in respect thereto to prevent leakage between the mandrel and shoe by 0-ring seals 38. The end shoes 34, 36 are also sealed in respect to sleeves 28, 30 via 0-ring or other seals 40. The tubular core or bladder element l8 is also sealed by way of threaded collars 42, 44 which pinch off the radially extending end of tube l8 against a shoulder 46 of the end sleeve, as best seen in Figure 3. The collars 42, 44 are also preferably provided with seals 48 (Figure 3) for effecting a fluid-tight seal with the respective end shoes. Mandrel l2 is reduced in outside diameter along its medial portion 50 to define in respect to the adjacent tube l8 a small annular clearance 52 which is in communication with passageway 54, valve means 56 (shown schematically), inlet port 58 and break-off plug 60. In a manner well known to those skilled in the art, inflating fluid such as well fluid may be selectively directed from the interior 62 of the casing string upon severance of break-off plug 60 as shown in Figure 2, through port 58, valve 56, passageway 54 and then into the annular clearance 52 to inflate the packer body. As internal inflating pressure is applied fluid flows into annulus 52 and expands the packer body radially outwardly against the formation l6 as shown in Figure 2. The internal inflating pressure will be substantially maintained within the resultant chamber 53 by virtue of the sealing of mandrel l2 to the packer assembly, controlled selectively by valve 56, which may be a check valve. Similarly, by means not shown but well known to those skilled in the art, valve 56 may selectively be opened to partially or fully deflate the packer and return it to its deflated position as shown in Figure l. As the packer assembly is inflated, the slidable end of the packer will move downwardly on the mandrel as shown in Figure 2 as the packer element effectively foreshortens. The use of a tough elastomeric cover material 20 of high elongation enables the packer to make a tight seal against the formation surface and, because of the unique reinforcement sheath and anchoring means the packer in its inflated position shown in Figure 2 is able to withstand the internal inflating pressure and simultaneously the upper and lower external formation pressures P₁ and P₂. External pressures P₁ and P₂ may be substantially different whereby a large differential pressure is applied against the respective surfaces 64, 66. This may cause a distortion or bulging of those shoulders (not shown) in operation. The detailed construction of the packer element which withstands the aforementioned internal and external pressures while maintaining the desired seal, and while permitting repeated deflations and inflations with substantially full elastic recovering to the initial configuration, will now be described, particularly in reference to Figure 3. The packer body is preferably a unitary vulcanized rubber or rubber-like body in which the reinforcement sheath 22 is embedded so that the individual reinforcement elements are substantially encapsulated in and bonded to, physically and/or chemically, the rubber-like matrix body. Accordingly, tube l8 is elastomeric, preferably formed of a natural or synthetic rubber compounded for chemical resistance to the well fluids and inflation fluids, and having the desired properties of sufficiently high elongation to inflate to the desired diameter, elastic recovery and ability to bond to the adjacent reinforcement layer. Examples of suitable materials for typical applications include rubber formulations based on neoprene or nitrile compounds, which formulations are well known. In certain applications plastic elastomers or blends of such with rubbers are useful. Similarly, the cover 20 is preferably formed of a rubber or rubber-like elastomeric material such as natural or synthetic rubber also resistant to abrasion, and having the ability to form a tight seal against the formation or well casing to which it is pressed. Suitable materials include compounds of neoprene and nitrile, and in some cases plastic based elastomers or plastic/rubber blends may be used. The reinforcement sheath 22 which is sandwiched between the core l8 and cover 20 is comprised of multiple reinforcement zones. The properties of the different reinforcement zones are selected to provide the minimum strength required to withstand the pressures involved (together with a safety factor) by provision of a gradation in strength radially through the zones. At least one transition or gradation layer is positioned between the tube and principal reinforcing members to provide a homogenizing backup layer of reinforcement which ensures that the tube l8 does not extrude through interstices which may exist between adjacent strength elements in strength zone 24. As is known, if the packer is inflated sufficiently, the principal reinforcing members may spread apart slightly, enhancing the potential for extrusion. As depicted in Figure 3, the reinforcement sheath 22 is composed of two distinct reinforcement zones, strength zone 24 and radially inwardly disposed transition reinforcement zone 26. The strength zone is composed of the principal strain-resisting elements of relatively high modulus, preferably wire, in the form of filaments or cables for instance, and preferably bearing a coating of brass or other material to enhance adhesion to the rubber-like matrix. The individual strain-resisting elements 25, preferably formed of brass coated steel cable, are helically disposed in two layers alternately in opposite lay sense, outer elements 25a being helically disposed in the right-hand sense, and underlying layer formed of strain-resisting elements 25b being helically disposed in the left-hand sense. The lead angle ϑ which the strength elements make with respect to the longitudinal axis of the packer is substantially less than the locking angle (i.e., about 54°). Preferably the lead angle is substantially less then 40°, more preferably less than about 30°, and most preferably less than about l8° (in deflated condition). Of course, the lead angle will be chosen to suit the particular application and particularly the amount of radial expansion which the packer must undergo to make sealing engagement with the formation, well casing or other outer surface. The greater the proportional radial excursion of the packer upon inflation, the lower the lead angle ϑ should be to ensure that in the inflated position the individual reinforcement elements make an angle with the longitudinal axis of the packer which is substantially less than the locking angle of about 54°. From a practical standpoint, however, the lead angle should not be reduced below about l0°. The strain-resisting elements of the strength zone are preferably applied as spiral sheaths as shown in Figure 3, but may also be in other configurations such as one or more braided sheaths which combine in a single layer elements of opposite lay sense. However, it has been found that braided reinforcement layers tend to lock up upon full expansion in certain situations and, therefore, not recover substantially to the original straight position upon deflation. This in turn causes abrasion and eventual failure of the braid reinforcement. To ensure torsional balance the spiralled reinforcement layers should be present in pairs of alternate lay sense, the number of pairs employed depending upon the gauge and modulus of the reinforcing elements, and the particular application. Between each pair of layers there is provided a skim layer of elastomer 68, and an additional such layer 70 between the strength and transition reinforcement zones. These layers provide embedment for the strain-resisting elements and allow the proper pantographing action of the elements during inflation/deflation with minimal (if any) abrasion between layers, as the lead angle ϑ changes. The transition reinforcement zone 26 is composed of a plurality of layers (four shown) of strain-resisting elements 27a, 27b, 27c, 27d which are helically disposed respectively in opposite lay sense within the reinforcement sheath annulus. The individual strain-resisting elements possess a relatively low modulus in comparison to the elements 25a, 25b of the strength zone but are disposed at lead angles which are substantially the same with the corresponding layer of the strength zone, e.g., elements 25a and 27a are disposed at substantially the same lead angle and in the same lay sense. And, unlike the teaching in the aforementioned U. S. Patent No. 2,643,722 to Lynes et al. adjoining layers of the strength zone and transition zone (i.e., the strength layer formed of elements 25b and transitional layer formed of elements 27a) as well as the adjoining layers within a distinct reinforcement zone should be in alternating lay sense. In this manner, upon inflation of the packer element the individual strain-resisting elements from the same or adjoining layered zones will be maintained in their distinctive layer rather than nesting together. Typically, the strain-resisting elements of the transitional zone may be formed of smaller gauge wire or more preferably from rubber carcass type reinforcement materials such as textile cords, preferably spiralled in a helix as shown or alternately applied as braided layers, or the like. An especially preferred reinforcement configuration is the so-called tire cord construction formed of wire or textile cord elements 27a, b, c, d, of polyester, aramid, fiber glass, nylon or the like, disposed at the lead angle as shown, and held together by spaced laterally disposed pic cords (of reduced denier) as is known. As in the case of the strength zone, it is highly preferred that the layers of reinforcement in the transition zone be separated by interposed elastomeric layers 72, 74, 76, etc., so that the strain-resisting elements in the respective layers are substantially fully encapsulated in the elastomeric matrix of the packer body. The overall packer body is made unitary such as by vulcanization under the appropriate pressure and temperature to effect a flowing of the rubber layers into a compact unitary mass with the reinforcement layers embedded therein. Referring now to Figure 4, an alternative embodiment is shown in which three different reinforcement zones 88, 90, 92 are employed. Layer 88 is formed of two alternately spiralled layers of high modulus strain-resisting elements similar to that shown in Figure 3, to form the strength zone. A first transitional zone 90 is composed of alternately spiralled strain-resisting elements of lesser gauge (and modulus) in comparison with the strain-resisting elements in zone 88. Similarly, second transitional zone 92 is employed radially inwardly of the first transitional zone which has, in comparison thereto, strain-resisting helical elments of lesser modulus than in zone 90 to provide an overall progressive gradation of reinforcement characteristic radially in respect to the body of the packer element. The reinforcement sheath is securely anchored by attachment to the sleeves 28, 30 at each end of the packer by embedding at least the strain-resisting elements of the strength zone in an annular anchoring matrix 32 positioned along the inside surface of the respective sleeves 28, 30. As shown in Figure 3, sleeve 28 has an inner bore having a nonuniform bore dimension which progresses generally from a minimum dimension at the packer end 28′ to an enlarged, preferably maximum bore dimension 28″ near the end of the packer body. In the preferred embodiment shown, the inner bore of the sleeve tapers gradually toward the end of the sleeve in substantially frustro-conical fashion. Alternatively, the inner bore may be stair-stepped, for instance, with the same overall progression of increase in diameter toward the sleeve end of the packer element. As shown, the inner bore of the sleeve may also be provided with indentations or grooves 78 e.g., annular or spiral, serving further to hold the matrix 32 in position when the packer element is subjected to extreme pressures tending to pull the packer body out of engagment with the end sleeves. It has been found that the sleeve ends of the packer and the reinforcing sheath can be connected securely by spreading the individual strain-resisting elements 25 apart in the area of the inner bore of the sleeve and by embedding such spread apart elements in the annular embedding matrix 32 of epoxy or other rigid material of high compressive strength. At least a portion of the high modulus strain-resisting elements of the strength zone are embedded in the anchoring matrix, although a portion or all of the transition zone lower modulus elements may also be so anchored. A similar anchoring construction has been used for hose couplings (see, for instance U. S. Patent No. 4,l43,892 to Murphy et al., commonly assigned). However, to Applicant's knowledge, this anchoring technique for hose (where the reinforcement helix is at or near the locking angle) has never been applied to connect an inflatable packer body to its end sleeves. The packer element of the invention may be constructed using the following process. The uncured inner core material l8 is first plied up on a building pole or mandrel in one or more plies (or applied as an extrusion) with reduced thickness under the sleeves, and then the first ply 27d of low modulus strain-resisting elements of the transition zone is laid onto the core at the desired lead angle. In practice the low modulus strain-resisting elements are generally spaced slightly apart from one another, as is characteristic of tire cord. A friction layer 76 of uncured rubber is then applied, followed by the next layer of elements 27c disposed helically in the opposite lay sense in respect to elements 27d. In like manner, friction layer 74, elements 27b, friction layer 72 and elements 27a are plied up in superimposed fashion. Alternatively the tire cord can be pre-frictioned and applied as a calendered fabric or layer. After the interposed elastomeric friction layer 70 is then applied over the last layer of the transition reinforcement zone, the first layer of wire cable or other high modulus strain-resisting elements 25b are applied in a lay opposite in sense to the previous layer of low modulus elements 27a. The first layer of strength elements 25b of wire cable or the like are then applied with the end fastened down temporarily, short of the end 28″ of the sleeve. After friction layer 68 is applied over the first ply of cables, the second ply of elements 25a are applied in the opposite lay sense and similarly tied down at their ends, short of the sleeve. To give the best spread for anchoring the elements 25 in the epoxy matrix it is preferred to apply the second ply of cables 25a in the right-hand sense, as shown. The second layer of strength cables 25 is also tied down e.g., with wire or clips. The end sleeve 28 is then slipped over the end of the (uncured) packer element and the end seal 47 of uncured rubber is positioned around the edge of the transition zone reinforcement in contact with the core member l8, as shown. Retention collar 42 is then threaded into place with the aid of tool-receiving detents 49. At this point the cables of the strength zone are released, e.g., in the manner shown in the aforementioned U.S. Patent No. 4,l43,892. The wires naturally spread apart upon releasing and more or less randomly distribute themselves in a spaced apart manner as shown in Figure 3. Alternatively, the port 80 for injecting epoxy or other anchoring matrix material may be positioned opposite the clips for access to aid in release of the cables. After release of the cables the epoxy is poured or forced into one or more of the ports 80 until preferably all of the voids around the spread apart cables 25 are substantially filled with the anchoring material. The cover 20 is then plied up in one or more layers and preferably over the end of the sleeve up to an intermediate point 82, and then a conventional curing tape of nylon or the like is wrapped over the structure and then the entire element is cured, as by vulcanization for a time period at the desired temperature and pressure. In an actual working example the previous method was generally used to produce an inflatable packer of 7 inch (17.8mm) outside diameter and 4.44 inch (11.3 mm) internal diameter, for use as an open hole inflatable packer. Six plies of frictioned polyester tire cord of l300 denier (14.4g/100m) were used for the transitional reinforcement zone, applied at a l5° lead angle. The strength zone was composed of two layers of spiralled brass finished steel cable, having a mean diameter of 0.l38 inches (3,5 mm), spiralled at l5° lead angles of opposite hand. The cable was applied in a tight pack, the individual wires substantially touching adjacent cables. The resultant built-up packer was cured in a steam atmosphere for about one hour at 300°F (149°C). The finished packer was tested by inserting it in a tubular test fixture, simulating a well bore and then inflating to an internal pressure of l200 psi (84.6 Kg/sq cm). After pressurizing the packer against the inner surface of the test fixture, a differential pressure (i.e., P₁ -P₂) of 5000 psi (352.5 Kg/sq cm) was applied without causing the packer to rupture or otherwise fail. After release of the differential pressure, the internal inflation pressure was released and the packer deflated to substantially its original uninflated configuration. This test cycle was repeated 5 times, without failure of the packer. The inflatable packer described above was also tested in a well penetrating a subterranean formation, under actual environmental conditions and it performed as designed.

Claims: Claims for the following Contracting States : BE, DE, IT, SE An inflatable packer having an inflatable portion and terminal end portions comprising: an elastomeric tubular core (l8); and outer cover (20); an annular reinforcement sheath (22) sandwiched between the core and cover and comprising a strength zone (24) composed of strain-resisting elements (25) having a first elastic modulus, said elements being helically disposed, alternately in opposite lay sense within the sheath annulus, at lead angle(s) (⊖) to the longitudinal axis of the packer of less than 40° in the deflated condition; and sleeve means (28) to which at least a portion of the reinforcement sheath is attached at respective ends of the packer, characterised by a transition zone (26) disposed radially inwardly of the strength zone composed of a plurality of layers of strain-resisting elements (27) having a second elastic modulus lower than the first elastic modulus, portions of the lower modulus elements being helically disposed respectively in opposite lay sense within the sheath annulus at lead angle(s) to the longitudinal axis of the packer of less than 40° in the deflated condition. A packer according to Claim l wherein the higher modulus elements are anchored by embeddment in an annular, substantially frusto-conical rigid matrix (32) attached to the sleeve means. A packer according to Claim l or 2 wherein the higher modulus elements are present in an even number of layers of spiralled elements. A packer according to Claim l, 2 or 3 wherein the higher modulus elements are disposed in a braid sheath or sheaths. A packer according to any one of Claims l to 4 wherein at least one of said higher modulus elements and lower modulus elements is embedded in elastomeric material, and wherein layers of higher modulus elements and lower modulus elements are separated by elastomeric layers (68, 70, 72, 74, 76). A packer according to any one of the previous claims wherein the higher modulus elements are formed of wire filament or cable, and the lower modulus elements are formed of textile cord. A packer according to Claim 6 wherein the textile cord is present in the form of tire cord. A packer according to claim 5 wherein the elastomeric material is vulcanised. An inflatable packer (l0) according to any one of the preceding claims wherein the sleeve means (28) have an inner bore (78) of differing dimension changing from a lesser dimension (28′) near the inflatable portion of the packer to an enlarged dimension (28″) near the terminal end of the packer, and at least a portion of the elements (25) near the terminal end of the packer have ends which are spread apart relative to elements in a portion remote from said terminal end, so as to provide gaps between the elements, and are anchored by embeddment in an annular anchoring matrix (32) disposed immediately adjacent said inner bore (78) of the sleeve means (28) and in the gaps around and between the spread apart elements whereby said core, reinforcement sheath and anchoring matrix are integrated into a unitary body. A packer according to any one of the previous claims wherein the core has through passageways at both ends thereof and means (38) are provided at one end of the packer to form a slidable seal between the packer and an axial element (l2) passing through the core. Claims for the following Contracting States : GB, FR, NL An inflatable packer having an inflatable portion and terminal end portions comprising: an elastomeric tubular core (18); an outer cover (20); an annular reinforcement sheath (22) sandwiched between the core and cover and comprising a strength zone (24) composed of strain-resisting elements (25) having a first elastic modulus, said elements being helically disposed, alternately in opposite lay sense within the sheath annulus, at lead angle(s) (⊖) to the longitudinal axis of the packer of less than 40° in the deflated condition; sleeve means (28) to which at least a portion of the reinforcement sheath is attached at respective ends of the packer, and a transition zone (26) disposed radially inwardly of the strength zone composed of a plurality of layers of strain-resisting elements (27) having a second elastic modulus lower than the first elastic modulus, portions of the lower modulus elements being helically disposed respectively in opposite lay sense within the sheath annulus at lead angle(s) to the longitudinal axis of the packer of less than 40° in the deflated condition; characterised in that the core has through passageways at both ends thereof and means (38) are provided at one end of the packer to form a slidable seal between the packer and an axial element (12) passing through the core. A packer according to Claim 1 wherein the higher modulus elements are anchored by embeddment in an annular, substantially frusto-conical rigid matrix (32) attached to the sleeve means. A packer according to Claim 1 or 2 wherein the higher modulus elements are present in an even number of layers of spiralled elements. A packer according to Claim 1, 2 or 3 wherein the higher modulus elements are disposed in a braid sheath or sheaths. A packer according to any one of Claims 1 to 4 wherein at least one of said higher modulus elements and lower modulus elements is embedded in elastomeric material, and wherein layers of higher modulus elements and lower modulus elements are separated by elastomeric layers (68, 70, 72, 74, 76). A packer according to any one of the previous claims wherein the higher modulus elements are formed of wire filament or cable, and the lower modulus elements are formed of textile cord. A packer according to Claim 6 wherein the textile cord is present in the form of tire cord. A packer according to claim 5 wherein the elastomeric material is vulcanised. An inflatable packer according to any one of the preceding claims wherein the sleeve means (28) have an inner bore (78) of differing dimension changing from a lesser dimension (28') near the inflatable portion of the packer to an enlarged dimension (28") near the terminal end of the packer, and at least a portion of the elements (25) near the terminal end of the packer have ends which are spread apart relative to elements in a portion remote from said terminal end, so as to provide gaps between the elements, and are anchored by embeddment in an annular anchoring matrix (32) disposed immediately adjacent said inner bore (78) of the sleeve means (28) and in the gaps around and between the spread apart elements whereby said core, reinforcement sheath and anchoring matrix are integrated into a unitary body. A packer according to claim 9 wherein said reinforcing elements are free from being mechanically clamped between opposed wedging surfaces.

Inventors: ITO, LEONARD N.
Applicants: THE GATES RUBBER COMPANY
Application year: 1983
Main classification: E21B33
IPC codes: F16J15, E21B33