Abstract:
A retrievable packer device for use in a wellbore includes first and second end rings configured to be mounted on a base member and a deformable sleeve extending from the first end ring to the second end ring and configured to extend around the base member. A swellable sleeve is mounted on the deformable sleeve.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a retrievable packer device and a retrievable packer assembly for use in a wellbore, particularly though not exclusively, for use in a wellbore tubular or a borehole of an oil, gas or water well. 
       BACKGROUND TO THE INVENTION 
       [0002]    It is well known to use packers for the purposes of sealing fluid flow paths in oil and gas wells such as oil and gas production wells and in water wells such as injection wells. For example, it is well known to sealingly mount such downhole packers on a base pipe and to prevent fluid flow along an annulus defined between an outer surface of the base pipe and an inner surface of a wellbore. Such downhole packers may, in particular, be used for isolating production zones in an oil or gas well. Such packers generally include a sealing element which, in use, exerts a sufficient pack-off force on an inner surface of the wellbore so as to provide an effective seal to fluid flow. Known downhole packers may include a deformable non-swellable sealing element which, in use, exerts a radially outward pack-off force on the inner surface of the wellbore in response to axial compression of the sealing element. The sealing element may be axially compressed by a variety of different methods which may include at least one of: the application of hydraulic pressure to a setting tool; the application of pressure into an integral setting chamber of the packer; the application of a set down weight; the application of over pull; and the use of a pyrotechnic method involving the use of slow-burning explosives. 
         [0003]    Swellable packers are also known which include a swellable sealing element which, in use, exerts a radially outward pack-off force on the inner surface of the wellbore on exposure of the sealing element to one or more fluids present in the wellbore. Swellable packers are generally mechanically simpler and less complex than deformable non-swellable packers. 
         [0004]    In some circumstances, it may be necessary or desirable to retrieve a packer from the wellbore, for example to permit well measurements, observations and/or well intervention operations to be performed. Deformable non-swellable packers are generally retrieved by releasing the mechanism that maintains the pack-off force and then pulling the base pipe out of the wellbore with the packer mounted thereon. The retrieval of deformable non-swellable packers generally requires well intervention to release the mechanism that maintains the pack-off force. Well intervention is, however, relatively expensive. 
         [0005]    In the case of a conventional swellable packer, it may not be possible to reverse the swelling of the swellable sealing element to permit easy retrieval of the swellable packer. In order to retrieve such a packer, it is generally necessary to apply a sufficient pulling force to the base pipe to overcome the considerable friction forces which arise between the outer surface of the swollen sealing element and the inner surface of the wellbore. Dragging a packer out of the wellbore in this way may cause disintegration of the sealing element. This may prevent re-use of at least some of the packer parts. In addition, debris may be generated in the wellbore which may be prejudicial to subsequent well measurements, observations and/or intervention operations. Moreover, the friction forces may be considerable, thereby requiring the use of high pull forces. Accordingly, dragging a conventional swellable packer out of a wellbore may be time-consuming and/or expensive. This may be particularly true when trying to retrieve multiple packers mounted on the same base pipe at the same time. 
       SUMMARY OF THE INVENTION 
       [0006]    According to a first aspect of the present invention there is provided a retrievable packer device for use in a wellbore, comprising: 
         [0007]    first and second end rings configured to be mounted on a base member; 
         [0008]    a deformable sleeve extending from the first end ring to the second end ring and configured to extend around the base member; and 
         [0009]    a swellable sleeve mounted on the deformable sleeve, 
         [0010]    wherein the deformable sleeve is supported by the first and second end rings. 
         [0011]    The deformable sleeve is supported by the first and second end rings so as to define a chamber between an outer surface of the base pipe and an inner surface of the deformable sleeve. The chamber may extend axially between the first and second end rings. The provision of such a chamber may permit the deformable sleeve to deform radially inwardly according to the lateral force exerted by the swellable sleeve on the deformable sleeve. 
         [0012]    The deformable sleeve may be sufficiently rigid so as to support a lateral force exerted by the swellable sleeve on the deformable sleeve resulting from the exertion of a pack-off force from the swellable sleeve against a surface adjacent to the swellable sleeve such as the surface of a tubular or a borehole. 
         [0013]    The deformable sleeve may comprise a metal, for example steel. 
         [0014]    The deformable sleeve may have a wall thickness in the range of 1 to 5 mm, 1.5 to 3 mm or 2 to 2.5 mm. 
         [0015]    The deformable sleeve may define a plurality of axially extending grooves or slots. The grooves or slots may be distributed circumferentially around the deformable sleeve. The grooves or slots may only extend axially along a middle axial portion of the deformable sleeve. 
         [0016]    The deformable sleeve may be joined to the first end ring. 
         [0017]    The deformable sleeve may be joined to the first end ring in a region of a first end of the deformable sleeve. 
         [0018]    A first end region of the deformable sleeve may be received within a complementary annular recess defined by the first end ring, for example a complementary annular recess defined in an axial end face of the first end ring. 
         [0019]    The deformable sleeve may be joined to the first end ring around a path defined on an outer surface of the deformable sleeve. 
         [0020]    The deformable sleeve may be joined to the first end ring around a path defined on an inner surface of the deformable sleeve. 
         [0021]    The deformable sleeve may be welded to the first end ring. 
         [0022]    The deformable sleeve may be bonded or adhered to the first end ring. 
         [0023]    The deformable sleeve may be formed integrally with the first end ring. 
         [0024]    The deformable sleeve may be sealed relative to the first end ring so as to prevent fluid flow therebetween. 
         [0025]    The deformable sleeve may be selectively sealed relative to the second end ring according to a lateral force exerted by the swellable sleeve on the deformable sleeve. 
         [0026]    The deformable sleeve may be movable relative to the second end ring. 
         [0027]    The deformable sleeve may be movable relative to the second end ring so as to provide a selective seal relative to the second end ring according to a lateral force exerted by the swellable sleeve on the deformable sleeve. 
         [0028]    The deformable sleeve may be selectively sealed relative to the second end ring in a region of a second end of the deformable sleeve. 
         [0029]    A second end region of the deformable sleeve may be slidingly received within a complementary annular recess defined in the second end ring, for example a complementary annular recess defined in an axial end face of the second end ring. 
         [0030]    The second end ring may comprise an O-ring seal located within a circumferential groove defined in a sidewall of the annular recess defined in the second end ring. A surface of the second end region of the deformable sleeve may define a sealing area which is disposed towards the O-ring seal. The sealing area may selectively engage the O-ring seal according to a lateral force exerted by the swellable sleeve on the deformable sleeve. The sealing area may be defined by circumferential grooves located either side of the sealing area. 
         [0031]    The deformable sleeve may comprise an O-ring seal located within a circumferential groove defined in a surface of the second end region of the deformable sleeve. A sidewall of the annular recess defined in the second end ring may define a sealing area which is disposed towards the O-ring seal. The sealing area may selectively engage the O-ring seal according to a lateral force exerted by the swellable sleeve on the deformable sleeve. The sealing area may be defined by circumferential grooves located either side of the sealing area. 
         [0032]    The deformable sleeve may be selectively supported by the second end ring according to a lateral force exerted by the swellable sleeve on the deformable sleeve. 
         [0033]    The deformable sleeve may be de-supported according to the lateral force exerted by the swellable sleeve on the deformable sleeve. This may permit the de-deformable sleeve to collapse radially. For example, this may permit a de-supported end or a de-supported end region of the deformable sleeve to collapse radially. This may permit the swellable sleeve to collapse radially. For example, this may permit a de-supported end or a de-supported end region of the swellable sleeve to collapse radially. 
         [0034]    The first and second end rings may be selectively sealable relative to a base member. 
         [0035]    The first and second end rings may each comprise an inner seal mounted on an inner surface thereof. 
         [0036]    Each inner seal may be configured to selectively seal between an inner surface of the corresponding end ring and an outer surface of a base member. 
         [0037]    The inner seal of each of the first and second end rings may comprise a swellable material. 
         [0038]    The swellable sleeve may be sealingly mounted on the deformable sleeve. 
         [0039]    The swellable sleeve may be bonded to an outer surface of the deformable sleeve. 
         [0040]    The swellable sleeve may be bonded to the first end ring, for example to an axial end face of the first end ring. 
         [0041]    The packer device may comprise at least one control line. 
         [0042]    The control line may provide for the transfer of an electrical signal, an optical signal or a fluid through the packer device. 
         [0043]    The control line may comprise an electrical cable, an optical fibre or a fluid line. 
         [0044]    The packer device may be configured to accommodate the control line. The packer device may, for example, comprise one or more through bore is, slots, slits, channels or the like for this purpose. 
         [0045]    It should be understood that one or more of the optional features disclosed in relation to one aspect of the present invention may apply alone or in any combination in relation to any other aspect of the present invention. 
         [0046]    According to a second aspect of the present invention there is provided a retrievable packer assembly, comprising: 
         [0047]    a base member; 
         [0048]    first and second end rings mounted on the base member; 
         [0049]    a deformable sleeve extending from the first end ring to the second end ring around the base member; and 
         [0050]    a swellable sleeve mounted on the deformable sleeve, 
         [0051]    wherein the deformable sleeve is supported by the first and second end rings. 
         [0052]    The first end ring of the packer may be attached to the base member using at least one connector. 
         [0053]    The first end ring of the packer may be attached to the base member using at least one set screw, grub screw or the like. 
         [0054]    The second end ring of the packer may be attached to the base member using at least one connector. 
         [0055]    The second end ring of the packer may be attached to the base member using at least one frangible connector. 
         [0056]    The second end ring of the packer may be attached to the base member using at least one shear screw. 
         [0057]    The base member may comprise an end stop at or adjacent to an end thereof. The end stop may be configured to prevent sliding of the second end ring past the end stop. The end stop may be defined by a coupling member configured to permit coupling of the base member to an adjacent further base member. 
         [0058]    The retrievable packer assembly may comprise a plurality of retrievable packer devices mounted on the base member. 
         [0059]    Each packer device may be the same or different. 
         [0060]    It should be understood that one or more of the optional features disclosed in relation to one aspect of the present invention may apply alone or in any combination in relation to any other aspect of the present invention. 
         [0061]    According to a third aspect of the present invention there is provided a method of retrieving a packer assembly from a wellbore, the packer assembly comprising: 
         [0062]    a base member; 
         [0063]    first and second end rings mounted on the base member; 
         [0064]    a deformable sleeve extending from the first end ring to the second end ring around the base member; and 
         [0065]    a swellable sleeve mounted on the deformable sleeve, 
         [0066]    wherein the deformable sleeve is supported by the first and second end rings and the method comprises: 
         [0067]    exerting a pulling force on the base pipe so as to deform the swellable sleeve and the deformable sleeve. 
         [0068]    The deformable sleeve is supported by the first and second end rings so as to define a chamber between an outer surface of the base pipe and an inner surface of the deformable sleeve. The chamber may extend axially between the first and second end rings. The provision of such a chamber may permit the deformable sleeve to deform radially inwardly according to the lateral force exerted by the swellable sleeve on the deformable sleeve. This may reduce the pulling force required to withdraw the packer assembly from a wellbore. 
         [0069]    The method may comprise exposing the packer assembly to well fluids. This may permit well fluids to flow into the annular chamber. 
         [0070]    The first and second end rings may be selectively sealable relative to the base member. The first and second end rings may each comprise an inner O-ring seal for this purpose. The inner or ring seals may comprise a swellable material. 
         [0071]    The deformable sleeve may be joined to the first end ring. 
         [0072]    The deformable sleeve may be selectively sealed relative to the second end ring according to a lateral force exerted by the swellable sleeve on the deformable sleeve. 
         [0073]    The deformable sleeve may be movable relative to the second end ring. 
         [0074]    The deformable sleeve may be movable relative to the second end ring so as to provide a selective seal relative to the second end ring according to a lateral force exerted by the swellable sleeve on the deformable sleeve. 
         [0075]    The method may comprise increasing the pulling force on the base pipe so as to break the seal between the deformable sleeve and the second end ring and permit fluid to flow between the deformable sleeve and the second end ring. This may permit fluid present in the annular chamber to be vented from the annular chamber for the equalisation of pressures inside and outside of the annular chamber. This may permit further deformation of the deformable sleeve. This may reduce the pulling force required to withdraw the packer assembly from a wellbore. 
         [0076]    The deformable sleeve may be selectively supported by the second end ring according to a lateral force exerted by the swellable sleeve on the deformable sleeve. 
         [0077]    The method may comprise exerting a sufficient pulling force on the base pipe so as to increase the lateral force exerted by the swellable sleeve on the deformable sleeve sufficiently to disengage the deformable sleeve from the second end ring. This may cause the deformable sleeve to become de-supported by the second end ring. This may permit the de-deformable sleeve to collapse radially. For example, this may permit a de-supported end or a de-supported end region of the deformable sleeve to collapse radially. This may permit the swellable sleeve to collapse radially. For example, this may permit a de-supported end or a de-supported end region of the swellable sleeve to collapse radially. This may further reduce the pulling force required to withdraw the packer assembly from a wellbore. 
         [0078]    The method may comprise exerting a sufficient pulling force on the base pipe so as to separate the first end ring from the swellable sleeve, for example to separate an axial end face of the first end ring from an axial end face of the swellable sleeve. 
         [0079]    The method may comprise exerting a sufficient pulling force on the base pipe so as to shear a shear screw attaching the second end ring to the base member. This may permit the first end ring and the deformable sleeve to separate axially from the second end ring. This may overcome a bond between the deformable sleeve and the swellable sleeve. This may further de-support the swellable sleeve to allow the further radial collapse thereof. 
         [0080]    It should be understood that one or more of the optional features disclosed in relation to one aspect of the present invention may apply alone or in any combination in relation to any other aspect of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0081]    The present invention will be further described by way of non-limiting example only with reference to the following figures of which: 
           [0082]      FIG. 1A  is a longitudinal cross-section of a swellable packer assembly located within a wellbore prior to setting of the packer assembly; 
           [0083]      FIG. 1B  is a longitudinal cross-section of the packer assembly of  FIG. 1A  after setting of the packer assembly; 
           [0084]      FIG. 1C  is a longitudinal cross-section of the packer assembly of  FIG. 1B  on application of an initial uphole force to a base pipe of the packer assembly during retrieval of the packer assembly from the wellbore; 
           [0085]      FIG. 1D  is a longitudinal cross-section of the packer assembly of  FIG. 1C  on application of an uphole force to the base pipe which is greater than the initial uphole force; 
           [0086]      FIG. 2A  is a longitudinal cross-section detail of the packer assembly of  FIG. 1A  in the vicinity of an upper end of a deformable sleeve prior to setting of the packer assembly; and 
           [0087]      FIG. 2B  is a longitudinal cross-section detail of the packer assembly of  FIG. 1C  in the vicinity of a lower end of the deformable sleeve on application of an initial uphole force to a base pipe of the packer assembly during retrieval of the packer assembly from the wellbore. 
       
    
    
     DETAILED DESCRIPTION 
       [0088]    Terms such as “up”, “down”, “upward”, “downward”, “uphole”, “downhole”, “upper”, “lower” and the like are used below for ease of illustration only. One skilled in the art will understand that such terms are intended to refer to the particular orientation of the features shown, but are not intended to be limiting. For example, terms such as “up”, “upward”, “uphole” and “upper” may be used to refer to a direction along a wellbore towards a point of entry of the wellbore into a surface such as the ground or the seabed, whilst terms such as “down”, “downward”, “downhole” and “lower” may be used to refer to a direction along a wellbore away from the point of entry. As such, when a wellbore is deviated from the vertical, such terms may refer to a direction which differs significantly from a vertical direction and may even refer to a horizontal direction. 
         [0089]    Referring initially to  FIG. 1A  there is shown a swellable packer assembly generally designated  2  located within a wellbore tubular in the form of a wellbore casing  4  prior to setting of the packer assembly  2 . The packer assembly  2  includes a packer device generally designated  6  mounted on a base member in the form of a base pipe  8 . The base pipe  8  includes a coupling  9  at either end thereof for coupling the base pipe  8  to a tubular string (not shown) such as a completion string or a production string (not shown). The packer assembly  2  may be run into the wellbore casing  4  on the tubular string (not shown) prior to setting of the packer device  6 . As will be described in more detail below, the tubular string (not shown) may also be used for pulling the packer assembly  2  out of the wellbore casing  4  some time after the packer device  6  has been set. 
         [0090]    The packer device  6  includes an upper end ring  10  and a lower end ring  12 . The packer device  6  includes a deformable sleeve  14  which extends around the base pipe  8  from the upper end ring  10  to the lower end ring  12 . The deformable sleeve  14  is formed from steel and has a wall thickness in the range of 1.5 mm to 3 mm. The packer device  6  includes a swellable sealing sleeve  16  bonded to an outer surface of the deformable sleeve  14 . The upper end ring  10  is fixed to the base pipe  8  by one or more set screws  15 . The upper end ring  10  is provided with a swellable inner O-ring seal  17  for sealing an inner surface of the upper end ring  10  against an outer surface of the base pipe  8 . The lower end ring  12  is frangibly connected to the base pipe  8  by one or more shear screws  18 . The lower end ring  12  is provided with a swellable inner O-ring seal  19  for sealing an inner surface of the lower end ring  12  against the outer surface of the base pipe  8 . 
         [0091]    The deformable sleeve  14  is supported by the upper end ring  10 . As will be described in more detail below, the deformable sleeve  14  is axially moveable relative to the lower end ring  12  according to a lateral force exerted by the swellable sealing sleeve  16  on the deformable sleeve  14 . Moreover, the deformable sleeve  14  is selectively supported by the lower end ring  12  according to the lateral force exerted by the swellable sealing sleeve  16  on the deformable sleeve  14 . 
         [0092]    An upper end  20  of the deformable sleeve  14  is received within a complimentary annular recess  22  defined within an axial end face  24  of the upper end ring  10 . The deformable sleeve  14  is joined to the upper end ring  10  by a full circle weld  26  which extends around an outer surface of the deformable sleeve  14 . The axial end face  24  of the upper end ring  10  is bonded to an upper axial end face  25  of the sealing sleeve  16 . 
         [0093]    A lower end  30  of the deformable sleeve  14  is received within a complimentary annular recess  32  defined within an axial end face  34  of the lower end ring  12 . The axial end face  34  of the lower end ring  12  engages but is unbonded to a lower axial end face  35  of the sealing sleeve  16 . 
         [0094]    An outer surface of the base pipe  8 , an inner surface of the deformable sleeve  14  and the axial end faces  24 ,  34  of the upper and lower end rings  10 ,  12  together define an annular chamber  36 . 
         [0095]    The packer device  6  accommodates one or more control lines  40  in through holes (not shown explicitly in  FIG. 1A ) formed in the upper and lower end rings  10 ,  12  and the swellable sealing sleeve  16 . The control lines  40  may provide for the transfer of electrical power, for communications and/or for the transfer of fluids through the packer assembly  2  between a tool or device (not shown) located below the packer assembly  2  and a further tool or device (not shown) or a wellhead (not shown) located above the packer assembly  2 . The packer device  6  includes an upper retaining cap  42  which is fixed to the upper end ring  10  over the control lines  40  by cap screws  44  to retain the control lines  40  relative to the upper end ring  10 . Similarly, the packer device  6  includes a lower retaining cap  46  which is fixed to the lower end ring  12  over the control lines  40  by cap screws  48  to retain the control lines  40  relative to the lower end ring  12 . 
         [0096]      FIG. 2A  shows a detailed view of the packer assembly  2  in the vicinity of the lower end  30  of the deformable sleeve  14  prior to setting of the packer assembly  2 . The annular recess  32  accommodates an O-ring seal  50  in a sidewall  52  thereof. Two circumferential grooves  54  are defined in an outer surface of the deformable sleeve  14 . The circumferential grooves  54  are axially separated so as to define a sealing area  56  therebetween on the outer surface of the deformable sleeve  14 . The sealing area  56  has a greater outer diameter compared to the outer diameters of the circumferential grooves  54 . As shown in  FIG. 2A , before retrieval of the packer assembly  2 , the lower end  30  of the deformable sleeve  14  is fully inserted into the annular recess  32  such that the O-ring seal  50  engages and seals against the sealing area  56 . 
         [0097]    As the packer assembly  2  is run into the wellbore casing  4 , the swellable inner O-rings  17 ,  19  are in an unswollen state and permit well fluids to flow into the annular chamber  36  to equalise pressure internally and externally of the deformable sleeve  14 . Following exposure of the inner O-rings  17 ,  19  to well fluids, the inner O-rings  17 ,  19  swell and sealingly engage the outer surface of the base pipe  8  and seal the annular chamber  36  from well pressure. 
         [0098]    As shown in  FIG. 1B , on exposure of the swellable sealing sleeve  16  to a fluid in the wellbore casing  4 , the sealing sleeve  16  swells sufficiently to engage an inner wall of the well casing  4  and exert a pack-off force on the inner wall of the well casing  4 . The deformable element  14  is sufficiently stiff so that when the deformable element  14  is supported by both the upper and lower end rings  10 ,  12  as shown in  FIG. 1B , the deformable element  14  supports the pack-off force without any significant deformation of the deformable element  14  and prevents fluid flow between the packer assembly  2  and the wellbore casing  4 . 
         [0099]    To retrieve the packer assembly  2  from the wellbore casing  4  after swelling of the swellable sealing sleeve  16 , an initial upward force is applied to the base pipe  8 . Depending on the friction forces acting between the outer surface of the swollen sealing sleeve  16  and the inner surface of the wellbore casing  4 , this may result in retrieval of the packer assembly  2  from the wellbore casing  4  in a number of different ways. 
         [0100]    For relatively low friction forces, a relatively low initial upward force may be sufficient to overcome the friction forces such that neither the sealing sleeve  16  nor the deformable sleeve  14  are deformed to any significant degree as the sealing assembly  2  is pulled out of the wellbore casing  4 . 
         [0101]    If the initial upward pulling force is not sufficient to overcome the friction forces, an increase in the upward pulling force may cause the sealing sleeve  16  to be compressed axially and react on the deformable sleeve  14  as shown in  FIG. 1C . The weakness of the deformable sleeve  14  allows it to flex inwards so as to partially withdraw the lower end  30  of the deformable sleeve  14  from the annular recess  32  in the lower end ring  12  as shown most clearly in  FIG. 2B . This results in the axial misalignment of the O-ring  50  and the sealing area  56  thereby providing a fluid flow path that extends from the outside of the packer assembly  2  along the interface between the lower axial end face  35  of the sealing sleeve  16  and the upper axial end face  34  of the lower end ring  12 , past the sealing area  56 , the O-ring seal  50 , and the lower end  30  of the deformable element  14  to the annular chamber  36 . The fluid flow path thus created permits fluid contained within the annular chamber  36  to be vented from the annular chamber  36  so as to permit further deformation of the deformable sleeve  14 . Deformation of the deformable sleeve  14  reduces the friction forces acting between the outer surface of the deformable sleeve  14  and the inner surface of the well casing  4  thereby reducing the upward force required to retrieve the packer assembly  2  from the well casing  4 . 
         [0102]    If the flexing of the deformable sleeve  14  is insufficient to overcome the friction forces between the outer surface of the sealing sleeve  16  and the inner surface of the wellbore casing  4 , then the upward force applied to the base pipe may be increased to overcome the bonding between the upper axial end face  25  of the sealing sleeve  16  and the axial end face  24  of the upper end ring  10 . The sealing sleeve  16  then acts on the lower end ring  12  to shear the shear screws  18 . This permits the lower end ring  12  to move downwardly thereby de-supporting the lower end  30  of the deformable sleeve  14 . This permits the lower end  30  of the deformable sleeve  14  and the sealing sleeve  16  to collapse inwardly to further reduce the friction forces and thereby permit retrieval of the packer assembly  2  from the well casing  4 . Downward movement of the lower end ring  12  is arrested when the lower end ring  12  locates against a shoulder  60  defined at an upper end of the lower coupling  9 . 
         [0103]    Thus, the packer assembly  2  may sequentially adopt one of three different configurations according to the magnitude of the upward force applied to the base pipe  8  that is required to overcome the friction forces acting between the outer surface of the sealing sleeve  16  and the inner surface of the wellbore casing  4 . The packer assembly  2  does not require well intervention to de-activate the packer assembly  2  prior to retrieval thereof from the wellbore and at least partially mitigates against any risk of disintegration of the packer assembly  2  and/or damage to the wellbore.