Patent Publication Number: US-10309186-B2

Title: Open-hole mechanical packer with external feed through run underneath packing system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is related to U.S. patent application Ser. No. 15/722,160 filed on Oct. 2, 2017, and entitled “Open-Hole Mechanical Packer with External Feed Through and Racked Packing System,” and U.S. patent application Ser. No. 15/722,197 filed on Oct. 2, 2017, and entitled “Locking Keyed Component for Downhole Tool,” the contents of each of which are hereby incorporated by reference in their entirety. 
     FIELD OF THE DISCLOSURE 
     The disclosure is related to the field of mechanically-set packers and more particularly to mechanically-set packers with external feed throughs run underneath packing elements. 
     BACKGROUND 
     In open-hole wellbore operations, a packer assembly system may sometimes be used to create a seal between an uphole portion of a wellbore and a downhole portion of the wellbore in order to enable operations to be performed by one or more tools on a string within the downhole portion. Mechanically-set packer assembly systems may rely on non-swellable materials that are expanded by mechanical means, as opposed to swelling means, to form a seal with a wall of the wellbore. Any interruptions between a packing element, or a sealing element, of the packer assembly system and the wellbore wall may prevent proper sealing and may adversely affect operations in the wellbore. 
     A typical packer assembly system may not provide accommodations for communication lines and/or control lines to be inserted within the packer system. If accommodations are provided, in a typical packer assembly, the line may be run either through the packing element, through an exterior of the packer assembly system, or through a drilled hole in the mandrel, which may result in the packer assembly not sealing completely when set within a wellbore. Some packer assemblies may rely on swellable materials to try to reduce this potential problem. However, in a mechanically set packer assembly, swellable materials may not be compatible with a packing or sealing element. Hence, in mechanically-set packer systems, it may be difficult to pass communication lines through the packer assembly. Packer assemblies that provide a line through either the packing element, an exterior of the packer assembly, or through the mandrel typically require splicing the communication line and/or control line above and below the packer assembly. Splicing enables an uphole portion of the line to be connected to a bridging communication line that is pre-installed through the packing system, which is in turn connected to a downhole portion of line. Splicing is a complex operation that may increase the resources necessary to run a packer system into a wellbore. Further, splices in a communication line and/or a control line may significantly degrade signal quality and may, therefore, adversely affect operations within the wellbore. Also, splices in the line may present a weak point, which may affect the integrity of the seal provided by the packer. Other disadvantages may exist. 
     SUMMARY 
     The present disclosure is directed a packer system for use in a wellbore. The packer system may be positioned along a string and includes a line that traverses the packer system along the string without the use of splices. 
     In an embodiment, a mechanically-set packer system for use in a wellbore environment includes a mandrel having an interior and an exterior. The system further includes a packing element positioned along the exterior of the mandrel. The system also includes a line positioned between the exterior of the mandrel and an interior of the packing element. 
     In some embodiments, the packing element is formed of a non-swellable material. In some embodiments, the non-swellable material includes a metallic material, an elastomeric material, or a thermoplastic material. In some embodiments, the packing element includes a cut to enable the line to be installed within the interior of the packing element. In some embodiments, the system includes a longitudinal recess in the exterior of the mandrel, the longitudinal recess configured to receive the line therein. In some embodiments, the system includes a cover positioned over at least a portion of the line positioned between the exterior of the mandrel and the interior of the packing element, the cover formed of a non-swellable material. In some embodiments, the line is a pneumatic line, an electrical line, or an optical line. In some embodiments, the line is continuous, without splices, from a surface location to a tool, the packing element being located between the surface location and the tool. In some embodiments, the mandrel has a first end and a second end and wherein the line is continuous, without splices, from the first end to the second end. 
     In some embodiments, the system includes at least one gauge ring positioned on the exterior of the mandrel, the at least one gauge ring connected to a first end of the packing element, the line positioned through a gap in the at least one gauge ring. In some embodiments, the system includes at least one C-ring positioned on the exterior of the mandrel, the at least one C-ring connected to a second end of the packing element the line positioned through a gap in the at least one C-ring. In some embodiments, the wellbore environment is an open-hole wellbore. 
     In an embodiment, a mechanically-set packer system for use in a wellbore environment includes a mandrel having an interior and an exterior. The system further includes a packing element positioned on the exterior of the mandrel. The mandrel and the packing element are configured to receive a line between the exterior of the mandrel and an interior of the packing element. 
     In some embodiments, the packing element is formed of a non-swellable material. In some embodiments, the non-swellable material includes a metallic material, an elastomeric material, or a thermoplastic material. In some embodiments, the packing element includes a cut to enable the line to be installed within the interior of the packing element. In some embodiments, the system includes a longitudinal recess in the exterior of the mandrel, the longitudinal recess configured to receive the line therein. In some embodiments, the system includes a cover positioned over at least a portion of the line positioned between the exterior of the mandrel and the interior of the packing element, the cover formed of a non-swellable material. 
     In an embodiment, a mechanically-set packer system for use in a wellbore environment includes a mandrel having an interior and an exterior. The system also includes a packing element positioned along the exterior of the mandrel. The system further includes a sleeve formed of a non-swellable material and configured to cover at least a portion of a surface of a line. The packing element is configured to receive the line and the protective sleeve therethrough, the protective sleeve forming a seal with the packing element. The sleeve formed of a non-swellable material may also be used in embodiments where the line is positioned between an exterior of the mandrel and an interior of the packing element. In some embodiments, the mandrel has a first end and a second end and wherein the line is continuous, without splices, from the first end to the second end. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic drawing depicting a side view of an embodiment of a mechanically-set packer system for use in a wellbore. 
         FIG. 2  is a schematic drawing depicting a top view of an embodiment of a mechanically-set packer system for use in a wellbore. 
         FIGS. 3 and 4  are schematic drawings depicting sectional views of an embodiment of a mechanically-set packer system for use in a wellbore. 
         FIG. 5  is a schematic drawing depicting an isometric view of an embodiment of a mechanically-set packer system for use in a wellbore is depicted. 
         FIG. 6  is a schematic drawing depicting an isometric view of an embodiment of a mechanically-set packer system for use in a wellbore. 
         FIG. 7  is a schematic drawing depicting an isometric view of an embodiment of a mechanically-set packer system for use in a wellbore. 
         FIG. 8  is a schematic drawing depicting an isometric view of an embodiment of a line system for use with a mechanically-set packer system. 
         FIG. 9  is a flowchart depicting an embodiment of a method for using a mechanically-set packer to isolate different portions of a wellbore while enabling communication therebetween. 
     
    
    
     While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the disclosure. 
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a side view of an embodiment of a mechanically-set packer system  100  for use in a wellbore is depicted. As discussed in the above related patent applications entitled “Open-Hole Mechanical Packer with External Feed Through and Racked Packing System” and “Locking Keyed Components for Downhole Tools,” it may be beneficial to run a continuous line, such as line  180  shown in  FIG. 1 , down a work or tubing string that does not require splices to traverse the string. The line  180  may provide communication with a downhole location, control of a downhole device, or both as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. As the line  180  travels along the string it may need to bypass the seal made by the packer system  100 . 
     The packer system  100  may include a packing element  104 . The packing element  104  may be suitable for mechanically-set packing. As such, the packing element  104  may be formed from a non-swellable material. The non-swellable material may include a metallic material, an elastomeric material, or a thermoplastic material. The process of mechanically setting the packing element  104  is further described herein. 
     The packer system  100  may further include multiple rings. For example, the packer system  100  may include a first inner grooved C-ring  106  and a second inner grooved C-ring  108 . The packer system  100  may also include a first outer grooved C-ring  110  and a second outer grooved C-ring  112 . The first inner grooved C-ring  106  and the first outer grooved C-ring  110  may be positioned on a first or uphole side of the packing element  104  while the second inner grooved C-ring  108  and the second outer grooved C-ring  112  may be positioned on a second or downhole side of the packing element  104 . 
     The packer system  100  may include a first keyed inner wedge ring  114  on an uphole side of the packing element  104  and a second keyed inner wedge ring  116  on a downhole side of the packing element  104 . The inner wedge rings  114 ,  116  may have a circumferential gap defined therein to enable the insertion of the line  180  into an interior of the wedge rings  114 ,  116 . A first inner wedge ring key  118  (shown in  FIG. 2 ) may correspond to a gap in the first keyed inner wedge ring  114  and may be inserted into the gap after the line  180  has been installed to complete the first keyed inner wedge ring  114  and to provide structural support thereto. Likewise, a second inner wedge ring key  120  (shown in  FIG. 2 ) may correspond to a gap in the second keyed inner wedge ring  116  and may be inserted into the gap to complete the second keyed inner wedge ring  116 . 
     The packer system  100  may further include a first wedge C-ring  122  positioned uphole to the packing element  104  and a second wedge C-ring  124  positioned downhole to the packing element  104 . During installation and setting, each of the uphole rings  106 ,  110 ,  114 ,  122  may be compressed and may, thereby, engage each other to expand the packing element  104  from an uphole side. Likewise, each of the downhole rings  108 ,  112 ,  116 ,  124  may be compressed and may engage each other to expand the packing element  104  from a downhole side. Thus, rather than swelling, the packing element  104  may be expanded mechanically. Expansion of the packing element  104  is further described herein. 
     The packer system  100  may also include a keyed gauge ring  126 . The keyed gauge ring  126  may engage the first wedge C-ring  122  uphole from the packing element  104 . The keyed gauge ring  126  may also include a gap defined therein to enable installation of the line  180  within the keyed gauge ring  126  after the packer system  100  is assembled. A first gauge ring key  128  (shown in  FIG. 2 s   ) may correspond to a gap in the keyed gauge ring  126  and may be inserted into the gap to complete the keyed gauge ring  126  and provide structural support thereto. 
     The number, shape, size, and/or configurations of the ring elements is shown for illustrative purposes only and may be varied depending on the application as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. As used herein, a “first ring” comprises any element configured to be positioned around the mandrel  152  on a first side of the packer element  104  and a “second ring” comprises any element configured to be positioned around the mandrel  152  on a second side of the packer element  104 . 
     The packer system  100  may include a mandrel  152  and a housing  154 . The housing  154  may also be referred to as a push wedge ring. The mandrel  152  and the housing  154  may be coupled to additional string elements (not shown) which may in turn attach to a tool for use within the wellbore. A second gauge ring key  156  (shown in  FIG. 2 ) may correspond to the housing  154  and may be inserted into a gap or groove  162  (shown in  FIG. 2 ) defined therein that enables the line  180  to pass from an interior of the housing  154  to an exterior of the housing  154  as described herein. 
     Thus, the line  180  may pass within an interior of the packer system  100  and over an exterior of the mandrel  152 . The line may be continuous, having no splices at least along the length of the mandrel  152 . In some embodiments, the line is continuous, having no splices from a surface of the wellbore to a tool attached to the end of the mandrel  152  or to a tool attached to a string attached to the end of the packer system  100 . The line may be a pneumatic line, an electrical line, an optical line, or another type of line capable of control or communication. 
     Referring to  FIG. 2 , a top view of an embodiment of a mechanically-set packer system  100  for use in a wellbore is depicted. While  FIG. 2  does not depict the line  180  for clarity, various features are depicted that enable the line  180  to pass within an interior of the packer system  100  and ultimately to an exterior of the housing  154  are shown. 
     As seen in  FIG. 2 , the mandrel  152  may include a longitudinal recess  160  defined in the exterior thereof. The longitudinal recess  160  may be configured to receive the line  180  therein, which is not shown in  FIG. 3  for clarity. The longitudinal recess  160  may retain the line  180  to prevent axial slippage and to prevent the line from interfering with the operation of the packer system  100 . Although  FIG. 2  depicts the longitudinal recess  160  as running along a limited portion of the length of the mandrel  152 , in some embodiments, the longitudinal recess  160  may run along the full length of the mandrel  152 . 
       FIG. 2  also depicts that the keys  118 ,  120 ,  128 ,  156  have been inserted into their respective keyed rings  114 ,  116 ,  126 ,  154 . Before the keys  118 ,  120 ,  128 ,  156  are inserted, the keyed rings  114 ,  116 ,  126 ,  154  may have a gap that enables the line  180  to be pass from an exterior to an interior of the keyed rings  114 ,  116 ,  126 ,  154 . The C-rings  106 ,  108 ,  110 ,  112 ,  122 ,  124  may also include gaps that enable the insertion of the line  180 . These rings, however, may not be keyed in order to allow for radial expansion. Instead, the rings may include a gap that permits both the radial expansion of the ring as well as removal of the ring component from off the line  180  as discussed in the above referenced related applications. 
     The gaps in each of the keyed rings  114 ,  116 ,  126 ,  154 , and in each of the C-rings  106 ,  108 ,  110 ,  112 ,  122 ,  124  may enable individual rings to be removed from their position on the mandrel  152  without affecting the remaining rings, such as for replacement or upgrading purposes. The line  180  may likewise be inserted or removed from rings individually. Other advantages of the gaps may exist. 
     In some embodiments, one or more fasteners may be used to retain the keys  118 ,  120 ,  128 ,  156 . For example,  FIG. 2  depicts one or more fasteners  129  locking the key  128  into place. Likewise, one or more fasteners  157  may lock the key  156  into place. Alternatively, other retention mechanisms may be used to lock the keys  118 ,  120 ,  128 ,  156  into place, such as interference fits, glue, welding, other attachment mechanism, or any combinations thereof. 
     The housing  154  may include a groove  162  defined therein. The groove  162  may provide a pathway for the line  180  to pass from an interior of the housing  154  to an exterior of the housing  154 . The key  156  may close off the groove  162 , thereby locking in the line  180  and providing structural support for the housing  154 . 
     As shown in  FIG. 2 , in some embodiments, the packing element  104  may include a cut  105  to enable the line  180  to be installed within an interior of the packing element  104 . The cut  105  may be a longitudinal cut across the length of the packing element  104  or the cut may have other shapes, such as a spiral shape or other patterned shape. In other embodiments, the packing element  104  may be cut by a technician assembling the packer assembly  104 . Yet in other embodiments, the packing element  104  may be threaded onto the line  180  before assembly. 
     Referring to  FIGS. 3 and 4 , sectional views of an embodiment of a mechanically-set packer system  100  for use in a wellbore are depicted. As shown in  FIG. 3 , the mandrel  152  may include an exterior  170  and an interior  172 . The line  180  may run along the exterior  170  of the mandrel  152 . The packing element  104  may also include an exterior  174  and an interior  176 . The line  180  may be positioned between the exterior  170  of the mandrel  152  and the interior  176  of the packing element  104 . The line may further be positioned between an interior of each of the rings  106 ,  108 ,  110 ,  112 ,  114 ,  116 ,  122 ,  124 ,  126  and the mandrel  152 . The keys  118 ,  120 ,  128 ,  156  may cover the line  180  retaining it in its position within the interior of the packing assembly  102 . 
     A cover  182  may be positioned over the line  180  between the packing element  104  and the mandrel  152 . The cover  182  may include a metallic material, an elastomeric material, a thermoplastic material, or a combination thereof. The cover  182  may assist with forming a seal with the packing element  104  against the line  180  when the packer assembly  102  is expanded and set. 
     The housing  154  may include an exterior  194  and an interior  196 . As depicted, the groove  162  may pass through the housing  154  providing a pathway for the line  180 . The line  180  may pass through the groove  162  from the interior  196  of the housing  154  to the exterior  194  of the housing  154 . From there, the line  180  may pass to a tool (not shown) attached to the housing  154 . 
     The mandrel  152  may include a first end  190 , shown in  FIG. 3 , and a second end  192 , shown in  FIG. 4 . The line  180  may pass from the first end  190  to the second end  192  without any splices. An advantage of passing the length of the mandrel  152  without any splices is that better communication through the line  180  may be enabled without interruption during the installation of the packer assembly  102 . Other advantages may exist. 
     Referring to  FIG. 5 , an isometric view of an embodiment of a mechanically-set packer system  100  for use in a wellbore is depicted. In  FIG. 5 , the packer system  100  is shown as being unset.  FIG. 5  depicts a first set of rings  602  and a second set of rings  604 . The first set of rings  602  may include the first inner grooved C-ring  106 , the first outer grooved C-ring  110 , the first keyed inner wedge ring  114 , the first wedge C-ring  122 , and the keyed gauge ring  126 . The second set of rings  604  may include the second inner grooved C-ring  108 , the second outer grooved C-ring  112 , the second keyed inner wedge ring  116 , and the second wedge C-ring  124 . 
     Referring to  FIG. 6 , an isometric view of an embodiment of a mechanically-set packer system  100  for use in a wellbore is depicted. In  FIG. 6 , the packer system  100  is shown as being set. In order to form a seal with the wellbore, the packer system  100  may be mechanically actuated to move the packing element  104  from an unset or unexpanded state (shown in  FIG. 5 ) to a set or expanded state (shown in  FIG. 6 ). In the set state, the first set of rings  602  and the second set of rings  604  may be compressed and may interact with each other to create an expansion force on the packing element  104 . The compression may include weight-set compression, hydraulic-set compression, or hydrostatic-set compression. As a result of the compression, the packing element  104  may be expanded to form a seal with a wall of a wellbore. The packing element  104  may also form a seal with the mandrel  152  and the line  180  positioned between the mandrel  152  and the packing element  104 . 
     Referring to  FIG. 7 , an isometric view of an embodiment of a mechanically-set packer system  700  for use in a wellbore is depicted. The system  700  may include a packing element  104 , a gauge ring  126 , a housing  154 , and a mandrel  152 . As shown in  FIG. 7 , the packing element  104  may include a recess  702  defined therein. The packing element  104  may include a longitudinal slit that enables the line  180  to be inserted into the packing element  104 . When the packing element is mechanically-set, or expanded, the longitudinal slit may compress around the line  180  forming a tight seal. The gauge ring  126  may include a groove  704  to receive the line  180  therein and, likewise, the housing  154  may include a groove  706  to receive the line  180  therein. In some embodiments, the system  700  may include additional rings. For example, the system  700  may include the first set of rings  602  and the second set of rings  604  described herein. An advantage of the system  700  is that by forming a seal around the line  180 , the longitudinal slit  702  in the packing element  104  may enable the use of a continuous line, without any splices, for communication with a downhole tool. Other advantages may exist. 
     Referring to  FIG. 8 , an isometric view of an embodiment of a line assembly is depicted. The line assembly may include the line  180  and a sleeve  802  positioned over a portion of the line  180 . The line assembly may be installed within the system  700 . When the packer system  700  is set by expanding the packing element  104 , the sleeve  802  and the packing element  104  may form a seal. The sleeve  802  may include a non-swellable material compatible with a material of the packing element  104 . The sleeve  802  may enable the line  180  to form a better seal than a line that does not include a sleeve. The sleeve  802  may further be included in embodiments where the line  180  is positioned between an exterior of the mandrel  152  and an interior of the packing element  104 . For example, the sleeve  802  may be coupled to the line  180  of  FIGS. 1-6 . 
     In some embodiments, the sleeve  802  may be configured to provide complete circumferential coverage along a portion of the line  180  as depicted in  FIG. 8 . Alternatively, the sleeve  802  may be configured to provide partial circumferential coverage along the portion of the line  180 . For example, the sleeve  802  may cover only a bottom half, only a top half, or another portion of the line  180 . The sleeve  802  may also include cuts to enable the sleeve  802  to be attached to the line  180 . For example, the sleeve  802  may include a spiral cut to wrap around the line  180 . Other cut patterns may also be used. In some embodiments, the sleeve  802  may comprise a single sleeve component. In other embodiments, the sleeve  802  may comprise multiple sleeve components that together form the sleeve  802 . 
     Referring to  FIG. 9 , an embodiment of a method for using a mechanically-set packer to isolate different portions of a wellbore while enabling communication therebetween is depicted. The method  900  may include actuating a packing element to cause the packing element to extrude radially outwards and seal against a portion of a wellbore, at  902 . For example, the packing element  104  may be actuated to cause the packing element  104  to extrude radially and seal against a portion of a wellbore. 
     The method  900  may further include sealing the packing element against a line positioned between an interior of the packing element and an exterior of a mandrel, at  904 . For example, the packing element  104  may be sealed against the line  180 . 
     The method  900  may also include communicating through the line, at  906 . For example, the line  180  may be used for communication, including sending control signals, between a surface of the wellbore and to a tool. 
     Although various embodiments have been shown and described, the present disclosure is not so limited and will be understood to include all such modifications and variations as would be apparent to one skilled in the art.