Patent Publication Number: US-10760371-B2

Title: System for limiting radial expansion of an expandable seal

Description:
BACKGROUND 
     In the resource exploration and recovery industry, seals are often used to limit fluid flow through and between various components of a drill string and/or a casing tubular. In some cases, the seal includes a sealing member coupled to a support. The support is shifted along a conical surface resulting in radial expansion of the sealing member. Radial expansion of the seal brings the sealing member into contact with a structure positioned adjacent to, and radially outwardly of, the conical surface. 
     In some instances, it is desirable to limit radial expansion of the seal. Limiting radial expansion may reduce stress that could result in cracking of the steel support and, ultimately lead to a loss of sealing capability. Various designs have been used to limit seal expansion. For example, some systems rely on rings that may extend about an outer diameter of the sealing member. In some cases, the rings may nest with gaps formed between adjacent ribs of the sealing member. 
     In such designs all interactions are between metallic components, e.g., the conical surface and the support, and the ring, and the casing. Metal to metal interactions may limit an over efficacy of seal integrity. That is, as a setting force is applied, the sealing member begins to conform to the inner surface of the casing or other tubular. As the sealing member conforms, the ring contacts the inner surface of the casing to prevent over expansion. However, once ring contact is established, the sealing member ceases to further conform. Therefore, the art would be appreciative of an expansion limiter for a seal that allows a sealing member to continue to conform to a sealing surface as radial expansion is being limited. 
     SUMMARY 
     Disclosed is a seal system for downhole use in a surrounding tubular, the seal system including a seal support including a frusto-conical surface, and a seal member positioned about the seal support. The seal member includes a seal support member including first side having a recess, a second, opposing side, and a seal element coupled to the second, opposing side. The seal element is engageable with the surrounding tubular. An expansion limiter is arranged between the seal support and the seal member. The expansion limiter is positioned in the recess of the seal support member to limit axial movement of the seal member relative to the frusto-conical surface. 
     Also disclosed is a resource exploration and recovery system including a first system, and a second system having a tubular string extending through a surrounding tubular. A seal including a seal support is connected to the tubular string. The seal support has a frusto-conical surface. A seal member is positioned about the seal support. The seal member includes a seal support member including a first side having recess, a second, opposing side, and a seal element coupled to the second, opposing side. The seal element is engageable with the surrounding tubular. An expansion limiter is arranged between the seal support and the seal member. The expansion limiter is positioned in the recess of the seal support member to limit axial movement of the seal member relative to the frusto-conical surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  depicts a resource exploration and recovery system including a system for limiting radial expansion of an expandable seal member, in accordance with an exemplary embodiment; 
         FIG. 2  depicts a cross-sectional view of an expandable seal member and an expansion limiter, in accordance with an exemplary aspect; 
         FIG. 3  depicts a perspective view of an expansion limiter, in accordance with an exemplary aspect; 
         FIG. 4  depicts a cross-sectional view of an expandable seal member including two expansion limiters, in accordance with another aspect of an exemplary embodiment; 
         FIG. 5  depicts a cross-sectional view of two expandable seal members mechanically linked by an expansion limiter in an un-set configuration, in accordance with yet another aspect of an exemplary embodiment; 
         FIG. 6  depicts a cross-sectional view of two expandable seal members mechanically linked by an expansion limiter in a set configuration, in accordance with yet another aspect of an exemplary embodiment 
         FIG. 7  depicts a perspective view of the expansion limiter of  FIG. 5 , in accordance with an exemplary aspect; and 
         FIG. 8  depicts a perspective view of the expansion limiter of  FIG. 5 , in accordance with another aspect of an exemplary aspect. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     A resource exploration and recovery system, in accordance with an exemplary embodiment, is indicated generally at  10 , in  FIG. 1 . Resource exploration and recovery system  10  should be understood to include well drilling operations, completions, resource extraction and recovery, CO 2  sequestration, and the like. Resource exploration and recovery system  10  may include a first system  14  which, in some environments, may take the form of a surface system  16  operatively and fluidically connected to a second system  18  which, in some environments, may take the form of a downhole system. 
     First system  14  may include a control system  23  that may provide power to, monitor, communicate with, and/or activate one or more downhole operations as will be discussed herein. Surface system  16  may include additional systems such as pumps, fluid storage systems, cranes and the like (not shown). Second system  18  may include a tubular string  30  that extends into a wellbore  34  formed in formation  36 . Wellbore  34  includes an annular wall  38  which may be defined by a surface of formation  36 , or, in the embodiment shown, by a casing tubular  40 . 
     Tubular string  30  may be formed by a series of interconnected discrete tubulars, or by a single tubular that could take the form of coiled tubing. Tubular string  30  supports a seal system  46  that may be selectively set to isolate one portion of wellbore  34  from another. While only a single seal system is shown, it should be understood that multiple seal systems may be employed to create a number of fluidically isolated zones along tubular string  30 . 
     In an embodiment, seal system  46  includes an expandable seal member  48  and an expansion limiter  52 . Expansion limiter  52  limits radial outward expansion of expandable seal member  48 . Referring to  FIG. 2 , tubular string  30  includes a seal support  58  having a radial outer frusto-conical surface  60 . Annular wall  38  defines a radial inner surface  62 . Expandable seal member  48  is posited between and activated to seal against radial outer frusto-conical surface  60  and inner surface  62 . 
     In an embodiment, expandable seal member  48  includes a seal support member  70  having a first side  72  and a second, opposing side  74 . Seal support member  70  may be formed from a material that is annealed to promote elongation (expansion) with relatively low expansion forces. First side  72  includes a first recess  79  and a second recess  81 . A seal  84 , shown in the form of an O-ring, is arranged in second recess  81 . It should be understood that seal  84  may take on various formed including molded elastomer members. Seal  84  seals against radially outer frusto-conical surface  60  of seal support  58 . Seal support  58  could take the form of a mandrel. Second side  74  includes a plurality of ribs  88  that project outwardly of seal support member  70 . Ribs  88  support a seal element  90  formed from an elastomer  94  that is selectively urged against radial inner surface  62  of casing tubular  40 . 
     In an embodiment, expansion limiter  52  nests within first recess  79 . As expandable seal member  48  is shifted along outer radial frusto-conical surface  60 , seal support member  70  expands forcing seal element  90  into contact with radial inner surface  62 . More specifically, axially shifting seal system  46  along outer radial frusto-conical surface  60  causes seal support member  70  to expand thereby allowing seal element  90  to be forced against and conform to any irregularities in radial inner surface  62  to form a robust seal. Expansion limiter  52  prevents seal support member  70  from expanding beyond selected dimensions in order to maintain compressive forces on seal element  90  below predetermined limits. 
     In an embodiment, expansion limiter  52  may be formed from a material that possess a stiffness and hardness greater than that of seal support member  70 . For example, expansion limiter may be formed from wrought low alloy steels. As shown in  FIG. 3 , expansion limiter  52  is formed from a number of segments including a first segment  100 , a second segment  102 , and a third segment  104 . The number of segments may vary. Segments  100 ,  102 ,  104  are arranged in an annulus with end portions (not separately labeled) having straight end surfaces  108 ,  110 , and  11 : 2 . Of course, segments may include end portions having different geometries including those forming expansion joints as will be discussed herein. 
     Expansion limiter  52  operates to increase contact pressure between seal element  90  and radial inner surface  62  as seal support member  70  travels over outer radial frusto-conical surface  60 . The increase in contact pressure acts as a stop limiting the travel of seal support member  70 . The increase in contact pressure also enhances seal ability of seal system  46 . At this point, it should be understood that while shown as being generally rectangular, the cross-section of the expansion limiter may vary. 
     Reference will now follow to  FIG. 4 , wherein like reference numbers represent corresponding parts in the respective views, in describing an expandable seal member  120  in accordance with another aspect of an exemplary embodiment. Expandable seal member  120  includes a seal support member  122  having a first side  124  and an opposing second side  126 . First side  124  includes a first recess  128 , a second recess  130  and a third recess  132  that is receptive of an O-ring seal.  1 . 34 . 
     Second side  126  includes a plurality of ribs  138  that support, a seal element  140  formed from an elastomer  142 . In an embodiment, a first expansion limiter  145  is arranged in first recess  128  and a second expansion limiter  147  is arranged in second recess  130 . First and second expansion limiters  145  and  147  limit travel of seal support member  122  over outer radial frusto-conical surface  60  in a manner similar to that discussed herein. 
     Reference will now follow  FIGS. 5 and 6 , wherein like reference numbers represent corresponding parts in the respective views, in describing a seal system  154  in accordance with another aspect of an exemplary embodiment. Seal system  154  includes a first expandable seal member  158  mechanically connected to a second expandable seal member  160 . First expandable seal member  158  includes a first seal support member  164  having a first side  166  and an opposing second side  168 . First side  166  includes a first recess  170  and a second recess  172  that may be receptive of a seal  174 , shown in the form of an O-ring. In a manner similar to that discussed herein, seal  174  may take on various forms including molded elastomer members. Second side  168  includes a plurality of ribs  176  that supports a seal element  178 . 
     Second expandable seal member  160  includes a second seal support member  184  having a first side  186  and an opposing second side  188 , First side  186  includes a first recess  190  and a second recess  192  that may be receptive of a seal  194  shown in the form of an O-ring. As discussed herein, seal  194  may take on various forms including molded elastomer members. Second side  188  includes a plurality of ribs  198  that support a seal element  200 . An expansion limiter  208  mechanically connects first seal support member  164  with second seal support member  184 . Expansion limiter  208  includes a first outwardly projecting tab  212  and a second outwardly projecting tab  214  joined by a central web  215 . First outwardly projecting tab  212  extends into first recess  170  of first seal support member  164  and second outwardly projecting tab  214  extends into first recess  190  of second seal support member  184 . 
     In  FIG. 7 , expansion limiter  208  is shown formed from multiple segments including a first segment  218 , a second segment  220 , and a third segment  222 . The number of segments may vary. Segments  218 ,  220 , and  222  are arranged in an annulus with end portions (not separately labeled) having straight end surfaces  225 ,  226 , and  228 . 
       FIG. 8  depicts an expansion limiter  240  including a first outwardly projecting tab  242  and a second outwardly projecting tab  244  connected through a central web  245 . Expansion limiter  240  is formed from multiple segments including a first segment  250 , a second segment  252 , a third segment  254 , a fourth segment  256 , a fifth segment  258 , and a sixth segment  260 . The number of segments may vary. Segments  250 ,  252 ,  254 ,  256 ,  258 , and  260  are arranged in an annulus with end portions (not separately labeled) defining expansion joints  270 ,  272 ,  274 ,  276 , and  278  that accommodate radial expansion of first and second seal supports  164  and  184 . 
     Although not shown, the expansion limiters described herein may be provided with a coating, including particles that enhance grip with outer radial frusto-conical surface  60 . It should also be understood that the expansion limiters allow the seal elements to fully contact and conform to the inner surface of the casing tubular (or other tubular) thereby enhancing seal integrity. 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1 
     A seal system for downhole use in a surrounding tubular, the seal system comprising a seal support including a frusto-conical surface; a seal member positioned about the seal support, the seal member including a seal support member including first side having a recess, a second, opposing side, and a seal element coupled to the second, opposing side, the a seal element being engageable with the surrounding tubular; and an expansion limiter arranged between the seal support and the seal member, the expansion limiter being positioned in the recess of the seal support member to limit axial movement of the seal member relative to the frusto-conical surface. 
     Embodiment 2 
     The seal system according to any prior embodiment, wherein the second, opposing side includes a plurality of ribs supporting the seal element. 
     Embodiment 3 
     The seal system according to any prior embodiment, wherein the seal element is formed from an elastomer. 
     Embodiment 4 
     The seal system according to any prior embodiment, wherein the expansion limiter includes a plurality of segments. 
     Embodiment 5 
     The seal system according to any prior embodiment, wherein one or more of the plurality of segments include straight end surfaces. 
     Embodiment 6 
     The seal system according to any prior embodiment, wherein the plurality of segments are joined through one or more expansion joints. 
     Embodiment 7 
     The seal system according to any prior embodiment, further comprising: another seal member arranged directly adjacent the seal member, wherein the expansion limiter mechanically connects the seal member and the another seal member. 
     Embodiment 8 
     The seal system according to any prior embodiment, wherein the another seal member includes another seal support member having a first side including a recess, a second, opposing side, and a seal element coupled to the second, opposing side, the seal element being engageable with the surrounding tubular. 
     Embodiment 9 
     The seal system according to any prior embodiment, wherein the expansion limiter includes a first radially projecting tab arranged in the recess of the seal member and another radially projecting tab arranged in the recess of the another seal member. 
     Embodiment 10 
     A resource exploration and recovery system comprising a first system; and a second system including a tubular string extending through a surrounding tubular; a seal including a seal support connected to the tubular string, the seal support having a frusto-conical surface; a seal member positioned about the seal support, the seal member including a seal support member including first side having recess, a second, opposing side, and a seal element coupled to the second, opposing side, the seal element being engageable with the surrounding tubular; and an expansion limiter arranged between the seal support and the seal member, the expansion limiter being positioned in the recess of the seal support member to limit axial movement of the seal member relative to the frusto-conical surface. 
     Embodiment 11 
     The resource exploration and recovery system according to any prior embodiment, wherein the second, opposing side includes a plurality of ribs supporting the seal element. 
     Embodiment 12 
     The resource exploration and recovery system according to any prior embodiment, wherein the seal element is formed from an elastomer. 
     Embodiment 13 
     The resource exploration and recovery system according to any prior embodiment, wherein the expansion limiter includes a plurality of segments. 
     Embodiment 14 
     The resource exploration and recovery system according to any prior embodiment, wherein one or more of the plurality of segments include straight end surfaces. 
     Embodiment 15 
     The resource exploration and recovery system according to any prior embodiment, wherein the plurality of segments are joined through one or more expansion joints. 
     Embodiment 16 
     The resource exploration and recovery system according to any prior embodiment, further comprising: another seal member arranged directly adjacent the seal member, wherein the expansion limiter mechanically connects the seal member and the another seal member. 
     Embodiment 17 
     The resource exploration and recovery system according to any prior embodiment, wherein the another seal member includes another seal support member having a first side including a recess, a second, opposing side, and seal element coupled to the second, opposing side, the seal element being engageable with the surrounding tubular. 
     Embodiment 18 
     The resource exploration and recovery system according to any prior embodiment, wherein the expansion limiter includes a first radially projecting tab arranged in the recess of the seal member and another radially projecting tab arranged in the recess of the another seal member. 
     The terms “about” and “substantially” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” can include a range of ±8% or 5%, or 2% of a given value. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. 
     The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.