Patent Description:
Annular barriers are used downhole for providing isolation of one zone from another in an annulus in a borehole of a well between a well tubular metal structure and the borehole wall or another well tubular metal structure. During insertion of the annular barrier into the borehole or during the process of setting the annular barrier, e.g. when an expandable metal sleeve has been expanded, fractures or cracks in the sealing elements may develop, and tests have shown that these fractures or cracks may cause fluid to leak across the seals after expansion as the fractures or cracks open up during expansion. Such prior art barriers are known from for instance <CIT>, <CIT>, <CIT>. <CIT> relates to a downhole expandable tubular to be expanded in a well downhole from a first outer diameter to a second outer diameter for abutting against an inner face of a casing or borehole, the downhole expandable tubular having an outer face and a longitudinal extension, and comprising at least one first circumferential edge and at least one second circumferential edge provided on the outer face and spaced apart in the longitudinal extension, wherein a sealing element and a split ring-shaped retaining element are arranged between the first and second circumferential edges, and wherein the split ring-shaped retaining element has more than one winding, so that when the expandable tubular is expanded from the first outer diameter to the second outer diameter, the split ring-shaped retaining element partly unwinds.

It is an object of the present invention to wholly or partly overcome the above disadvantages and drawbacks of the prior art. More specifically, it is an object to provide an improved annular barrier which has an improved sealing unit able to withstand insertion and expansion without allowing fluid to leak across the sealing unit.

The above objects, together with numerous other objects, advantages and features, which will become evident from the below description, are accomplished by a solution in accordance with the present invention by an annular barrier for providing zonal isolation in an annulus downhole between a well tubular metal structure and another well tubular metal structure or a wall of a borehole, comprising:.

wherein the annular sealing element in a cross-section along the axial extension has a first width, a second width and a third width; the second width is larger than the first width and the third width and is arranged between the first width and the third width; the back-up sealing element has a first contact area, and the annular sealing element has a second contact area, where the first contact area has a shape that mates with the second contact area.

Also, by having the back-up sealing element with a mating shape as that of the annular sealing element having a second width that is larger than the first width and the third width, the back-up sealing element may be able to restrict the annular sealing element from opening a potential crack therein. Thus, even though the annular sealing element has a crack, the back-up sealing element will compress the crack so that no sealing ability is lost.

Moreover, the first contact area and the second contact area may abut each other.

In addition, the back-up sealing element may abut the annular sealing element forming the first contact area of the back-up sealing element and the second contact area of the annular sealing element.

Further, the annular sealing element in a cross-section means the cross-sectional plane extending along the axial extension and a radial extension extending perpendicular thereto, and the annular sealing element along the axial extension may have an extension which is a first width.

Furthermore, the annular sealing element has a second thickness along the radial extension perpendicular to the axial extension, and the second width is arranged at least <NUM>% of the second thickness from the first face and less than <NUM>% of the second thickness from the first face, and preferably the second width is arranged at least <NUM>% of the second thickness from the first face and less than <NUM>% of the second thickness from the first face, and more preferably the second width is arranged at least <NUM>% of the second thickness from the first face and less than <NUM>% of the second thickness from the first face.

Moreover, the first contact area may have a shape that mates with or corresponds to the second contact area. The first contact area may be the inverse shape of the second contact area so as to mate with the second contact area.

In addition, the annular sealing element may comprise a first face facing the circumferential groove and a second face facing away from the circumferential groove; the first width is the width at the first face, and the third width is the width at the second face.

Additionally, the second face may face the other well tubular metal structure and/or the wall of the borehole.

Furthermore, the back-up sealing element may have a first face part and a second face part forming the first contact area of the back-up sealing element; the first face part inclining and facing away from the circumferential groove, and the second face part inclining and facing towards the groove.

Also, by having the first face part inclining and facing away from the circumferential groove, and the second face part inclining and facing towards the groove, the back-up sealing element is able to restrict the annular sealing element from opening a potential crack therein. Thus, even though the annular sealing element has a crack, the back-up sealing element will compress the crack so that no sealing ability is lost.

Further, the first face part may be equal to or larger than the second face part.

Moreover, the first face part may be smaller than the second face part.

In addition, the first face part and/or the second face part may form part of a curvature.

Furthermore, the annular sealing element may also comprise a key ring element surrounding at least part of the back-up sealing element.

Also, the annular barrier may further comprise a second back-up sealing element arranged so that the annular sealing element is between the two back-up sealing elements when seen along the axial extension.

Further, the circumferential groove may be formed between two projections.

Moreover, the first width may be larger than or equal to the third width.

In addition, the first width may be smaller than the third width.

Furthermore, the circumferential groove may have a first end face and a second end face, the first end face and the second end face extending radially to the axial extension.

Also, the first contact area of the back-up sealing elements may have faces facing the annular sealing element, and each back-up sealing element may have an end face opposite the annular sealing element facing and abutting the first end face and the second end face, respectively.

Further, the back-up sealing element may have a first thickness in a direction radial to the axial extension, and the annular sealing element may have a second thickness in a direction radial to the axial extension, the first thickness being substantially equal to or smaller than the second thickness.

Moreover, the circumferential groove may have a depth corresponding to the first thickness and/or the second thickness.

In addition, the annular barrier may further comprise an anchoring element arranged in a second circumferential groove, the anchoring element comprising a first anchoring part at least partly overlapping a second anchoring part in a radial direction perpendicular to the axial extension so that an inner face of the first anchoring part at least partly abuts an outer face of the second anchoring part.

Furthermore, the inner face of the first anchoring part and the outer face of the second anchoring part may be inclined in relation to the axial extension.

Also, the first anchoring part and the second anchoring part may be one monolithic whole.

Further, the first anchoring part may form one monolithic whole, and the second anchoring part may form a second monolithic whole.

Moreover, the first anchoring part may be shaped as a first slit ring, and the second anchoring part may be shaped as a second slit ring.

In addition, the first anchoring part may further comprise an outer face, and the second anchoring part may comprise an inner face; the outer face of the first anchoring part may comprise friction-enhancing means and may face the other well tubular metal structure or the wall of the borehole.

Furthermore, the friction-enhancing means may be spikes or grooves.

Also, the expandable metal sleeve may comprise at least two sealing units, and the anchoring element may be arranged between two sealing units.

Further, the back-up sealing element may be made of elastomer or polymer.

Moreover, the back-up sealing element may be made of Polytetrafluoroethylene (PTFE).

In addition, the key ring element may be made of metal such as spring steel.

Finally, the invention also relates to a downhole completion system comprising an annular barrier and a well tubular metal structure.

The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which:.

<FIG> shows an unexpanded annular barrier <NUM> for providing zonal isolation in an annulus <NUM> downhole between a well tubular metal structure <NUM> and a wall <NUM> of a borehole <NUM>, or another well tubular metal structure 3b, as shown in <FIG>. The annular barrier <NUM> comprises a tubular metal part <NUM> configured to be mounted as part of the well tubular metal structure <NUM>, where the tubular metal part <NUM> has an outer face <NUM>, an opening <NUM> for letting fluid in during expansion of the annular barrier <NUM> and an axial extension L along the well tubular metal structure <NUM>. The annular barrier <NUM> comprises an expandable metal sleeve <NUM> surrounding the tubular metal part <NUM> and having a circumferential groove <NUM>, a first end <NUM> and a second end <NUM>, and each end of the expandable metal sleeve <NUM> is connected with the outer face <NUM> of the tubular metal part <NUM>. The annular barrier <NUM> further comprises an annular sealing unit <NUM> arranged in the circumferential groove <NUM> of the expandable metal sleeve <NUM>, and the annular sealing unit <NUM> comprises an annular sealing element <NUM> and a back-up sealing element <NUM> abutting and supporting the annular sealing element <NUM>. In a cross-section along the axial extension L, the annular sealing element <NUM> has a first width W1, a second width W2 and a third width W3, and the second width W2 is larger than the first width W1 and the third width W3 and is arranged between the first width W1 and the third width W3. The back-up sealing element <NUM> has a first contact area A1, and the annular sealing element <NUM> has a second contact area A2, where the first contact area A1 has a shape that mates with the second contact area A2, as shown in <FIG>. The annular sealing element <NUM> in a cross-section along the axial extension L means the cross-sectional plane extending in an axial extension L, and a radial extension along the axial extension L has a first width W1.

By having the back-up sealing element <NUM> with a mating shape as that of the annular sealing element <NUM> having the second width W2 that is larger than the first width W1 and the third width W3, the back-up sealing element <NUM> is able to restrict the annular sealing element <NUM> from opening a potential crack <NUM> therein, as illustrated by arrows in <FIG>. Thus, even though the annular sealing element <NUM> has a crack <NUM>, the back-up sealing element <NUM> will compress the crack <NUM> so that no sealing ability is lost. In prior art seals A having a back-up element B in the groove of the expandable sleeve E, as shown in <FIG>, a crack C in the seal A will be forced open as shown in <FIG> as the seal A is not restricted, and then there is a risk of fluid leaking across the seal A.

As seen in <FIG>, the annular sealing element <NUM> comprises a first face <NUM> facing the circumferential groove <NUM> and a second face <NUM> facing away from the circumferential groove <NUM>; the first width W1 (shown in <FIG>) is the width at the first face <NUM>, and the third width W3 (shown in <FIG>) is the width at the second face <NUM>.

Thus, the first contact area A1 has a shape that mates with or corresponds to the second contact area A2. The first contact area A1 may thus be the inverse shape of the second contact area A2 so as to mate with the second contact area A2.

As shown in <FIG> and <FIG>, the back-up sealing element <NUM> has a first face part <NUM> and a second face part <NUM> forming the first contact area A1 of the back-up sealing element <NUM>; the first face part <NUM> inclines and faces away from the circumferential groove <NUM>, and the second face part <NUM> inclines and faces towards the circumferential groove <NUM>.

When expanding the expandable metal sleeve <NUM>, cracks or fractures may occur in the elastomeric sealing element; however, if restricted by the back-up sealing element <NUM>, such cracks or fractures will not damage the function of the annular sealing unit <NUM>. Thus, by having the first face part <NUM> inclining and facing away from the circumferential groove <NUM>, and the second face part <NUM> inclining and facing towards the circumferential groove <NUM>, the back-up sealing element <NUM> is able to restrict the annular sealing element <NUM> from opening a potential crack <NUM> therein.

Therefore, even though the annular sealing element <NUM> has a crack <NUM>, the back-up sealing element <NUM> will compress the crack <NUM> so that no sealing ability is lost.

In <FIG>, the first face part <NUM> of the back-up sealing element <NUM> is equal to the second face part <NUM>, and the back-up sealing element <NUM> is thus symmetrical around a centre line along the axial extension L when seen in cross-section as in <FIG>. The annular sealing unit <NUM> has two back-up sealing elements <NUM>', <NUM>" arranged one on each side and both having a shape matching the shape of the annular sealing element <NUM> so as to form an optimal back-up seal.

To the left in the cross-sectional view of the annular sealing unit <NUM> of <FIG>, the first face part <NUM> of the back-up sealing element <NUM>' is smaller than the second face part <NUM>, and to the right the first face part <NUM> of the back-up sealing element <NUM>" is larger than the second face part <NUM>. Thus, the two back-up sealing elements <NUM>', <NUM>" may be of a different shape and be designed to be arranged at different locations along the axial extension L of the annular barrier <NUM>. The annular sealing units <NUM> may be arranged at a location where the pressure along one annular sealing unit <NUM> is varying, and thus the shape of the back-up sealing element <NUM> has a similar varying shape so as to match the varying pressure and so as to cope with larger pressure on the annular sealing unit <NUM> from one side than from the opposite side. The first width W1 of the annular sealing element <NUM> is larger than the third width W3, but in <FIG> and <FIG> the first width W1 of the annular sealing element <NUM> is equal to the third width W3.

In <FIG>, a second back-up sealing element 26B is arranged so that the annular sealing element <NUM> is between the two back-up sealing elements <NUM>, 26B when seen along the axial extension L. As mentioned above, the second back-up sealing element 26B does not necessarily have the same shape as the other back-up sealing element <NUM>, <NUM>', but it may have a straighter contact area towards the annular sealing element <NUM>. In <FIG>, the second width W2 of the annular sealing element <NUM> is also larger than the first width W1 and the third width W3; however, the first width W1 of the annular sealing element <NUM> is smaller than the third width W3.

In <FIG>, the first face part <NUM> and the second face part <NUM> of the first back-up sealing element <NUM>' form a curvature, and the first face part <NUM> and the second face part <NUM> of the second back-up sealing element <NUM>" form a curvature. As can be seen in <FIG>, the second width W2 of the annular sealing element <NUM> is also larger than the first width W1 and third width W3, and the back-up sealing elements <NUM> are able to restrict the annular sealing element <NUM> arranged therebetween.

The back-up sealing element has a first thickness, and the annular sealing element has a second thickness t<NUM> along the radial extension perpendicular to the axial extension, and the second width W2 is arranged at least <NUM>% of the second thickness from the first face and less than <NUM>% of the second thickness from the first face. In <FIG>, the second width is arranged approximately <NUM>% of the second thickness from the first face, and in <FIG> the second width is arranged approximately <NUM>% of the second thickness from the first face. In <FIG>, the second width is arranged approximately <NUM>% of the second thickness from the first face and in <FIG>. In <FIG> and <FIG>, the second width is arranged at least <NUM>% of the second thickness from the first face and less than <NUM>% of the second thickness from the first face.

In <FIG>, the annular sealing element <NUM> further comprises a key ring element <NUM> surrounding part of the back-up sealing element <NUM> to maintain the back-up sealing element <NUM> in the circumferential groove <NUM> during insertion of the annular barrier <NUM> and also during and after expansion. The back-up sealing elements <NUM> thus have a circumferential recess <NUM> to accommodate the key ring element <NUM>, the key ring elements <NUM> unwind as the expandable metal sleeve <NUM> is expanding, and the key ring elements are made of metal such as spring steel. As shown in <FIG>, the annular sealing element <NUM> has a groove <NUM>. As shown in <FIG>, the circumferential groove <NUM> is formed between two projections <NUM> in the expandable metal sleeve <NUM>. The circumferential groove <NUM> has a first end face <NUM> and a second end face <NUM>, and the first end face <NUM> and the second end face <NUM> extend radially to the axial extension L so as to provide back-up to the back-up sealing element <NUM>. The first contact area A1 of the back-up sealing elements <NUM>, <NUM>', <NUM>" have faces <NUM>, <NUM> facing the annular sealing element <NUM>, and each back-up sealing element <NUM>', <NUM>" has an end face <NUM> opposite the annular sealing element <NUM> facing and abutting the first end face <NUM> and the second end face <NUM>, respectively.

As shown in <FIG>, the back-up sealing element <NUM> has a first thickness t<NUM> in a direction radial to the axial extension L, and the annular sealing element <NUM> has a second thickness t<NUM> in a direction radial to the axial extension L, where the second thickness t<NUM> is substantially equal to or larger than the first thickness t<NUM>, as shown in <FIG>. In <FIG>, the first thickness t<NUM> is varying as the second face <NUM> is curved slightly radially outwards away from the circumferential groove <NUM>. The circumferential groove <NUM> has a depth corresponding to the first thickness t<NUM> and the second thickness t<NUM>.

Furthermore, in <FIG> the annular sealing element <NUM> has the circumferential recess 43B, and the back-up sealing element <NUM> has a shape matching the circumferential recess 43B so as to mate with the circumferential recess 43B.

Each end <NUM>, <NUM> of the expandable metal sleeve <NUM> is connected with the outer face <NUM> of the tubular metal part <NUM>, e.g. by means of a connection part <NUM> as shown in <FIG> and/or by means of weld metal as shown in <FIG>. In <FIG>, the annular barrier <NUM> further comprises a valve assembly <NUM> fluidly connected with the opening <NUM> and an expandable space <NUM> so as to fluidly connect the opening <NUM> and the expandable space <NUM> during expansion of the expandable metal sleeve <NUM> and close the fluid connection after the expandable metal sleeve <NUM> has been properly expanded. The valve assembly <NUM> may in the second position open for a fluid connection between the annulus <NUM> and the expandable space <NUM> in order to equalise the pressure therebetween.

In <FIG>, the annular barrier <NUM> further comprises an anchoring element <NUM> arranged in a second circumferential groove 10b. The anchoring element <NUM> comprises a first anchoring part <NUM> at least partly overlapping a second anchoring part <NUM> in a radial direction perpendicular to the axial extension L so that an inner face <NUM> of the first anchoring part <NUM> at least partly abuts an outer face <NUM> of the second anchoring part <NUM>.

In order to provide increased anchoring during axial loading of the annular barrier <NUM>, the inner face <NUM> of the first anchoring part <NUM> and the outer face <NUM> of the second anchoring part <NUM> are inclined in relation to the axial extension L. Thus, when the temperature changes, and at least part of the expandable metal sleeve <NUM> moves in one direction along the axial direction L, the first anchoring part <NUM> moves in an opposite direction along the inclined outer face <NUM> of the second anchoring part <NUM>, and the first anchoring part <NUM> is then forced radially outwards, anchoring the expandable metal sleeve <NUM> even further to the other well tubular metal structure 3b (shown in <FIG>) or the wall <NUM> of the borehole <NUM>.

An outer face <NUM>, 19b of the first anchoring part <NUM>, 15b comprises friction-enhancing means <NUM>, such as spikes 21a, as shown in <FIG>, or is provided with grooves (not shown). The annular barrier <NUM> further comprises a second anchoring element 14b comprising a first anchoring part 15b at least partly overlapping a second anchoring part 16b in a radial direction perpendicular to the axial extension L so that an inner face 17b of the first anchoring part 15b at least partly abuts an outer face 18b of the second anchoring part 16b. The inner face <NUM>, 17b of the first anchoring part <NUM>, 15b and the outer face <NUM>, 18b of the second anchoring part <NUM>, 16b have low friction between them so that no substantial force is lost in order for the anchoring parts to slide in relation to each other. Thus, the inner face <NUM>, 17b of the first anchoring part <NUM>, 15b and the outer face <NUM>, 18b of the second anchoring part <NUM>, 16b have lower friction between them than between the inner face <NUM>, 20b of the second anchoring part <NUM>, 16b and the circumferential groove <NUM>. The inner face 17b of the first anchoring part 15b and the outer face 18b of the second anchoring part 16b are inclined in relation to the axial extension L in an opposite direction to that of the first anchoring element <NUM>. The first anchoring element <NUM> has inclined faces which, when mirrored around a line R, correspond to the inclined faces of the second anchoring element 14b. By having first anchoring elements <NUM> with inclined faces in one direction and second anchoring elements 14b with inclined faces in an opposite direction as shown in <FIG>, the annular barrier <NUM> can withstand axial loads in both directions along the axial extension L as the first anchoring elements <NUM> are activated when the axial load is in one direction, and the second anchoring elements 14b are activated when the axial load pulls in the opposite direction. In <FIG>, the first anchoring part <NUM> forms one monolithic whole, and the second anchoring part <NUM> forms a second monolithic whole. The first anchoring part <NUM> is shaped as a first slit ring, and the second anchoring part <NUM> is shaped as a second slit ring in order to be able to widen and thus to be mounted in the circumferential groove 10b. The annular barrier <NUM> comprises several sealing units <NUM>, and the anchoring elements <NUM>, 14b are arranged between two sealing units <NUM>.

The annular sealing element <NUM> is made of elastomer or polymer. The back-up sealing element <NUM> is preferably made of Polytetrafluoroethylene (PTFE), and the key ring element <NUM> is made of metal, such as spring steel.

In <FIG>, <FIG> and <FIG>, a downhole completion system <NUM> comprises an annular barrier <NUM> as described above, and the tubular metal part <NUM> of the annular barrier <NUM> is mounted as part of the well tubular metal structure <NUM>.

By "fluid" or "well fluid" is meant any kind of fluid that may be present in oil or gas wells downhole, such as natural gas, oil, oil mud, crude oil, water, etc. By "gas" is meant any kind of gas composition present in a well, completion or open hole, and by "oil" is meant any kind of oil composition, such as crude oil, an oil-containing fluid, etc. Gas, oil and water fluids may thus all comprise other elements or substances than gas, oil and/or water, respectively.

By "casing" or "well tubular metal structure" is meant any kind of pipe, tubing, tubular, liner, string, etc., used downhole in relation to oil or natural gas production.

Claim 1:
An annular barrier (<NUM>) for providing zonal isolation in an annulus (<NUM>) downhole between a well tubular metal structure (<NUM>) and another well tubular metal structure (3b) or a wall (<NUM>) of a borehole (<NUM>), comprising:
- a tubular metal part (<NUM>) configured to be mounted as part of the well tubular metal structure, the tubular metal part having an outer face (<NUM>), an opening (<NUM>) and an axial extension (L) along the well tubular metal structure,
- an expandable metal sleeve (<NUM>) surrounding the tubular metal part, the expandable metal sleeve having a circumferential groove (<NUM>), a first end (<NUM>) and a second end (<NUM>), each end of the expandable metal sleeve being connected with the outer face of the tubular metal part, and
- a sealing unit (<NUM>) arranged in the circumferential groove, the annular sealing unit comprising an annular sealing element (<NUM>) and a back-up sealing element (<NUM>, <NUM>', <NUM>") abutting and supporting the annular sealing element,
wherein the annular sealing element in a cross-section along the axial extension has a first width (W1), a second width (W2) and a third width (W3); the second width is larger than the first width and the third width and is arranged between the first width and the third width; the back-up sealing element has a first contact area (A1), and the annular sealing element has a second contact area (A2), where the first contact area has a shape that mates with the second contact area.