Patent Description:
<CIT> describes an annular barrier that is configured for expansion in an annulus between a well tubular structure and an inside wall of a borehole downhole. The annular barrier comprises a tubular part for mounting as part of the well tubular structure and an expandable sleeve made of a first metal, surrounding the tubular part and defining a space being in fluid communication with an inside of the tubular part. The expandable sleeve has a longitudinal extension with an inner face facing the tubular part and two ends. The barrier also includes a connection part made of a second metal that connects the expandable sleeve with the tubular part and an opening for letting fluid into the space to expand the sleeve. <CIT> describes a device comprising a tubular conduit (<NUM>) designed to be placed within a well and comprising at least one expandable part along its length that is radially expandable under the action of fluid pressure so as to be applied tightly against the inner wall of the well or its casing. The wall of the tubular conduit is of reduced thickness along the length of the expandable part, and the expandable part has an inner diameter smaller than the tubular conduit outer diameter when unexpanded.

The present invention resides in a system and a method as defined in claims <NUM> and <NUM> respectively. The system and method are provided for utilizing a packer in a borehole or within other tubular structures. The packer is constructed for mounting about a generally tubular base pipe. The packer generally comprises a metal sleeve combined with extremities located at each axial end of the metal sleeve. The metal sleeve maintains a seal once expanded to a surrounding wellbore wall, e.g. a casing wall. For example, the metal sleeve may be combined with an elastomer along its exterior, the elastomer sealing against the surrounding wellbore wall when the metal sleeve is radially expanded. Additionally, an anchoring system is disposed within one or both of the extremities and oriented for engagement with the tubular base pipe so as to act against rotation and sliding of the packer with respect to the tubular base pipe.

Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein, and:.

In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

The disclosure herein generally involves a system and methodology for utilizing a packer in a borehole or within other tubular structures. For example, one or more of the packers are deployed downhole into a wellbore via a well string. The packer or packers are then be actuated to a set position to form a seal with the surrounding wellbore surface, e.g. an interior casing surface or an open hole surface, and to isolate sections of the annulus along the well string.

By way of example, the packer is an expandable metal packer constructed with a metal sealing element. The metal sealing element is mounted around a base pipe which is part of a well string, e.g. a drilling string, or other tubing string. When the packer is positioned at a desired location within the borehole or other tubular structure, the metal sealing element is expanded under fluid pressure for sealing engagement with a surrounding wall surface. For example, the metal sealing element may be a permanently deformable metal bladder, e.g. a metal membrane, which is deformed downhole via the fluid pressure, e.g. hydroforming.

According to an embodiment, a system and methodology are provided for utilizing a packer in a borehole or within other tubular structures. The packer is constructed for mounting about a generally tubular base pipe. In general, the packer comprises a metal sleeve combined with extremities located at each axial end of the metal sleeve. The metal sleeve maintains a seal once expanded to a surrounding wellbore wall, e.g. a casing wall. For example, the metal sleeve may be combined with an elastomer along its exterior. The elastomer may be a single piece or a plurality of pieces positioned to seal against the surrounding wellbore wall when the metal sleeve is radially expanded. Additionally, an anchoring system is disposed within one or both of the extremities and oriented for engagement with the tubular base pipe so as to act against rotation and sliding of the packer with respect to the tubular base pipe.

As described in greater detail below, the packer is fixed in both axial and rotational directions on a variety of tubular base pipes. The anchoring system enables the packer to hold against high torque that may occur between the packer and the base pipe. Consequently, the packer may be used in various types of well applications which can incur torque loads. An example of a suitable application is a casing while drilling application. In such an application, the packer or packers may be mounted as part of a drill string to perform a stage cementing operation.

Referring generally to <FIG>, an example of a well system <NUM> is illustrated as deployed in a borehole <NUM>, e.g. a wellbore. The well system <NUM> comprises an expandable metal packer <NUM> mounted along a base pipe <NUM> which is part of an overall tubing string <NUM>, e.g. a well production or casing string. With additional reference to <FIG>, the packer <NUM> comprises an expandable metal sleeve <NUM> combined with a sealing element(s) <NUM>, e.g. an elastomeric sealing element. The metal sleeve <NUM> maintains a seal once expanded to a surrounding borehole wall surface <NUM>, e.g. a casing wall or open hole wellbore wall surface. For example, the elastomeric sealing element <NUM> may be positioned along an exterior of the metal sleeve <NUM> so as to seal against the surrounding wellbore wall surface <NUM> when the metal sleeve <NUM> is radially expanded outwardly to the wall surface <NUM>.

The expandable metal sleeve <NUM> is disposed between extremities <NUM>. For example, the extremities <NUM> may be coupled with the expandable metal sleeve <NUM> and positioned with one extremity <NUM> on each axial end of the expandable metal sleeve <NUM>. Each extremity <NUM> may comprise a metal collar <NUM> positioned around the base pipe <NUM>. During mounting of packer <NUM> along tubing string <NUM>, the metal collars <NUM> may be plastically deformed, e.g. crimped, to secure the packer <NUM> to the base pipe <NUM>.

The packer <NUM> further comprises an anchoring system <NUM> positioned between at least one of the extremities <NUM> and the base pipe <NUM> to prevent both axial sliding and rotation of the expandable metal packer <NUM> relative to the base pipe <NUM>. In the example illustrated, the anchoring system <NUM> operates between each of the extremities <NUM> and the base pipe <NUM>. As described in greater detail below, the anchoring system <NUM> may utilize various features to create interference between the packer <NUM> and the base pipe <NUM> so as to prevent relative rotation even under high torque loads.

Depending on the application, the expandable metal sleeve <NUM> may comprise a metal membrane, e.g. a bladder, or other metal structure which may be plastically deformed into a permanent expanded structure engaging the surrounding wall surface <NUM>. In some embodiments, the metal sleeve <NUM> is expanded via fluid pressure, e.g. via a hydroforming process. For example, high pressure fluid may be delivered along an interior of tubing string <NUM> and directed into an interior of the expandable metal sleeve <NUM> via a passage or passages extending through a wall of base pipe <NUM>.

Referring generally to <FIG>, an embodiment of the anchoring system <NUM> is illustrated. In this example, the anchoring system <NUM> may comprise seals <NUM> and an axial mechanism <NUM> to prevent relative movement between packer <NUM> and base pipe <NUM> in the axial direction. The anchoring system <NUM> also may comprise a separate rotational mechanism <NUM> to prevent relative rotational movement between packer <NUM> and base pipe <NUM>.

The axial mechanism <NUM> comprises at least one axial movement prevention ring <NUM>, e.g. a plurality of rings <NUM>. The rings <NUM> may be located in corresponding grooves <NUM> formed in collar <NUM> of the corresponding extremity <NUM>. It should be noted the axial mechanism <NUM> and rotational mechanism <NUM> may be employed in each of the extremities <NUM>.

As illustrated in <FIG>, the rings <NUM> also have gripping features <NUM> oriented toward the base pipe <NUM> for engagement with the base pipe <NUM>. The location of rings <NUM> and corresponding grooves <NUM> and the gripping engagement with base pipe <NUM> via features <NUM> create an interference between the collar <NUM> and the base pipe <NUM>. This interference prevents linear or axial movement of the packer <NUM> with respect to the base pipe <NUM>.

With additional reference to <FIG>, the rotational mechanism <NUM> comprises at least one pad <NUM>, e.g. a plurality of pads, disposed between the collar <NUM> and the base pipe <NUM>. For example, the plurality of pads <NUM> may be positioned within corresponding recesses <NUM> formed in collar <NUM> of the corresponding extremity <NUM>. The pads <NUM> each have a gripping side with rotational gripping features <NUM> oriented toward the base pipe <NUM> for engagement with the base pipe <NUM>. Each pad <NUM> also has a curved side <NUM> disposed in the corresponding recess <NUM> and oriented against the corresponding collar <NUM>/extremity <NUM>.

When a torque, as represented by arrow <NUM>, is applied to the base pipe <NUM>, the corresponding curved side <NUM> of each pad <NUM> wedges against the corresponding curved side of recess <NUM> to create a load as represented by arrows <NUM> (load side depends on the direction of the applied torque). The pads <NUM> effectively create interference via the wedge effect to prevent rotational motion of the packer <NUM> with respect to the base pipe <NUM>.

When packer <NUM> is mounted to base pipe <NUM> at a desired location, the collars <NUM> may initially be in an expanded configuration, as illustrated in <FIG>. Once the packer <NUM> is located at the desired position along base pipe <NUM> and tubing string <NUM>, the extremities <NUM> are plastically deformed in a radially inward direction to reduce their diameters. For example, the extremities <NUM> may be crimped so the collars <NUM> plastically deform in a radially inward direction until a desired reduction in diameter occurs. The plastic deformation is applied sufficiently to squeeze the pads <NUM> between the base pipe <NUM> and the corresponding collars <NUM>, as illustrated in <FIG>. As illustrated in <FIG>, a retention member <NUM>, e.g. a spring or a split ring, may be used to initially maintain the pads <NUM> in their corresponding recesses <NUM> prior to the plastic deformation. In some embodiments, the pads <NUM> may be glued or otherwise suitably maintained in their recesses <NUM>. Once plastically deformed, the anchoring system <NUM> prevents both axial movement and rotational movement of the packer <NUM> relative to the base pipe <NUM>.

According to another embodiment, additional recesses <NUM> also may be formed in base pipe <NUM> as illustrated in <FIG>. The additional recesses <NUM> are sized and located for receiving pads <NUM>, as illustrated in <FIG>. In this type of embodiment, the pads <NUM> may initially be located on base pipe <NUM> and then the corresponding extremity <NUM> may be slid over the pads <NUM> as illustrated in <FIG>. The collar <NUM> of the corresponding extremity <NUM> may then be crimped or otherwise plastically deformed to secure the pads <NUM> between the extremity <NUM> and the base pipe <NUM>. In some embodiments, a suitable retention member <NUM> may be used to initially secure pads <NUM> in the additional recesses <NUM> formed along base pipe <NUM>.

Referring generally to <FIG>, another embodiment of anchoring system <NUM> is illustrated. In this example, the anchoring system <NUM> comprises a plurality of wedge members <NUM> which are arranged between the collar <NUM> and the base pipe <NUM> at one or both of the extremities <NUM>. By way of example, the wedge members <NUM> may be arranged in a helical pattern between each extremity <NUM> and the base pipe <NUM>. In some embodiments, each wedge member <NUM> may have a generally helicoidal shape and may be oriented helically about the interior of the corresponding collar <NUM>. Because of the helical orientation, the wedge members <NUM> serve as both axial mechanism <NUM> and rotational mechanism <NUM> to prevent relative movement of the packer <NUM> with respect to the base pipe <NUM> in both an axial direction and a rotational direction.

By way of example, each wedge member <NUM> may have a cross-sectional shape with a hump or curved portion <NUM> received in a corresponding recess <NUM> formed in the interior surface of the corresponding collar <NUM>. Additionally, the interior of each wedge member <NUM> may comprise gripping features <NUM> oriented to grip into base pipe <NUM> once the collar <NUM> is suitably plastically deformed in a radially inward direction. Similar to other embodiments described herein, the wedge members <NUM> create an interference between the base pipe <NUM> and the packer <NUM>. However, the orientation of wedge members <NUM> serve to create interference in both axial and rotational directions.

Referring generally to <FIG>, another embodiment of anchoring system <NUM> is illustrated. In this example, the anchoring system <NUM> comprises an annular ring <NUM>, e.g. a split annular ring, having a cross-sectional cone shape (or other suitable shape) to create a cone shaped portion <NUM> received in a corresponding recess <NUM>. In some embodiments, the corresponding recess <NUM> may be formed in the interior surface of the corresponding collar <NUM> along a portion of the circumference of the interior surface. Additionally, the interior of annular ring <NUM> may comprise gripping features <NUM> oriented to grip into base pipe <NUM> once the collar <NUM> is suitably plastically deformed in a radially inward direction.

The annular ring <NUM> may extend circumferentially along the corresponding recess <NUM>, e.g. groove, formed along a portion of the interior of the corresponding collar <NUM>. The annular ring <NUM> also comprises ends <NUM>. The ring ends <NUM> are located adjacent interference portions <NUM> of collar <NUM> at the ends of recess <NUM> to prevent movement of annular ring <NUM> along the recess/groove <NUM> (see <FIG>). Thus, when the collar <NUM> of the corresponding extremity <NUM> is crimped radially inward into engagement with base pipe <NUM>, the gripping features <NUM> engage base pipe <NUM> and cooperate with the cone shaped portion <NUM> to prevent sliding axial movement of the packer <NUM> with respect to the base pipe <NUM>. It should be noted some embodiments may route hydraulic lines <NUM> between ends <NUM>, e.g. hydraulic lines for connecting the packer body to an expansion valve system.

Furthermore, once the collar <NUM> is suitably plastically deformed in the radially inward direction, the ring ends <NUM> of split annular ring <NUM> prevent relative rotation of the packer <NUM> with respect to the base pipe <NUM> via interfering engagement with interference members <NUM> (as the base pipe <NUM> is gripped via gripping features <NUM>). In this manner, the annular ring <NUM> serves as both the axial mechanism <NUM> and rotational mechanism <NUM>.

Referring generally to <FIG>, another embodiment of anchoring system <NUM> is illustrated. In this example, anchoring system <NUM> comprises a waved annular ring <NUM> having a cross-sectional shape with a hump or curved portion <NUM> received in a corresponding recess <NUM> formed in the interior surface of the corresponding collar <NUM>. However, the sides of the waved annular ring <NUM> are shaped in an undulating or waved pattern such that the ring <NUM> has axially wide sections <NUM> and axially narrow sections <NUM>. The size of the hump or curved section <NUM> is thus greater in the axially wide sections <NUM> and smaller in the axially narrow sections <NUM>. The corresponding recess <NUM> may be formed with a similar or matching waved pattern.

Additionally, the interior of waved annular ring <NUM> may comprise gripping features <NUM> oriented to grip into base pipe <NUM> once the collar <NUM> is suitably plastically deformed in a radially inward direction. The waved annular ring <NUM> may extend circumferentially along the corresponding recess <NUM> formed in the interior of the corresponding collar <NUM>. For example, the waved annular ring <NUM> may extend circumferentially along a portion of the interior of the corresponding collar <NUM> between ring ends <NUM>, as illustrated in <FIG>.

When the collar <NUM> of the corresponding extremity <NUM> is crimped radially inward into engagement with base pipe <NUM>, the gripping features <NUM> engage base pipe <NUM> and cooperate with the hump or curved portion <NUM> to prevent sliding axial movement of the packer <NUM> with respect to the base pipe <NUM>. Once the collar <NUM> is suitably plastically deformed in the radially inward direction, the gripping features <NUM> and the larger humps of axially wide sections <NUM> prevent relative rotation of the packer <NUM> with respect to the base pipe <NUM>. In other words, the larger humps of axially wide sections <NUM> create an interfering engagement with the corresponding collar <NUM> to prevent rotation of the collar <NUM> (thus preventing rotation of the packer <NUM>) with respect to the base pipe <NUM>. In this manner, the waved annular ring <NUM> effectively serves as the axial mechanism <NUM> and the rotational mechanism <NUM>.

Referring generally to <FIG>, another embodiment of anchoring system <NUM> is illustrated. In this example, the axial mechanism <NUM> and rotational mechanism <NUM> are again combined in the form of a plurality of dome-shaped members <NUM> disposed between the collar <NUM> and the base pipe <NUM>. For example, the plurality of dome-shaped members <NUM> may be positioned within corresponding dome recesses <NUM> formed in collar <NUM> of the corresponding extremity <NUM>.

The dome-shaped members <NUM> each have a gripping side with rotational gripping features <NUM> oriented toward base pipe <NUM> for engagement with base pipe <NUM> when the corresponding collar <NUM> is plastically deformed in an inward direction. Each dome-shaped member <NUM> also has a curved side <NUM>, e.g. domed side, disposed in the corresponding recess <NUM> and oriented against the corresponding collar <NUM>/extremity <NUM>. Placement of dome-shaped members <NUM> in corresponding recesses <NUM> effectively creates interference between the base pipe <NUM> and the collar <NUM>/packer <NUM> in both an axial direction and a rotational direction. As illustrated, a retention member <NUM>, e.g. a spring or a split ring, may be used to initially maintain the dome-shaped members <NUM> in their corresponding recesses <NUM> prior to the plastic deformation.

When the collar <NUM> of the corresponding extremity <NUM> is crimped radially inward into engagement with base pipe <NUM>, the gripping features <NUM> of each dome-shaped member <NUM> engage base pipe <NUM> and cooperate with the domed side <NUM> to prevent sliding axial movement of the packer <NUM> with respect to the base pipe <NUM>. Furthermore, once the collar <NUM> is suitably plastically deformed in the radially inward direction, the gripping features <NUM> and the domed side <NUM> also prevent relative rotation of the packer <NUM> with respect to the base pipe <NUM>. In other words, the dome-shaped members <NUM> create an interfering engagement with the corresponding collar <NUM> to prevent rotation of the collar <NUM> and overall packer <NUM> with respect to the base pipe <NUM>. In this manner, the dome-shaped members <NUM> serve as both the axial mechanism <NUM> and the rotational mechanism <NUM>.

Depending on the characteristics of a given application and environment, well system <NUM> may have many types of configurations. For example, the well system <NUM> may utilize tubing string <NUM> in the form of a casing while drilling string or other suitable tubing string used in high torque load applications. Additionally, the expandable metal packer <NUM> may be employed as an isolation device in a variety of operations and environments which may be subjected to high differential pressures. For example, the expandable metal packer <NUM> may be used in well applications and in other applications in which isolation between sections of a tubular structure is desired. The expandable metal packer <NUM> may be constructed with various types and sizes of expandable metal sleeves <NUM> depending on the parameters of a given operation. In a variety of well applications, the expandable metal sleeve <NUM> may be formed from a plastically deformable metal membrane, bladder, or other metal structure which may be radially expanded via fluid pressure.

Similarly, the anchoring system <NUM> may have various configurations and may be located between one of the extremities <NUM> and the base pipe <NUM> or between both extremities <NUM> and the base pipe <NUM>. Additionally, the expandable metal sleeve <NUM> may be secured to extremities <NUM> via a variety of techniques, including threaded engagement, welding, combined seals and fasteners, crimping, and/or other suitable coupling techniques. The anchoring system <NUM> also may utilize features of various sizes and configurations to create interference between the packer <NUM> and the base pipe <NUM> so as to prevent relative rotation of the packer <NUM> with respect to the base pipe <NUM>.

Claim 1:
A system for use in a well, comprising:
a tubing string (<NUM>) having a base pipe (<NUM>);
an expandable metal packer (<NUM>) mounted around the base pipe (<NUM>) and having an expandable metal sleeve (<NUM>) operatively anchored along the base pipe (<NUM>) via a pair of extremities (<NUM>) and an anchoring system (<NUM>), the anchoring system (<NUM>) being positioned between at least one of the extremities (<NUM>) and the base pipe (<NUM>) and including one or more features to create interference between the expandable metal packer (<NUM>) and the base pipe (<NUM>) so as to prevent axial sliding of the expandable metal packer (<NUM>) with respect to the base pipe (<NUM>) and to prevent rotational movement of the expandable metal packer (<NUM>) with respect to the base pipe (<NUM>).