Patent Description:
In the oilfield industry, downhole tools are employed in the wellbore at different stages of operation of the well. For example, an expandable liner hanger may be employed during the formation stage of the well. After a first string of casing is set in the wellbore, the well is drilled a designated depth and a liner assembly is run into the well to a depth whereby the upper portion of the liner assembly is overlapping a lower portion of the first string of casing. The liner assembly is fixed in the wellbore by expanding a liner hanger into the surrounding casing and then cementing the liner assembly in the well. The liner hanger includes seal members disposed on an outer surface of the liner hanger. The seal members are configured to create a seal with the surrounding casing upon expansion of the liner hanger.

In another example, a packer may be employed during the production stage of the well. The packer typically includes a packer assembly with seal members. The packer may seal an annulus formed between production tubing disposed within casing of the wellbore. Alternatively, some packers seal an annulus between the outside of a tubular and an unlined borehole. Routine uses of packers include the protection of casing from pressure, both well and stimulation pressures, and protection of the wellbore casing from corrosive fluids. Packers may also be used to hold kill fluids or treating fluids in the casing annulus.

Both the liner hanger and the packer include seal members that are configured to create a seal with the surrounding casing or an unlined borehole. Each seal member is typically disposed in a groove (or gland) formed in an expandable tubular assembly of the liner hanger or packer. However, the seal member may extrude out of the groove during expansion of the expandable tubular assembly due to the characteristics of the seal member. Further, the seal member may extrude out of the groove after expansion of the expandable tubular assembly due to pressure differentials applied to the seal member. Therefore, there is a need for extrusion-resistant seals for use with an expandable tubular assembly. <CIT> describes a slip assembly for well packers.

The present invention generally relates to an anchor seal for an expandable tubular assembly. In one aspect, an anchoring seal assembly for creating a seal and an anchor between a first tubular and a second tubular is provided, in accordance with claim <NUM>. Further aspects and preferred embodiments are laid out in claim <NUM> et seq. In another aspect, an associated method is provided, in accordance with claim <NUM>. Further aspects and preferred embodiments are laid out in claim <NUM> et seq.

Described herein is an anchoring seal assembly. The anchoring seal assembly includes a wedge member movably disposed around the first tubular; an expandable annular member disposed around the wedge member, the annular member having a groove formed in an outer surface of the annular member. The anchoring seal assembly further includes a seal member disposed in the groove, the seal member having one or more anti-extrusion bands embedded within the seal member; and a slip assembly disposed around the first tubular, wherein the wedge member pushes the expandable annular member along an axial direction of the first tubular to urge the slip assembly into engagement with the second tubular. The expandable annular member is movable on a tapered outer surface of the wedge member, the tapered outer surface is configured to radially expand the expandable annular member into contact with an inner wall of the second tubular to create the seal and the anchor as the expandable annular member moves from a first position to second position. A gap is defined between a side of the groove and a side of the seal member, wherein the gap is configured to close upon expansion of the expandable annular member.

A method of creating a seal portion and an anchor portion between a first tubular and a second tubular is also described. The method includes the step of positioning the first tubular within the second tubular. The first tubular has a wedge member movably disposed therearound and an expandable annular member disposed around the wedge member, the expandable annular member having a groove and a seal member with at least one anti-extrusion band disposed within the groove and wherein a gap is defined between a side of the seal member and a side of the groove. The method further includes the step of moving the annular member along a tapered surface of the wedge member to expand the expandable annular member radially outward, which causes the at least one anti-extrusion band to move toward an interface area between the first tubular and the second tubular. The method also includes the step of urging the annular member into contact with an inner wall of the second tubular to create the seal portion and the anchor portion between the first tubular and the second tubular, wherein the gap is reduced in response to urging the annular member into contact with the inner wall of the second tubular.

Further described, yet not forming part of the claimed invention, is a seal assembly for creating a seal between a first tubular and a second tubular. The seal assembly includes an annular member attached to the first tubular, the annular member having a groove formed on an outer surface of the annular member. The seal assembly further includes a seal member disposed in the groove, the seal member having one or more anti-extrusion bands. The seal member is configured to be expandable radially outward into contact with an inner wall of the second tubular by the application of an outwardly directed force supplied to an inner surface of the annular member. Additionally, the seal assembly includes a gap defined between the seal member and a side of the groove.

Also described, yet not forming part of the claimed invention, is a method of creating a seal between a first tubular and a second tubular. The method includes the step of positioning the first tubular within the second tubular, the first tubular having a annular member with a groove, wherein a seal member with at least one anti-extrusion band is disposed within the groove and wherein a gap is formed between a side of the seal member and a side of the groove. The method further includes the step of expanding the annular member radially outward, which causes the first anti-extrusion band and the second anti-extrusion band to move toward a first interface area and a second interface area between the annular member and the second tubular. The method also includes the step of urging the seal member into contact with an inner wall of the second tubular to create the seal between the first tubular and the second tubular.

Further described, yet not forming part of the claimed invention, is a seal assembly for creating a seal between a first tubular and a second tubular. The seal assembly includes an annular member attached to the first tubular, the annular member having a groove formed on an outer surface thereof. The seal assembly further includes a seal member disposed in the groove of the annular member such that a side of the seal member is spaced apart from a side of the groove, the seal member having one or more anti-extrusion bands, wherein the one or more anti-extrusion bands move toward an interface area between the annular member and the second tubular upon expansion of the annular member.

Also described, yet not forming part of the claimed invention, is a hanger assembly. The hanger assembly includes an expandable annular member having an outer surface and an inner surface. The hanger assembly further includes a seal member disposed in a groove formed in the outer surface of the expandable annular member, the seal member having one or more anti-extrusion spring bands embedded within the seal member. The hanger assembly also includes an expander sleeve having a tapered outer surface and an inner bore. The expander sleeve is movable between a first position in which the expander sleeve is disposed outside of the expandable annular member and a second position in which the expander sleeve is disposed inside of the expandable annular member. The expander sleeve is configured to radially expand the expandable annular member as the expander sleeve moves from the first position to the second position.

Further described, yet not forming part of the claimed invention, is a downhole tool for use in a wellbore. The tool includes a body having a bore. The tool further includes a seal assembly attached to the body. The seal assembly having an expandable annular member, a seal member and an expander sleeve, wherein the seal member includes one or more anti-extrusion spring bands embedded within the seal member. The tool further includes a slip assembly attached to the body. The slip assembly includes slips that are configured to engage the wellbore.

Also described, yet not forming part of the claimed invention, is downhole tool for use in a wellbore. The tool includes a tubular having a tapered outer surface. The tool further includes an expandable annular member disposed on the tubular. The expandable member has an anchor portion. The tool further includes a seal member disposed in a groove of the expandable annular member. The seal member has one or more anti-extrusion bands, wherein the seal member and the anchor portion are configured to be expandable radially outward into contact with the wellbore as the expandable annular member moves along the tapered outer surface of the tubular.

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings.

The present invention involves extrusion-resistant seals for a downhole tool. The extrusion-resistant seals will be described herein in relation to a liner hanger in <FIG>, a packer in <FIG> and a hanger assembly in <FIG>. It is to be understood, however, that the extrusion-resistant seals may also be used with other downhole tools. Further, the extrusion-resistant seals may be used in a downhole tool that is disposed within a cased wellbore or within an open-hole wellbore. To better understand the novelty of the extrusion-resistant seals and the methods of use thereof, reference is hereafter made to the accompanying drawings.

<FIG> illustrates a view of an expandable hanger <NUM> in a run-in (unset) position. At the stage of completion shown in <FIG>, a wellbore <NUM> has been lined with a string of casing <NUM>. Thereafter, a subsequent liner assembly <NUM> is positioned proximate the lower end of the casing <NUM>. Typically, the liner assembly <NUM> is lowered into the wellbore <NUM> by a running tool disposed at the lower end of a work string <NUM>.

The liner assembly <NUM> includes a tubular <NUM> and the expandable hanger <NUM>. The hanger <NUM> is an annular member that is used to attach or hang the tubular <NUM> from an internal wall of the casing <NUM>. The expandable hanger <NUM> includes a plurality of seal assemblies <NUM> disposed on the outer surface of the hanger <NUM>. The plurality of seal assemblies <NUM> are circumferentially spaced around the hanger <NUM> to create a seal between liner assembly <NUM> and the casing <NUM> upon expansion of the hanger <NUM>. Although the hanger <NUM> in <FIG> shows four seal assemblies <NUM>, any number of seal assemblies <NUM> may be attached to liner assembly <NUM>.

<FIG> illustrates an enlarged view of the seal assemblies <NUM> in the run-in position. For clarity, the wellbore <NUM> is not shown in <FIG>. Each seal assembly <NUM> includes a seal ring <NUM> disposed in a gland <NUM>. The gland <NUM> includes a first side 140A, a second side 140B and a third side 140C. As shown in <FIG>, a bonding material, such as glue (or other attachment means), may be used on sides 140B, 140C during the fabrication stage of the seal assembly <NUM> to attach the seal ring <NUM> in the gland <NUM>. Bonding the seal ring <NUM> in the gland <NUM> is useful to prevent the seal ring <NUM> from becoming unstable and swab off when the hanger <NUM> is positioned in the casing <NUM> and prior to expansion of the hanger <NUM>. The side 140A may have an angle α (see <FIG>) of approximately <NUM> degrees prior to expansion, and side 140A has an angle β (see <FIG>) between about <NUM> degrees and about <NUM> degrees after expansion of the seal assembly <NUM>.

As shown in <FIG>, a volume gap <NUM> is created between the seal ring <NUM> and the side 140A of the gland <NUM>. Generally, the volume gap <NUM> is used to substantially prevent distortion of the seal ring <NUM> upon expansion of the hanger <NUM>. The volume gap <NUM> is a free-space (empty space, clearance or void) between a portion of the seal ring <NUM> and a portion of the gland <NUM> prior to expansion of the hanger <NUM>. In other words, during the fabrication process of the hanger, the volume gap <NUM> is created by positioning the seal ring <NUM> within the gland <NUM> such that the seal ring <NUM> is spaced apart from at least one side of the gland <NUM>. Even though the volume gap <NUM> in <FIG> is created by having a side of the gland <NUM> at an angle, the volume gap <NUM> may be created in any configuration (see <FIG>, for example). Additionally, the size of the volume gap <NUM> may vary depending on the configuration of the gland <NUM>. The gland <NUM> may have <NUM>-<NUM>% more volume due to the volume gap <NUM> than a standard gland without a volume gap.

Referring back to <FIG>, the seal ring <NUM> includes one or more anti-extrusion bands, such as a first seal band <NUM> (first anti-extrusion band) and a second seal band <NUM> (second anti-extrusion band). As shown, the seal bands <NUM>, <NUM> are embedded in the seal ring <NUM> in an upper corner of each side of the seal ring <NUM>. The seal bands <NUM>, <NUM> may be disposed on an outer circumference of the seal ring <NUM>. In another example, the seal bands <NUM>, <NUM> may be springs. The seal bands <NUM>, <NUM> may be used to limit the extrusion of the seal ring <NUM> during expansion of the seal assembly <NUM>. The seal bands <NUM>, <NUM> may also be used to limit the extrusion of applied differential pressure after expansion of the seal assembly <NUM>.

<FIG> illustrates a view of the seal assemblies <NUM> during expansion and <FIG> illustrate the seal assemblies <NUM> after expansion. As shown, an axially movable expander tool <NUM> contacts an inner surface <NUM> of the liner assembly <NUM>. Expander tools are well known in the art and are generally used to radially enlarge an expandable tubular by urging the expander tool <NUM> axially through the tubular, thereby swaging the tubular wall radially outward as the larger diameter tool is forced through the smaller-diameter tubular member. The expander tool <NUM> may be attached to a threaded mandrel which is rotated to move the expander tool <NUM> axially through the hanger <NUM> and expand the hanger <NUM> outward in contact with the casing <NUM>. It is to be understood, however, that other means may be employed to urge the expander tool <NUM> through the hanger <NUM> such as hydraulics or any other means known in the art. Furthermore, the expander tool <NUM> may be disposed in the hanger <NUM> in any orientation, such as in a downward orientation as shown for a top down expansion or in an upward orientation for a bottom up expansion. Additionally, a rotary expandable tool (not shown) may be employed. The rotary expandable tool moves between a first smaller diameter and a second larger diameter, thereby allowing for both a top down expansion and a bottom up expansion depending on the directional axial movement of the rotary expandable tool.

As shown in <FIG>, the expander tool <NUM> has expanded a portion of the hanger <NUM> toward the casing <NUM>. During expansion of the hanger <NUM>, the seal ring <NUM> moves into contact with the casing <NUM> to create a seal between the hanger <NUM> and the casing <NUM>. As the seal ring <NUM> contacts the casing <NUM>, the seal ring <NUM> changes configuration and occupies a portion of the volume gap <NUM>. As shown, the volume gap <NUM> is located on the side of the seal assembly <NUM> which is the first portion to be expanded by the expander tool <NUM>. The location of the volume gap <NUM> in the seal assembly <NUM> allows the seal ring <NUM> to change position (or reconfigure) within the gland <NUM> during the expansion operation. Additionally, the volume of the volume gap <NUM> may change during the expansion operation. As shown in <FIG>, the expander tool <NUM> is removed from the hanger <NUM> after the hanger <NUM> is expanded into contact with the casing <NUM>.

The seal ring <NUM> changes configuration during the expansion operation. As shown in <FIG>, the seal ring <NUM> has a volume which is represented by reference number <NUM>. Prior to expansion, a portion of the volume <NUM> of the seal ring <NUM> is positioned within the gland <NUM> and another portion of the volume <NUM> of the seal ring <NUM> extends outside of the gland <NUM> (beyond line <NUM>). After expansion, the volume <NUM> of the seal ring <NUM> is repositioned such that the seal ring <NUM> moves into the volume gap <NUM> as shown in <FIG>. In other words, the volume <NUM> of the seal ring <NUM> is substantially the same prior to expansion and after expansion. However, the volume of the seal ring <NUM> within the gland <NUM> increases after the expansion operation because the portion of the volume <NUM> of the seal ring <NUM> that was outside of the gland <NUM> (beyond line <NUM>) has moved within the gland <NUM> (compare <FIG>). Thus, the volume <NUM> of the seal ring <NUM> is substantially within the gland <NUM> after the expansion operation. Alternatively, the seal ring <NUM> does not extend outside of the gland <NUM> (beyond line <NUM>) prior to expansion. The volume <NUM> of the seal ring <NUM> is repositioned during the expansion operation such that the seal ring <NUM> moves into the volume gap <NUM>. The volume <NUM> of the seal ring <NUM> is substantially the same prior to expansion and after expansion. In this manner, the seal ring <NUM> changes configuration during the expansion operation and occupies (or closes) the volume gap <NUM>.

The volume of the gland <NUM> and/or the volume gap <NUM> may decrease as the seal assembly <NUM> is expanded radially outward during the expansion operation. As set forth herein, the angle α (<FIG>) decreases to the angle β (<FIG>), which causes the size of the volume gap <NUM> to decrease. The height of the gland <NUM> may also become smaller, which causes the volume of the gland <NUM> to decrease. As such, the combination of the change in configuration of the seal ring <NUM> and the change of configuration of the volume of the gland <NUM> (and/or the volume gap <NUM>) allows the seal ring <NUM> to create a seal with the casing <NUM>. The volume of the gland <NUM> (including the volume gap <NUM>) after the expansion operation may be substantially the same as the volume <NUM> of the seal ring <NUM>. In another example, the volume of the gland <NUM> (including the volume gap <NUM>) after the expansion operation may be equal to the volume <NUM> of the seal ring <NUM> or may be greater than the volume <NUM> of the seal ring <NUM>.

As shown in <FIG>, the seal bands <NUM>, <NUM> in the seal ring <NUM> are urged toward an interface <NUM> between the seal assembly <NUM> and the casing <NUM> during the expansion operation. The volume gap <NUM> permits the seal ring <NUM> to move within the gland <NUM> and position the seal bands <NUM>, <NUM> at a location proximate the interface <NUM>. In this position, the seal bands <NUM>, <NUM> substantially prevent the extrusion of the seal ring <NUM> past the interface <NUM>. In other words, the seal bands <NUM>, <NUM> expand radially outward with the hanger <NUM> and block the elastomeric material of the seal ring <NUM> from flowing through the interface <NUM> between the seal assembly <NUM> and the casing <NUM>. The seal bands <NUM>, <NUM> may be springs, such as toroidal coil springs, which expand radially outward due to the expansion of the hanger <NUM>. As the spring expands radially outward, the coils of spring act as a barrier to the flow of the elastomeric material of the seal ring <NUM>. In this manner, the seal bands <NUM>, <NUM> in the seal ring <NUM> act as an anti-extrusion device or an extrusion barrier.

There are several benefits of the extrusion barrier created by the seal bands <NUM>, <NUM>. One benefit of the extrusion barrier would be that the outer surface of the seal ring <NUM> in contact with the casing <NUM> is limited to a region between the seal bands <NUM>, <NUM>, which allows for a high-pressure seal to be created between the seal assembly <NUM> and the casing <NUM>. The seal assembly <NUM> may create a high-pressure seal in the range of <NUM>,<NUM> to <NUM>,<NUM> psi (<NUM> to <NUM> N/mm<NUM>). A further benefit of the extrusion barrier would be that the seal assembly <NUM> is capable of creating a seal with a surrounding casing that may have a range of inner diameters due to API tolerances. Another benefit would be that the extrusion barrier created by the seal bands <NUM>, <NUM> may prevent erosion of the seal ring <NUM> after the hanger <NUM> has been expanded. The erosion of the seal ring <NUM> could eventually lead to a malfunction of the seal assembly <NUM>. A further benefit is that the seal bands <NUM>, <NUM> act as an extrusion barrier after expansion of the expandable hanger <NUM>. More specifically, the extrusion barrier created by the seal bands <NUM>, <NUM> may prevent extrusion of the seal ring <NUM> when the gap between the expandable hanger <NUM> and the casing <NUM> is increased due to downhole pressure. In other words, the seal bands <NUM>, <NUM> bridge the gap, and the net extrusion gap between coils of the seal bands <NUM>, <NUM> grows considerably less as compared to an annular gap that is formed when a seal ring does not include the seal bands. For instance, the annular gap (without seal bands) may be on the order of. <NUM>" (<NUM>) radial as compared to the net extrusion gap between coils of the seal bands <NUM>, <NUM> which may be on the order of. <NUM>" (<NUM>/<NUM>).

<FIG> illustrate views of the seal assembly. For convenience, the components in the seal assembly in <FIG> that are similar to the components in the seal assembly <NUM> will be labeled with the same number indicator. <FIG> illustrates a view of a seal assembly <NUM> that includes the volume gap <NUM> on a lower portion of the seal assembly <NUM>. As shown, the volume gap <NUM> is between the side 140C and the seal ring <NUM>. A bonding material, such as glue, may be applied to sides 140A, 140B during the fabrication stage of the seal assembly <NUM> to attach the seal ring <NUM> in the gland <NUM>. The seal ring <NUM> will be reconfigured and occupy at least a portion of the volume gap <NUM> upon expansion of the seal assembly <NUM>.

<FIG> illustrates a view of a seal assembly <NUM> that includes the volume gap <NUM> on a lower portion and an upper portion of the seal assembly <NUM>. As shown, a first volume gap 145A is between the side 140A and the seal ring <NUM> and a second volume gap 145B is between the side 140C and the seal ring <NUM>. The first volume gap 145A and the second volume gap 145B may be equal or may be different. The bonding material may be applied to the side 140B during the fabrication stage of the seal assembly <NUM> to attach the seal ring <NUM> in the gland <NUM>. The seal ring <NUM> will be reconfigured and occupy at least a portion of the first volume gap 145A and at least a portion of the second volume gap 145B upon expansion of the seal assembly <NUM>.

<FIG> illustrates a view of a seal assembly <NUM> that includes the volume gap <NUM> with a biasing member <NUM>. As shown, the side 140A of the gland <NUM> is perpendicular to the side 140B. The biasing member <NUM>, such as a spring washer or a crush ring, is disposed in the volume gap <NUM> between the side 140A and the seal ring <NUM>. The biasing member <NUM> may be used to maintain the position of the seal ring <NUM> in the gland <NUM>. In addition to seal band <NUM>, the biasing member <NUM> may also act as an extrusion barrier upon expansion of the seal assembly <NUM>. During the expansion operation, the seal ring <NUM> will be reconfigured in the gland <NUM> and compress the biasing member <NUM>. Additionally, the bonding material may be used on sides 140B, 140C during the fabrication stage of the seal assembly <NUM> to attach the seal ring <NUM> in the gland <NUM>.

<FIG> illustrates a view of a seal assembly <NUM> that includes a volume gap <NUM> in a portion of a seal ring <NUM>. The bonding material may be used on sides 140A, 140B, 140C during the fabrication stage of the seal assembly <NUM> to attach the seal ring <NUM> in the gland <NUM>. The seal ring <NUM> will be reconfigured upon expansion of the seal assembly <NUM>. However, the volume gap <NUM> in the portion of the seal ring <NUM> will be close or decrease in size when the seal ring <NUM> is urged into contact with the surrounding casing. In another example, the seal ring <NUM> may include seal bands (not shown) embedded in the seal ring <NUM> similar to seal bands <NUM>, <NUM>. In a further example, an equalization vent (not shown) may be formed in the seal ring <NUM> to provide communication between the volume gap <NUM> and an external portion of the seal ring <NUM>. The equalization vent may be used to prevent the collapse of the seal ring <NUM> due to exposure of hydrostatic pressure.

<FIG> illustrates a view of a typical subterranean hydrocarbon well <NUM> that defines a vertical wellbore <NUM>. The well <NUM> has multiple hydrocarbon-bearing formations, such as oil-bearing formation <NUM> and/or gas-bearing formations (not shown). After the wellbore <NUM> is formed and lined with casing <NUM>, a tubing string <NUM> is run into an opening <NUM> formed by the casing <NUM> to provide a pathway for hydrocarbons to the surface of the well <NUM>. Hydrocarbons may be recovered by forming perforations <NUM> in the formations <NUM> to allow hydrocarbons to enter the casing opening <NUM>. The perforations <NUM> are formed by operating a perforation gun <NUM>, which is a component of the tubing string <NUM>. The perforating gun <NUM> is used to perforate the casing <NUM> to allow the hydrocarbons trapped in the formations <NUM> to flow to the surface of the well <NUM>.

The tubing string <NUM> also carries a downhole tool <NUM>, such as a packer, a bridge plug or any other downhole tool used to seal a desired location in a wellbore. Although generically shown as a singular element, the downhole tool <NUM> may be an assembly of components. Generally, the downhole tool <NUM> may be operated by hydraulic or mechanical means and is used to form a seal at a desired location in the wellbore <NUM>. The downhole tool <NUM> may seal, for example, an annular space <NUM> formed between a production tubing <NUM> and the wellbore casing <NUM>. Alternatively, the downhole tool <NUM> may seal an annular space between the outside of a tubular and an unlined wellbore. Common uses of the downhole tool <NUM> include protection of the casing <NUM> from pressure and corrosive fluids; isolation of casing leaks, squeezed perforations, or multiple producing intervals; and holding of treating fluids, heavy fluids or kill fluids. However, these uses for the downhole tool <NUM> are merely illustrative, and application of the downhole tool <NUM> is not limited to only these uses. The downhole tool <NUM> may also be used with a conventional liner hanger (not shown) in a liner assembly. Typically, the downhole tool <NUM> would be positioned in the liner assembly proximate the conventional liner hanger. The downhole tool assembly is positioned above the conventional liner hanger. After the conventional liner hanger is set inside the wellbore casing, a cementation operation may be done to secure the liner within the wellbore. Thereafter, the downhole tool <NUM> may be activated to seal an annular space formed between liner assembly and the wellbore casing.

<FIG> illustrates the downhole tool <NUM> in a run-in (unset) position. As shown in <FIG>, the tubing string <NUM> includes a mandrel <NUM> which defines an inner diameter of the depicted portion of the tubing string <NUM>. An actuator sleeve <NUM> is slidably disposed about at least a portion of the mandrel <NUM>. The mandrel <NUM> and the actuator sleeve <NUM> define a sealed interface by the provision of an O-ring (not shown) carried on an outer diameter of the mandrel <NUM>. A terminal end of the actuator sleeve <NUM> is shouldered against a wedge member <NUM>. The wedge member <NUM> is generally cylindrical and slidably disposed about the mandrel <NUM>. An O-ring <NUM> seal is disposed between the mandrel <NUM> and the wedge member <NUM> to form a sealed interface therebetween. The seal <NUM> is carried on the inner surface of the wedge member <NUM>; however, the seal <NUM> may also be carried on the outer surface of the mandrel <NUM>. The seal <NUM> includes seal bands (i.e., anti-extrusion bands) in a similar manner as sealing element 450A-B. Further, a volume gap is defined between the seal <NUM> and a portion of the wedge member <NUM> in a similar manner as volume gap 470A-B.

The downhole tool <NUM> includes a locking mechanism which allows the wedge member <NUM> to travel in one direction and prevents travel in the opposite direction. The locking mechanism may be implemented as a ratchet ring <NUM> disposed on a ratchet surface <NUM> of the mandrel <NUM>. The ratchet ring <NUM> is recessed into, and carried by, the wedge member <NUM>. In this case, the interface of the ratchet ring <NUM> and the ratchet surface <NUM> allows the wedge member <NUM> to travel only in the direction of the arrow <NUM>.

A portion of the wedge member <NUM> forms an outer tapered surface <NUM>. In operation, the tapered surface <NUM> forms an inclined glide surface for a packing element <NUM>. Accordingly, the wedge member <NUM> is shown disposed between the mandrel <NUM> and packing element <NUM>, where the packing element <NUM> is disposed on the tapered surface <NUM>. In the depicted run-in position, the packing element <NUM> is located at a tip of the wedge member <NUM>, the tip defining a relatively smaller outer diameter with respect to the other end of the tapered surface <NUM>.

The packing element <NUM> is held in place by a retaining sleeve <NUM>. The packing element <NUM> may be coupled to the retaining sleeve <NUM> by a variety of locking interfaces. The retaining sleeve <NUM> includes a plurality of collet fingers <NUM>. The terminal ends of the collet fingers <NUM> are interlocked with an annular lip <NUM> of the packing element <NUM>. The collet fingers <NUM> may be biased in a radial direction. For example, it is contemplated that the collet fingers <NUM> have outward radial bias urging the collet fingers <NUM> into a flared or straighter position. However, in this case the collet fingers <NUM> do not provide a sufficient force to cause expansion of the packing element <NUM>.

The downhole tool <NUM> includes a self-adjusting locking mechanism which allows the retaining sleeve <NUM> to travel in one direction and prevents travel in the opposite direction. The locking mechanism is implemented as a ratchet ring <NUM> disposed on a ratchet surface <NUM> of the mandrel <NUM>. The ratchet ring <NUM> is recessed into, and carried by, the retaining sleeve <NUM>. In this case, the interface of the ratchet ring <NUM> and the ratchet surface <NUM> allows the retaining sleeve <NUM> to travel only in the direction of the arrow <NUM>, relative to the mandrel <NUM>. As will be described in more detail below, this self-adjusting locking mechanism ensures that a sufficient seal is maintained by the packing element <NUM> despite counter-forces acting to subvert the integrity of the seal.

In operation, the downhole tool <NUM> is run into a wellbore in the run-in position shown in <FIG>. To set the downhole tool <NUM>, the actuator sleeve <NUM> is driven axially in the direction of the arrow <NUM>. The axial movement of the actuator sleeve <NUM> may be caused by, for example, applied mechanical force from the weight of a tubing string or hydraulic pressure acting on a piston. The actuator sleeve <NUM>, in turn, engages the wedge member <NUM> and drives the wedge member <NUM> axially along the outer surface of the mandrel <NUM>. The ratchet ring <NUM> and the ratchet surface <NUM> ensure that the wedge member <NUM> travels only in the direction of the arrow <NUM>. With continuing travel over the mandrel <NUM>, the wedge member <NUM> is driven underneath the packing element <NUM>. The packing element <NUM> is prevented from moving with respect to the wedge member <NUM> by the provision of the ratchet ring <NUM> and the ratchet surface <NUM>. As a result, the packing element <NUM> is forced to slide over the tapered surface <NUM>. The positive inclination of the tapered surface <NUM> urges the packing element <NUM> into a diametrically expanded position. The set position of the downhole tool <NUM> is shown in <FIG>. In the set position, the packing element <NUM> rests at an upper end of the tapered surface <NUM> and is urged into contact with the casing <NUM> to form a fluid-tight seal which is formed in part by a metal-to-elastomer seal and a metal-to-metal contact. More generally, the metal may be any non-elastomer.

In the set position, the collet fingers <NUM> are flared radially outwardly but remain interlocked with the lip <NUM> formed on the packing element <NUM>. This coupling ties the position of the retaining sleeve <NUM> and ratchet ring <NUM> to the axial position of packing element <NUM>. This allows the packing element <NUM> to move up the wedge member <NUM> in response to increased pressure from below, maintaining its tight interface with the casing inner diameter, but prevents relative movement of the packing element <NUM> in the opposite direction (shown by the arrow <NUM>). The pressure from below the downhole tool <NUM> may act to diminish the integrity of the seal formed by the packing element <NUM> since the interface of the packing element <NUM> with the casing <NUM> and wedge member <NUM> will loosen due to pressure swelling the casing <NUM> and likewise acting to collapse the wedge member <NUM> from under the packing element <NUM>. The downhole tool <NUM> may counteract such an undesirable effect by the provision of the self-adjusting locking mechanism implemented by the ratchet ring <NUM> and ratchet surface <NUM>. In particular, the retaining sleeve <NUM> is permitted to travel up the mandrel <NUM> in the direction of the arrow <NUM> in response to a motivating force acting on the packing element <NUM>, as shown in <FIG>. However, the locking mechanism prevents the retaining sleeve <NUM> from traveling in the opposite direction (i.e., in the direction of arrow <NUM>), thereby ensuring that the seal does not move with respect to the casing <NUM> when pressure is acting from above, thus reducing wear on the packing element <NUM>.

<FIG> illustrates an enlarged view of the packing element <NUM> in the unset position. As such, the packing element <NUM> rests on the diametrically smaller end of the tapered surface <NUM>. The packing element <NUM> includes a tubular body <NUM> which is an annular member. The tubular body <NUM> includes a substantially smooth outer surface at its outer diameter, and defining a shaped inner diameter. In this context, a person skilled in the art will recognize that a desired smoothness of the outer surface is determined according to the particular environment and circumstances in which the packing element <NUM> is set. For example, the expected pressures to be withstood by the resulting seal formed by the packing element <NUM> will affect the smoothness of the outer surface. The tubular body <NUM> includes a portion of the outer surface that includes knurling or a rough surface area which is used as an anchor portion when the packing element <NUM> is set.

To form a seal with respect to the casing <NUM>, the packing element <NUM> includes one or more sealing elements 450A-B. The sealing elements 450A-B may be elastomer bands. In another example, the sealing elements 450A-B may be swelling elastomers. The sealing elements 450A-B are secured in grooves 455A-B formed in the tubular body <NUM>. For example, the sealing elements 450A-B may be bonded to the grooves 455A-B by a bonding material during the fabrication stage of the packing element <NUM>. Each groove 455A-B includes a volume gap 470A-B. As shown in <FIG>, the volume gap 470A-B is located on a lower portion of the groove 455A-B. However, the volume gap 470A-B may be located at different positions and in different configurations in the groove 455A-B (see volume gap in <FIG>, for example). Generally, the volume gap 470A-B is used to substantially prevent distortion of the sealing element 450A-B upon expansion of the packing element <NUM>. The size of the volume gap 470A-B may vary depending on the configuration of the groove 455A-B. The groove 455A-B may have <NUM>-<NUM>% more volume due to the volume gap 470A-B than a groove without a volume gap.

Each sealing element 450A-B includes a first seal band <NUM> and a second seal band <NUM>. The seal bands <NUM>, <NUM> are embedded in the sealing element 450A-B. The seal bands <NUM>, <NUM> may be springs. The seal bands <NUM>, <NUM> are used to limit the extrusion of the sealing element 450A-B upon expansion of the packing element <NUM>.

The portions of the outer surface between the sealing elements 450A-B form non-elastomer sealing surfaces 430A-C. The non-elastomer sealing surfaces 430A-C include grip members, such as carbide inserts, knurling or a rough surface which allows the non-elastomer sealing surfaces 430A-C to seal and act as an anchor upon expansion of the packing element <NUM>. For instance, the anchor portion (i.e., rough surface on the surfaces 430A-C) would contact and engage with the surrounding casing <NUM> when the packing element <NUM> is set, as shown in <FIG>. The anchor portion may be used to hold the packing sealing elements 450A-B in place by preventing movement of the packing element <NUM>. In other words, the anchor portion ensures that the packing sealing elements 450A-B do not move with respect to the casing <NUM> when subjected to high differential pressure, thus allowing the packing sealing elements 450A-B to maintain the sealing relationship with the casing <NUM> while at the same time reducing wear on the packing element <NUM>. The surfaces 430A-C may be induction hardened or similar means so that the surfaces 430A-C penetrate an inner surface of the casing <NUM> to provide a robust anchoring means when the packing element <NUM> is activated. In this manner, the anchor portion may be used to help resist axial movement of the packing sealing elements 450A-B relative to the casing <NUM> when the packing sealing elements 450A-B are subjected to high differential pressure.

The anchor portion (i.e., rough surface on the surfaces 430A-C) is used in place of a gripping member (not shown) in the downhole tool <NUM>. Rather than having a separate gripping member, such as slips, on the downhole tool <NUM>, the anchor portion may be configured to hold the downhole tool <NUM> within the casing <NUM>, thus reducing the number of components in the downhole tool <NUM> and reducing the overall length of the downhole tool <NUM>. Other benefits of using the anchor portion (rather than separate slips) would be that the overall stroke length of the downhole tool <NUM> would be reduced; elimination of potential leak paths and manufacturing costs would be reduced without compromising performance. The length and/or the size of the surfaces 430A-C may be arranged such that when the packing element <NUM> is set, a sufficient gripping force is created between the anchor portion and the surrounding casing <NUM> to support the downhole tool <NUM> within the wellbore. The surfaces 430A-C may also be induction hardened so that the surfaces 430A-C penetrate the casing <NUM> surface to provide a robust anchoring means upon activation of the packing element <NUM>. As discussed herein in relation to <FIG>, the wedge member <NUM> slides relative to the mandrel <NUM> to a position under the tubular body <NUM> to expand the packing element <NUM> radially outward into contact with the casing <NUM>. In another example, the wedge member <NUM> and the mandrel <NUM> may be formed as a single member (not shown) with a tapered surface, thus eliminating the need for the seal <NUM> and creating a thicker portion of the downhole tool <NUM> proximate the packing element <NUM>. Further, the tubular body <NUM> could be configured to move along the tapered surface of the single member to expand the packing element <NUM> radially outward into contact with the casing <NUM>.

The number and size of the sealing elements 450A-B define the surface area of the non-elastomer sealing surfaces 430A-C. It is to be noted that any number of sealing elements 450A-B and non-elastomer sealing surfaces 430A-C may be provided. The packing element <NUM> shown includes two sealing elements 450A-B and defining three non-elastomer sealing surfaces 430A-C. In general, a relatively narrow width of each non-elastomer sealing surface 430A-C is preferred in order to achieve a sufficient contact force between the surfaces and the casing <NUM>.

The shaped inner diameter of the tubular body <NUM> is defined by a plurality of ribs <NUM> separated by a plurality of cutouts <NUM> (e.g., voids). The cutouts <NUM> allow a degree of deformation of the tubular body <NUM> when the packing element <NUM> is placed into a sealed position. Further, the cutouts <NUM> aid in reducing the amount of setting force required to expand the packing element <NUM> into the sealed position. In other words, by removing material (e.g., cutouts <NUM>) of the tubular body <NUM>, the force required to expand the packing element <NUM> is reduced. The volume of the cutouts <NUM> (voids) may be between <NUM>-<NUM>% of the volume of the tubular body <NUM>. The ribs <NUM> are annular members integrally formed as part of the tubular body <NUM>. Each rib <NUM> forms an actuator-contact surface <NUM> at the inner diameter of the tubular body <NUM>, where the rib <NUM> is disposed on the tapered surface <NUM>. The tapered surface <NUM> may have an angle γ between about <NUM> degrees and about <NUM> degrees. Accordingly, the shaped inner diameter defined by the actuator-contact surfaces <NUM> may have a substantially similar taper angle.

The tubular body <NUM> further includes an O-ring seal <NUM> in cutout <NUM>. The seal <NUM> is configured to form a fluid-tight seal with respect to the outer tapered surface <NUM> of the wedge member <NUM>. The seal <NUM> may include seal bands (i.e., anti-extrusion bands) in a similar manner as sealing element 450A-B. Further, a volume gap may be defined between the seal <NUM> and a portion of the cutout <NUM> in a similar manner as volume gap 470A-B. It is noted that, the cutouts <NUM> may also, or alternatively, carry seals at their respective inner diameters.

In <FIG>, the packing element <NUM> is shown in the sealed (set) position, corresponding to <FIG>. During expansion of the packing element <NUM>, the sealing element 450A-B moves into contact with the casing <NUM> to create a seal between the packing element <NUM> and the casing <NUM>. As the sealing element 450A-B contacts the casing <NUM>, the sealing element 450A-B changes configuration and occupies a portion of the volume gap 470A-B. As shown, the volume gap 470A-B is located on the side of the packing element <NUM>, which is the last portion to be expanded by the wedge member <NUM>. The location of the volume gap 470A-B in the packing element <NUM> allows the sealing element 450A-B to change position (or reconfigure) within the groove 455A-B during the expansion operation. Additionally, the volume of the volume gap 470A-B may change during the expansion operation. The volume of the volume gap 470A-B may be reduced by <NUM>-<NUM>% during the expansion operation.

During the expansion operation, the seal bands <NUM>, <NUM> in the sealing element 450A-B are urged toward an interface <NUM> between the packing element <NUM> and the casing <NUM>, as shown in <FIG>. The volume gap 470A-B permits the sealing element 450A-B to move within the groove 455A-B and position the seal bands <NUM>, <NUM> at a location proximate the interface <NUM>. In comparing the volume gap 470A-B prior to expansion (<FIG>) and after expansion (<FIG>), a small volume gap remains after the expansion operation. It is to be noted that the small volume gap is optional. In other words, there may not be a small volume gap (see volume gap 470A-B on <FIG>) after the expansion operation.

The seal bands <NUM>, <NUM> are configured to substantially prevent the extrusion of the sealing element 450A-B past the interface <NUM>. In other words, the seal bands <NUM>, <NUM> expand radially outward with the packing element <NUM> and block the elastomeric material of the sealing element 450A-B from flowing through the interface <NUM> between the packing element <NUM> and the casing <NUM>. The seal bands <NUM>, <NUM> may be springs, such as toroidal coil springs, which expand radially outward due to the expansion of the packing element <NUM>. As the spring expands radially outward during the expansion operation, the coils of spring act as a barrier to the flow of the elastomeric material of the sealing element 450A-B. After the expansion operation, the seal bands <NUM>, <NUM> may prevent extrusion of the sealing element 450A-B when a gap between the packing element <NUM> and the casing <NUM> is increased due to downhole pressure. In other words, the seal bands <NUM>, <NUM> bridge the gap between the packing element <NUM> and the casing <NUM> and prevent extrusion of the sealing element 450A-B. In this manner, the seal bands <NUM>, <NUM> in the sealing element 450A-B act as an anti-extrusion device or an extrusion barrier during the expansion operation and after the expansion operation.

There are several benefits of the extrusion barrier created by the seal bands <NUM>, <NUM>. One benefit of the extrusion barrier would be that the outer surface of the sealing element 450A-B in contact with the casing <NUM> is limited to a region between the seal bands <NUM>, <NUM>, which allows for a high pressure seal to be created between the packing element <NUM> and the casing <NUM>. The packing element <NUM> may create a high-pressure seal in the range of <NUM>,<NUM> to <NUM>,<NUM> psi (<NUM> to <NUM> N/mm<NUM>). A further benefit of the extrusion barrier would be that the packing element <NUM> is capable of creating a seal with a surrounding casing that may have a range of inner diameters due to API tolerances. Another benefit would be that the extrusion barrier created by the seal bands <NUM>, <NUM> may prevent erosion of the sealing element 450A-B after the packing element <NUM> has been expanded. The erosion of the sealing element 450A-B could eventually lead to a malfunction of the packing element <NUM>.

The packing element <NUM> rests at the diametrically enlarged end of the tapered surface <NUM> and is sandwiched between the wedge member <NUM> and the casing <NUM>. The dimensions of the downhole tool <NUM> are preferably such that the packing element <NUM> is fully engaged with the casing <NUM>, before the tubular body <NUM> reaches the end of the tapered surface <NUM>. Note that in the sealed position, the sealing elements 450A-B and the non- elastomer sealing surfaces 430A-C have been expanded into contact with the casing <NUM>.

As such, it is clear that the tubular body <NUM> has undergone a degree of deformation. The process of deformation may occur, at least in part, as the packing element <NUM> slides up the tapered surface <NUM>, prior to making contact with the inner diameter of the casing <NUM>. Additionally or alternatively, deformation may occur as a result of contact with the inner diameter of the casing <NUM>. In any case, the process of deformation causes the sealing elements 450A-B and the non-elastomer sealing surfaces 430A-C to contact the inner diameter of the casing <NUM> in the sealed position. In addition, the non-elastomeric backup seals prevent extrusion of the sealing elements 450A-B.

<FIG> illustrates a hanger assembly <NUM> in an unset position. At the stage of completion shown in <FIG>, a wellbore has been lined with a string of casing <NUM>. Thereafter, the hanger assembly <NUM> is positioned within the casing <NUM>. The hanger assembly <NUM> includes a hanger <NUM>, which is an annular member. The hanger assembly further includes an expander sleeve <NUM>. Typically, the hanger assembly <NUM> is lowered into the wellbore by a running tool disposed at the lower end of a work string (not shown).

The hanger assembly <NUM> includes the hanger <NUM> of this present invention. The hanger <NUM> may be used to attach or hang liners from an internal wall of the casing <NUM>. The hanger <NUM> may also be used as a patch to seal an annular space formed between hanger assembly <NUM> and the wellbore casing <NUM> or an annular space between hanger assembly <NUM> and an unlined wellbore. The hanger <NUM> optionally includes grip members, such as tungsten carbide inserts or slips. The grip members may be disposed on an outer surface of the hanger <NUM>. The grip members may be used to grip an inner surface of the casing <NUM> upon expansion of the hanger <NUM>.

As shown in <FIG>, the hanger <NUM> includes a plurality of seal assemblies <NUM> disposed on the outer surface of a tubular body of the hanger <NUM>. The plurality of seal assemblies <NUM> are circumferentially spaced around the hanger <NUM> to create a seal between hanger assembly <NUM> and the casing <NUM>. Each seal assembly <NUM> includes a seal ring <NUM> disposed in a gland <NUM>. A bonding material, such as glue (or other attachment means), may be used on selective sides of the gland <NUM> to attach the seal ring <NUM> in the gland <NUM>. Bonding the seal ring <NUM> in the gland <NUM> is useful to prevent the seal ring <NUM> from becoming unstable and swab off when the hanger <NUM> is positioned in the casing <NUM> and prior to expansion of the hanger <NUM>. Bonding the seal ring <NUM> in the gland <NUM> is also useful to resist circulation flow swab off as installation of liners typically require fluid displacements prior to sealing and anchoring of the hanger assembly <NUM>.

The side of the gland <NUM> creates a volume gap <NUM> between the seal ring <NUM> and the gland <NUM>. As set forth herein, the volume gap <NUM> is generally used to minimize distortion of the seal ring <NUM> upon expansion of the hanger <NUM>. The volume gap <NUM> may be created in any configuration (see <FIG>, for example). Additionally, the size of the volume gap <NUM> may vary depending on the configuration of the gland <NUM>. The seal ring <NUM> includes a first seal band <NUM> and a second seal band <NUM>. The seal bands <NUM>, <NUM> are embedded in opposite sides of the seal ring <NUM>. The seal bands <NUM>, <NUM> are used to limit the extrusion of the seal ring <NUM> during and after expansion of the seal assembly <NUM>.

The hanger assembly <NUM> includes the expander sleeve <NUM> which is used to expand the hanger <NUM>. The expander sleeve <NUM> may be attached to the hanger <NUM> by an optional releasable connection member <NUM>, such as a shear pin. The expander sleeve <NUM> includes a tapered outer surface <NUM> and a bore <NUM>. The expander sleeve <NUM> further includes an end portion <NUM> that is configured to interact with an actuator member (not shown). The expander sleeve <NUM> optionally includes a self-adjusting locking mechanism (not shown) which allows the expander sleeve <NUM> to travel in one direction and prevents travel in the opposite direction.

To set the hanger assembly <NUM>, the actuator member is driven axially in a direction toward the hanger <NUM>. The axial movement of the actuator member may be caused by, for example, applied mechanical force from the weight of a tubing string or hydraulic pressure acting on a piston. The actuator member, in turn, engages the end portion <NUM> of the expander sleeve <NUM> in order to move the expander sleeve <NUM> axially toward the hanger <NUM>. At a predetermined force, the optional releasable connection member <NUM> is disengaged, which allows the expander sleeve <NUM> to move relative to the hanger <NUM>. The hanger <NUM> is prevented from moving with respect to the wedge expander sleeve <NUM>. As the tapered outer surface <NUM> of expander sleeve <NUM> engages the inner surface of the hanger <NUM>, the hanger <NUM> is moved into a diametrically expanded position.

The set position of the hanger assembly <NUM> is shown in <FIG>. In the set position, the expander sleeve <NUM> is positioned inside the hanger <NUM>. In other words, the expander sleeve <NUM> is not removed from the hanger <NUM>. This arrangement may allow the expander sleeve <NUM> to apply a force on the hanger <NUM> after the expansion operation. The bore <NUM> of the expander sleeve <NUM> permits other wellbore tools to pass through the hanger assembly <NUM> prior to expansion of the hanger <NUM> and after expansion of the hanger <NUM>. In comparing the hanger assembly <NUM> in the unset position (<FIG>) and the hanger assembly <NUM> in the set position (<FIG>), it is noted that the expander sleeve <NUM> is disposed substantially outside of the hanger <NUM> in the unset position and the expander sleeve <NUM> is disposed inside the hanger <NUM> in the set position. The expander sleeve <NUM> remains inside the hanger <NUM> after the expansion operation is complete. As such, the expander sleeve <NUM> is configured to support the hanger <NUM> after the expansion operation.

As shown in <FIG>, the hanger <NUM> is urged into contact with the casing <NUM> to form a fluid-tight seal which is formed in part by a metal-to-elastomer seal and a metal-to-metal contact. More specifically, the seal ring <NUM> moves into contact with the casing <NUM> to create a seal between the hanger <NUM> and the casing <NUM>. As the seal ring <NUM> contacts the casing <NUM>, the seal ring <NUM> changes configuration and occupies a portion of the volume gap <NUM>. As shown, the volume gap <NUM> is located on the side of the seal assembly <NUM> which is the first portion to be expanded by the expander sleeve <NUM>. The location of the volume gap <NUM> in the seal assembly <NUM> allows the seal ring <NUM> to change position (or reconfigure) within the gland <NUM> during the expansion operation. Additionally, the seal bands <NUM>, <NUM> in the seal ring <NUM> are urged toward an interface between the seal assembly <NUM> and the casing <NUM> to block the elastomeric material of the seal ring <NUM> from flowing through the interface <NUM> between the seal assembly <NUM> and the casing <NUM>. The seal bands <NUM>, <NUM> may be springs, such as toroidal coil springs, which expand radially outward due to the expansion of the hanger <NUM>. As the spring expands radially outward during the expansion operation, the coils of spring act as a barrier to the flow of the elastomeric material of the seal ring <NUM>. In addition, after expansion of the hanger <NUM>, the seal bands <NUM>, <NUM> may prevent extrusion of the seal ring <NUM> when the gap between the hanger assembly <NUM> and the casing <NUM> is increased due to pressure. In other words, the seal bands <NUM>, <NUM> bridge the gap, and the net extrusion gap between coils of the seal bands <NUM>, <NUM> grows considerably less as compared to an annular gap that is formed when a seal ring does not include the seal bands. In this manner, the seal bands <NUM>, <NUM> in the seal ring <NUM> act as an anti-extrusion device or an extrusion barrier during the expansion operation and after the expansion operation.

<FIG> illustrates a view of an installation tool <NUM> for use in a dry seal stretch operation. The seal ring <NUM> is installed in the gland <NUM> during the fabrication process of the hanger <NUM> by the dry seal stretch operation. The installation tool <NUM> generally includes a taper tool <NUM>, a loading tool <NUM> and a push plate <NUM>. A low-friction coating may be used in the dry seal stretch operation to reduce the friction between the seal ring <NUM> and the components of the installation tool <NUM>. The low-friction coating may be applied to a portion of a taper <NUM> of the taper tool <NUM> and a portion of a lip <NUM> on the loading tool <NUM>. In another example, the low-friction coating may be applied to a portion of the seal ring <NUM>. The low-friction coating may be a dry lubricant, such as Impregion or Teflon®.

As shown in <FIG>, the seal ring <NUM> is moved up the taper <NUM> of the taper tool <NUM> in the direction indicated by arrow <NUM>. The taper tool <NUM> is configured to change the seal ring <NUM> from a first configuration having a first inner diameter to a second configuration having a second larger inner diameter (e.g., stretch the seal ring). As illustrated, the loading tool <NUM> is positioned on a reduced diameter portion <NUM> of the taper tool <NUM> such that the lip <NUM> can receive the seal ring <NUM>. The loading tool <NUM> is secured to the taper tool <NUM> by a plurality of connection members <NUM>, such as screws. After the seal ring is in the second configuration, the seal ring <NUM> is moved to the lip <NUM> of the loading tool <NUM>.

<FIG> illustrates a view of the loading tool <NUM> with the seal ring <NUM>. The loading tool <NUM> and the push plate <NUM> are removed from the end <NUM> of the taper tool <NUM> in the direction indicated by arrow <NUM>. Generally, the loading tool <NUM> is an annular tool that is configured to receive and hold the seal ring <NUM> in the second configuration (e.g., large inner diameter). <FIG> illustrates a view of the loading tool <NUM> and the push plate <NUM> on the expandable hanger <NUM>. The loading tool <NUM> is positioned on the hanger <NUM> such that the lip <NUM> of the loading tool <NUM> (and seal ring <NUM>) is located adjacent the gland <NUM>. Thereafter, the loading tool <NUM> is secured to the hanger <NUM> by the plurality of connection members <NUM>. Prior to placing the seal ring <NUM> in the gland <NUM>, a bonding material, such as glue, is applied to the selective sides of the gland <NUM>.

<FIG> illustrates a view of the push plate <NUM> and the loading tool <NUM>. During the dry seal stretch operation, the push plate <NUM> engages the seal member <NUM> as the push plate <NUM> is moved in a direction indicated by arrow <NUM>. The push plate urges the seal ring <NUM> off the lip <NUM> of the loading tool <NUM> and into the gland <NUM> of the hanger <NUM>. This sequence of steps may be repeated for each seal ring <NUM>.

As mentioned herein, the packing element <NUM> may be used with different downhole tools. For instance, the packing element <NUM> may be used as a back-up for a compression or inflatable element, or in conjunction with a stage tool, or integral with a pack-off stage tool. <FIG> illustrate an example of the packing element with a pack-off stage tool <NUM>. For convenience, the components in the stage tool <NUM> that are similar to the components in the downhole tool <NUM> will be labeled with the same number indicator. The stage tool <NUM> is attached to casing <NUM> and lowered into the wellbore <NUM>. The stage tool <NUM> is used during a cementing operation to inject cement into an annulus <NUM> formed between the casing <NUM> and the wellbore <NUM> at specified locations in the wellbore <NUM>. As shown, the stage tool <NUM> includes the packing element <NUM>, the expansion cone <NUM>, a mechanical piston assembly <NUM> and slips <NUM>.

As shown in <FIG>, the stage tool <NUM> includes slips <NUM> and a gauge ring <NUM>. The slips <NUM> are configured to travel along the gauge ring <NUM> upon activation of the slips <NUM>. The stage tool <NUM> further includes a self-adjusting locking mechanism which allows the slips <NUM> to travel in one direction and prevents travel in the opposite direction. The locking mechanism is implemented as a lower locking ring <NUM>. Upon activation, the slips <NUM> are configured to grip the wellbore <NUM> to support the stage tool <NUM> in the wellbore <NUM>.

An anchor portion (i.e., rough surface on the surfaces 430A-C on the packing element <NUM>) may be used in place of the slips <NUM> to support the stage tool <NUM> in the wellbore <NUM>, thus reducing the number of components in the stage tool <NUM> and reducing the overall length of the stage tool <NUM>. As set forth herein, the length and/or the size of the surfaces 430A-C may be arranged such that when the packing element <NUM> is set, a sufficient gripping force is created between the anchor portion and the surrounding wellbore <NUM> to support the downhole tool <NUM> within the wellbore <NUM>. The surfaces 430A-C may also be induction hardened so that the surfaces 430A-C penetrate the surface of the wellbore <NUM> to provide a robust anchoring means upon activation of the packing element <NUM>.

<FIG> illustrates a view of an upper end of the stage tool <NUM>. As shown, the stage tool <NUM> includes an inner sleeve <NUM> with ports <NUM> and a body member <NUM> with ports <NUM>. As will be described herein, the inner sleeve <NUM> is configured to move relative to the body member <NUM> to align the ports <NUM>, <NUM> and thus create a fluid pathway between an inside portion and an outside portion of the stage tool <NUM>. The stage tool <NUM> further includes a closing seat <NUM> and an opening seat <NUM>. The stage tool <NUM> also includes an upper lock ring <NUM> that is attached to a housing via shear screws <NUM>. Additionally, the stage tool <NUM> includes an external sleeve <NUM>.

As shown in <FIG>, a plug <NUM> is disposed in the stage tool <NUM>. After the stage tool <NUM> is located in the wellbore <NUM>, the plug <NUM> is dropped into the stage tool <NUM>. The plug <NUM> moves through a bore <NUM> of the stage tool <NUM> until it contacts the opening seat <NUM> in the inner sleeve <NUM>. The plug <NUM> is configured to block fluid communication through the bore <NUM> of the stage tool <NUM>.

<FIG> and <FIG> illustrate the activation of the slips <NUM> in the stage tool <NUM>. After the plug <NUM> blocks fluid communication through the bore <NUM> of the stage tool <NUM>, the fluid pumped from the surface creates a fluid pressure within the bore <NUM> of the stage tool <NUM>. At a predetermined pressure, the inner sleeve <NUM> moves relative to the body member <NUM> until the ports <NUM> in the inner sleeve <NUM> align with the ports <NUM> in the body member.

After the ports <NUM>, <NUM> are aligned, fluid in the bore <NUM> may flow through the ports <NUM>, <NUM> into a fluid passageway <NUM> to set the packing element <NUM> and the slips <NUM>. The fluid moving through the fluid passageway <NUM> generates a fluid pressure which causes the mechanical piston assembly <NUM> to apply a force on the wedge member <NUM> which is subsequently applied to the retaining sleeve <NUM>. The force on the retaining sleeve <NUM> causes shear pin <NUM> to break and allows the slips <NUM> to move along the gauge ring <NUM>. The movement of the slips <NUM> in a first direction relative to the gauge ring <NUM> causes the slips <NUM> to move radially outward and engage the wellbore <NUM>, as shown in <FIG>. The self-adjusting locking mechanism (i.e., locking ring <NUM>) prevents travel in the slips <NUM> in a second opposite direction. The slips <NUM> and the packing element <NUM> are configured such that the force to break the shear pin <NUM> is less than the force to move the packing element <NUM> along the expansion cone <NUM>. As a result, the shear pin <NUM> breaks and the slips <NUM> move along the gauge ring <NUM> prior to the movement of the packing element <NUM> along the expansion cone <NUM>. After the slips <NUM> have been set, the retaining sleeve <NUM> moves under the packing element <NUM>, as set forth herein.

The packing element <NUM> may be configured such that a force of a preselected magnitude is required in order to radially expand it during the packer setting process. This radial expansion is effected by the axial movement of wedge member <NUM> with respect to the packing element <NUM>. Therefore, because of the angle of inclination of the wedge member <NUM> and friction between the wedge member <NUM> and packing element <NUM>, the radial force required to radially expand packing element <NUM> can be correlated to a corresponding axial force which must be applied to the wedge member <NUM> in order to achieve relative movement between wedge member <NUM> and packing element <NUM>. Hence, there exists a threshold axial force which must be applied to the wedge member <NUM> in order to radially expand packing element <NUM>.

In operation, an axial force may be applied to the wedge member <NUM> (and therefore onto the packing element <NUM>) which is less than this threshold axial force. In such instances, the applied axial force is communicated from the wedge member <NUM> to the packing element <NUM>, and from the packing element <NUM> to collet fingers <NUM>, and the retaining sleeve <NUM> without the packing element <NUM> experiencing any radial expansion (or any substantial radial expansion). Therefore, such an applied axial force less than the threshold axial force may be applied through the packing element <NUM> in order to effect the operation of another tool and/or another part of the same tool, such as setting slips <NUM> as described herein.

Furthermore, in operation, an axial force may be applied to the wedge member <NUM> (and therefore onto the packing element <NUM>) which is greater than the aforementioned threshold axial force. In such instances, if there exists little or no available space for the packing element <NUM>, collet fingers <NUM>, and the retaining sleeve <NUM> to move axially, then the wedge member <NUM> may move axially with respect to the packing element <NUM>. In this way, the wedge member <NUM> is forced further under the packing element <NUM>, resulting in radial expansion of the packing element <NUM>, which may continue until the packing element <NUM> has been moved to its set position in the wellbore.

The aforementioned threshold axial force may be preselected by including a latch and/or a shearable fastening between the wedge member <NUM> and the packing element <NUM>. This threshold axial force may be preselected by the configuration and (for example) selection of construction materials of the packing element <NUM> alone, or in combination with the configuration and selection of a suitable latch and/or shearable fastening between the wedge member <NUM> and the packing element <NUM>.

In practice, by way of example, the aforementioned threshold axial force may be circa <NUM>,<NUM> lbs (<NUM> kN), though other magnitudes above and below this figure are contemplated, and may be tailored to suit specific applications.

<FIG> illustrate the activation of the packing element <NUM> in the stage tool <NUM>. After the slips <NUM> have engaged the wellbore <NUM>, the fluid pressure generated by the fluid moving through the fluid passageway <NUM> causes the mechanical piston assembly <NUM> to activate the packing element <NUM>. In a similar manner as described herein, the wedge member <NUM> is urged under the tubular body <NUM> of the packing element <NUM>. As a result, the packing element <NUM> moves radially outward into contact with the wellbore <NUM>, and a seal is formed between the stage tool <NUM> and the wellbore <NUM>.

<FIG> illustrate the movement of the external sleeve <NUM> of the stage tool <NUM>. After the packing element <NUM> and the slips <NUM> have engaged the wellbore <NUM>, the fluid pressure generated by the fluid moving through the fluid passageway <NUM> causes the external sleeve <NUM> to move relative to the body member <NUM>. The movement of the external sleeve <NUM> exposes the ports <NUM>, <NUM>, as shown in <FIG>. The exposure of the ports <NUM>, <NUM> opens a fluid passageway between the bore <NUM> of the stage tool <NUM> and the annulus <NUM> formed between the stage tool <NUM> and the wellbore <NUM>. Cement may be pumped through the bore <NUM>, the ports <NUM>, <NUM> and into the annulus <NUM> during the cementing operation. After the cementation operation is complete, the closing plug <NUM> is dropped into the stage tool <NUM>.

<FIG> illustrate the closing of the ports <NUM>, <NUM> of the stage tool <NUM> after the cementation operation is complete. The closing plug <NUM> moves through the bore <NUM> of the stage tool <NUM> until it contacts the closing seat <NUM> attached to the inner sleeve <NUM>, as shown in <FIG>. The closing plug <NUM> is configured to block fluid communication through the bore <NUM> of the stage tool <NUM>. The fluid pumped from the surface creates a fluid pressure within the bore <NUM> of the stage tool <NUM>. At a predetermined pressure, the inner sleeve <NUM> moves relative to the body member <NUM> until the ports <NUM> in the inner sleeve <NUM> misalign with the ports <NUM> in the body member <NUM>. At this point, fluid in the bore <NUM> may no longer flow through the ports <NUM>, <NUM>; thus the fluid passageway between the bore <NUM> and the annulus <NUM> is closed.

<FIG> illustrate a downhole tool <NUM> in a run-in (unset) position. The downhole tool <NUM> may be used to seal a desired location in a wellbore. For convenience, the components in the tool <NUM> that are similar to the components in the tool <NUM> will be labeled with the same number indicator. The tool <NUM> includes a slip assembly <NUM> and a packing element <NUM>.

The slip assembly <NUM> includes slips <NUM> and a wedge member <NUM>. The wedge member <NUM> is generally cylindrical and slidably disposed about the mandrel <NUM>. The downhole tool <NUM> includes a locking mechanism which allows the wedge member <NUM> to travel in one direction (arrow <NUM>) and prevents travel in the opposite direction (arrow <NUM>). The locking mechanism may be implemented as a ratchet ring <NUM> is disposed on a ratchet surface <NUM> of the mandrel <NUM>. The ratchet ring <NUM> is recessed into, and carried by, the sleeve <NUM>. In this case, the interface of the ratchet ring <NUM> and the ratchet surface <NUM> allows the sleeve <NUM> and the wedge member <NUM> to travel only in the direction as indicated by arrow <NUM>. As shown, the sleeve <NUM> is attached to the wedge member <NUM> by a dog <NUM>, and the sleeve is attached to the mandrel <NUM> by a shear pin <NUM>.

The packing element <NUM> includes a tubular body <NUM>, which is an annular member. The tubular body <NUM> includes an optional grip member <NUM> with a grip surface <NUM>. The grip member <NUM> is configured to engage the casing <NUM> upon activation of the packing element <NUM>. In a similar manner as described herein, the wedge member <NUM> is configured to move axially along the outer surface of the mandrel <NUM>. The packing element <NUM> is prevented from moving with respect to the wedge member <NUM>. As a result, the packing element <NUM> is forced to slide over the tapered surface of the wedge member <NUM>. The positive inclination of the tapered surface urges the packing element <NUM> into a diametrically expanded position.

In operation, an axial force may be applied to the wedge member <NUM> (and therefore onto the packing element <NUM>) which is less than this threshold axial force. In such instances, the applied axial force is communicated from the wedge member <NUM> to the packing element <NUM>, and from the packing element <NUM> to collet fingers <NUM>, and retaining sleeve <NUM> without the packing element <NUM> experiencing any radial expansion (or any substantial radial expansion). Therefore, such an applied axial force less than the threshold axial force may be applied through the packing element <NUM> in order to effect the operation of another tool and/or another part of the same tool, such as setting slips <NUM> as described hereafter.

Furthermore, in operation, an axial force may be applied to the wedge member <NUM> (and therefore onto the packing element <NUM>) which is greater than the aforementioned threshold axial force. In such instances, if there exists little or no available space for the packing element <NUM>, collet fingers <NUM>, and retaining sleeve <NUM> to move axially, then the wedge member <NUM> may move axially with respect to the packing element <NUM>. In this way, the wedge member <NUM> is forced further under the packing element <NUM>, resulting in radial expansion of the packing element <NUM>, which may continue until the packing element <NUM> has been moved to its set position in the wellbore.

<FIG> illustrate the setting of the slips <NUM> in the tool <NUM>. As shown, the setting sequence for the tool <NUM> is to set the slip assembly <NUM> (<FIG>) and then set the packing element <NUM> (<FIG>). In another example, the packing element <NUM> may be set, and then the slip assembly <NUM> may be set.

To set the slip assembly <NUM>, an actuator sleeve (not shown) is driven axially in the direction of arrow <NUM>. The axial movement of the actuator sleeve may be caused by, for example, applied mechanical force from the weight of a tubing string or hydraulic pressure acting on a piston. The actuator sleeve applies a force on the wedge member <NUM>, which drives the wedge member <NUM> axially along the outer surface of the mandrel <NUM>. The movement of the sleeve <NUM> along the outer surface of the mandrel <NUM> toward the wedge member <NUM> causes the shear pin <NUM> to break. Thereafter, the sleeve <NUM> moves along the mandrel <NUM> thereby allowing the dog <NUM> to be released. The sleeve <NUM> moves until a surface <NUM> of the sleeve <NUM> contacts an end surface <NUM> of the wedge member <NUM> (compare <FIG> and <FIG>). At this point, the sleeve <NUM> urges the wedge member <NUM> under the slips <NUM>. As a result, the slips <NUM> expand radially outward and engage the casing <NUM>.

<FIG> illustrate the setting of the packing element <NUM> in the tool <NUM>. After the slip assembly <NUM> has been set, the packing element <NUM> is set. To set the packing element <NUM>, the actuator sleeve drives the wedge member <NUM> axially along the outer surface of the mandrel <NUM> in a similar manner as described herein. With continuing travel over the mandrel <NUM>, the wedge member <NUM> is driven underneath the packing element <NUM>. The packing element <NUM> is prevented from moving with respect to the wedge member <NUM> by the provision of the ratchet ring <NUM> and the ratchet surface <NUM>. As a result, the packing element <NUM> is forced to slide over the tapered surface <NUM>. The positive inclination of the tapered surface urges the packing element <NUM> into a diametrically expanded position. As the packing element <NUM> expands radially outward, the gripping surface <NUM> of the gripping member <NUM> engages the wellbore. The gripping member <NUM> may be used to hold the packing sealing elements 450A-B in place by preventing movement of the packing element <NUM>. In other words, the gripping member <NUM> ensures that the packing sealing elements 450A-B do not move with respect to the casing <NUM> when subjected to high differential pressure, thus allowing the packing sealing elements 450A-B to maintain the sealing relationship with the casing <NUM>. The gripping surface <NUM> may be induction hardened or similar means so that the gripping surface <NUM> penetrates an inner surface of the casing <NUM> to provide a robust anchoring means when the packing element <NUM> is activated. In this manner, the gripping member <NUM> may be used to help resist axial movement of the packing sealing elements 450A-B relative to the casing <NUM> when the packing sealing elements 450A-B are subjected to high differential pressure.

<FIG> illustrate views of a downhole tool <NUM> in a run-in (unset) position. For convenience, the components in the tool <NUM> that are similar to the components in the tool <NUM> and tool <NUM> will be labeled with the same number indicator. The tool <NUM> includes a biasing member <NUM>, such as a spring, between the sleeve <NUM> and the sleeve <NUM>. A sleeve <NUM> is attached to sleeve <NUM> via a lock screw <NUM>. The tool <NUM> operates in a similar manner as tool <NUM>. The biasing member is configured to apply a biasing force on the wedge member <NUM> after the slips <NUM> are set (see <FIG>). In other words, after the shear pin <NUM> breaks and the dogs <NUM> are released, the movement of the sleeve <NUM> along the mandrel <NUM> causes the biasing member <NUM> to be compressed between sleeves <NUM>, <NUM>. The sleeve <NUM> is locked in one direction and is able to move in the other direction due to the locking mechanism <NUM>, <NUM>. Thus, the compressed biasing member <NUM> applies a biasing force on the wedge member <NUM> (via the sleeve <NUM>). The biasing force may be used to maintain the wedge member <NUM> under the slip <NUM> after the slips <NUM> have been set.

<FIG> illustrate a downhole tool <NUM> in a run-in (unset) position. For convenience, the components in the tool <NUM> that are similar to the components in the tool <NUM> will be labeled with the same number indicator. The tool <NUM> includes a packing element <NUM> that may be used to seal a desired location in a wellbore. The packing element <NUM> is held in place by the retaining sleeve <NUM>. The packing element <NUM> may be coupled to the retaining sleeve <NUM> by a variety of locking interfaces. The retaining sleeve <NUM> may include a plurality of collet fingers <NUM>. The terminal ends of the collet fingers <NUM> are interlocked with the annular lip <NUM> of the packing element <NUM>.

The packing element <NUM> includes the tubular body <NUM>, which is an annular member. The tubular body <NUM> has an anchor <NUM> with a grip surface <NUM>. The anchor <NUM> is configured to engage the casing <NUM> upon activation of the packing element <NUM>. The anchor <NUM> may be used in place of a gripping member (not shown) in the downhole tool <NUM>. Rather than having a separate gripping member, such as slips, on the downhole tool <NUM>, the anchor <NUM> may be configured to hold the downhole tool <NUM> within the casing <NUM>, thus reducing the number of components in the downhole tool <NUM> and reducing the overall length of the downhole tool <NUM>. Other benefits of using the anchor <NUM> (rather than separate slips) would be that the overall stroke length of the downhole tool <NUM> would be reduced; elimination of potential leak paths and manufacturing costs would be reduced without compromising performance. The length and/or the size of the grip surface <NUM> may be arranged such that when the packing element <NUM> is set, a sufficient gripping force is created between the anchor <NUM> and the surrounding casing <NUM> to support the downhole tool <NUM> within the wellbore.

The downhole tool <NUM> includes a self-adjusting locking mechanism which allows the retaining sleeve <NUM> to travel in one direction and prevents travel in the opposite direction. The locking mechanism is implemented as a ratchet ring <NUM> disposed on a ratchet surface <NUM> of a mandrel <NUM>. The ratchet ring <NUM> is recessed into, and carried by, the retaining sleeve <NUM>. In this case, the interface of the ratchet ring <NUM> and the ratchet surface <NUM> allows the retaining sleeve <NUM> to travel only in the direction of the arrow <NUM>, relative to the mandrel <NUM>.

As shown in <FIG>, the mandrel <NUM> has an outer tapered surface <NUM>. As such, the mandrel <NUM> has a first portion 950A with a first thickness and a second portion 950B with a greater second thickness. As will be described herein, the packing element <NUM> is urged along the tapered surface <NUM> of the mandrel <NUM> during the setting process. The use of the tapered surface <NUM> of the mandrel <NUM> to activate the packing element <NUM>, rather than having a separate wedge member, reduces the number of components in the downhole tool <NUM> and reduces the overall length of the downhole tool <NUM>. Other benefits of using the tapered surface <NUM> of the mandrel <NUM> (rather than a separate wedge member) would be the elimination of potential leak paths between the separate wedge member and the mandrel, and manufacturing costs would be reduced without compromising performance. Another benefit of using the tapered surface <NUM> of the mandrel <NUM> would be that the added thickness of the mandrel <NUM> provides ultra high pressure body integrity below the packing element <NUM>.

<FIG> illustrate the downhole tool <NUM> in a set position. To set the downhole tool <NUM>, an actuator sleeve <NUM> is driven axially in the direction of the arrow <NUM>. The axial movement of the actuator sleeve <NUM> may be caused by, for example, applied mechanical force from the weight of a tubing string or hydraulic pressure acting on a piston. The actuator sleeve <NUM>, in turn, drives the retaining sleeve <NUM> and the packing element <NUM> axially along the tapered surface <NUM> of the mandrel <NUM>. The ratchet ring <NUM> and the ratchet surface <NUM> ensure that the retaining sleeve <NUM> and the packing element <NUM> travel only in the direction of the arrow <NUM>. With continuing travel over the mandrel <NUM>, the packing element <NUM> moves along the tapered surface <NUM> into a diametrically expanded position. The set position of the downhole tool <NUM> is shown in <FIG>.

In the set position, the packing element <NUM> is urged into contact with the casing <NUM> to form a fluid-tight seal and the gripping surface <NUM> of the anchor <NUM> engages the casing <NUM>. The anchor <NUM> may be used to support the tool <NUM> in the casing <NUM>. Additionally, the anchor <NUM> may be used to hold the packing sealing elements 450A-B in place by preventing movement of the packing element <NUM>. More specifically, the anchor <NUM> ensures that the packing sealing elements 450A-B do not move with respect to the casing <NUM> when subjected to high differential pressure, thus allowing the packing sealing elements 450A-B to maintain the sealing relationship with the casing <NUM>, while at the same time reducing wear on the packing element <NUM>. The gripping surface <NUM> of the anchor <NUM> may be induction hardened or similar means so that the gripping surface <NUM> penetrates an inner surface of the casing <NUM> to provide a robust anchoring means when the packing element <NUM> is activated. In this manner, the anchor <NUM> may be used to support the tool <NUM> within the casing <NUM> and also help resist axial movement of the packing sealing elements 450A-B relative to the casing <NUM> when the packing sealing elements 450A-B are subjected to high differential pressure.

The following examples are not necessarily within the scope of the appended claims, which form the only definition of the invention. In one example, an anchoring seal assembly for creating a seal portion and an anchor portion between a first tubular that is disposed within a second tubular is provided. The anchoring seal assembly includes an expandable annular member attached to the first tubular. The annular member has an outer surface and an inner surface. The anchoring seal assembly further includes a seal member disposed in a groove formed in the outer surface of the expandable annular member. The seal member has one or more anti-extrusion spring bands embedded within the seal member, wherein the outer surface of the expandable annular member adjacent the groove includes a rough surface. The anchoring seal assembly also includes an expander sleeve having a tapered outer surface and an inner bore. The expander sleeve is movable between a first position in which the expander sleeve is disposed outside of the expandable annular member and a second position in which the expander sleeve is disposed inside of the expandable annular member, wherein the expander sleeve is configured to radially expand the expandable annular member into contact with an inner wall of the second tubular to create the seal portion and the anchor portion as the expander sleeve moves from the first position to the second position.

In another example, a method of creating a seal portion and an anchor portion between a first tubular and a second tubular is provided. The method includes the step of positioning the first tubular within the second tubular. The first tubular has an annular member with a groove and a rough outer surface, wherein a seal member with at least one anti-extrusion band is disposed within the groove and wherein a gap is formed between a side of the seal member and a side of the groove. The method further includes the step of expanding the annular member radially outward, which causes the at least one anti-extrusion band to move toward an interface area between the first tubular and the second tubular. The method also includes the step of urging the annular member into contact with an inner wall of the second tubular to create the seal portion and the anchor portion between the first tubular and the second tubular.

In one example, a seal assembly for creating a seal between a first tubular and a second tubular is provided. The seal assembly includes an annular member attached to the first tubular, the annular member having a groove formed on an outer surface of the annular member. The seal assembly further includes a seal member disposed in the groove, the seal member having one or more anti-extrusion bands. The seal member is configured to be expandable radially outward into contact with an inner wall of the second tubular by the application of an outwardly directed force supplied to an inner surface of the annular member. Additionally, the seal assembly includes a gap defined between the seal member and a side of the groove.

In one example, the gap is configured to close upon expansion of the annular member. In another example, the gap is configured to close completely upon expansion of the annular member. In a further example, a portion of the seal member is used to close the gap. In an additional example, the one or more anti-extrusion bands comprise a first anti-extrusion band and a second anti-extrusion band. In yet a further example, the first anti-extrusion member is embedded on a first side of the seal member and the second anti-extrusion band is embedded on a second side of the seal member. In another example, the first anti-extrusion band and the second anti-extrusion band are springs. In a further example, the first anti-extrusion band and the second anti-extrusion band are configured to move toward a first interface area and a second interface area between the annular member and the second tubular upon expansion of the annular member. In an additional example, the first interface area is adjacent a first side of the groove and the second interface area is adjacent a second side of the groove.

In one example, the seal member is configured to move into the gap upon expansion of the seal member. In another example, a second gap is defined between the seal member and another side of the groove. In a further example, a biasing member disposed within the gap. In an additional example, a plurality of cutouts formed on an inner surface of the annular member. In another example, the annular member is a liner hanger. In yet a further example, the annular member is a packer.

In another example, a method of creating a seal between a first tubular and a second tubular is provided. The method includes the step of positioning the first tubular within the second tubular, the first tubular having a annular member with a groove, wherein a seal member with at least one anti-extrusion band is disposed within the groove and wherein a gap is formed between a side of the seal member and a side of the groove. The method further includes the step of expanding the annular member radially outward, which causes the first anti-extrusion band and the second anti-extrusion band to move toward a first interface area and a second interface area between the annular member and the second tubular. The method also includes the step of urging the seal member into contact with an inner wall of the second tubular to create the seal between the first tubular and the second tubular.

In one example, the gap is closed between the seal member and the groove upon expansion of the annular member. In another example the gap is closed by filling the gap with a portion of the seal member. In a further example, an expander tool is urged into the annular member to expand the annular member radially outward. In an additional example, the expander tool is removed from the annular member after the expansion operation. In yet another example, the expander tool remains within the annular member after the expansion operation.

In yet another example, a seal assembly for creating a seal between a first tubular and a second tubular is provided. The seal assembly includes an annular member attached to the first tubular, the annular member having a groove formed on an outer surface thereof. The seal assembly further includes a seal member disposed in the groove of the annular member such that a side of the seal member is spaced apart from a side of the groove, the seal member having one or more anti-extrusion bands, wherein the one or more anti-extrusion bands move toward an interface area between the annular member and the second tubular upon expansion of the annular member.

In one example, the one or more anti-extrusion bands comprise a first anti-extrusion band and a second anti-extrusion band. In another example, the first anti-extrusion band and the second anti-extrusion band are configured to move into an annular gap formed between the annular member and the second tubular after expansion of the annular member due to downhole pressure. In a further example, at least one side of the seal member is attached to the groove via glue.

In a further example, a hanger assembly is provided. The hanger assembly includes an expandable annular member having an outer surface and an inner surface. The hanger assembly further includes a seal member disposed in a groove formed in the outer surface of the expandable annular member, the seal member having one or more anti-extrusion spring bands embedded within the seal member. The hanger assembly also includes an expander sleeve having a tapered outer surface and an inner bore. The expander sleeve is movable between a first position in which the expander sleeve is disposed outside of the expandable annular member and a second position in which the expander sleeve is disposed inside of the expandable annular member. The expander sleeve is configured to radially expand the expandable annular member as the expander sleeve moves from the first position to the second position.

Claim 1:
An anchoring seal assembly for creating a seal portion and an anchor portion between a first tubular (<NUM>) and a second tubular (<NUM>), the anchoring seal assembly comprising:
a wedge member (<NUM>) movably disposed around the first tubular (<NUM>);
an expandable annular member (<NUM>) disposed around the wedge member (<NUM>), the annular member (<NUM>) having a groove (<NUM>) formed in an outer surface of the annular member (<NUM>) and a rough surface (430A-C) adjacent the groove (<NUM>);
a seal member (<NUM>) disposed in the groove (<NUM>), the seal member (<NUM>) having one or more anti-extrusion bands (<NUM>,<NUM>) embedded within the seal member (<NUM>);
a retaining sleeve (<NUM>) coupled to the expandable annular member (<NUM>) and configured to move axially in response to a force acting on the expandable annular member (<NUM>) and
wherein the wedge member (<NUM>) is configured to push the expandable annular member (<NUM>) along an axial direction of the first tubular (<NUM>) to move the retaining sleeve (<NUM>) and to urge the rough surface (430A-C) into engagement with the second tubular (<NUM>);
wherein the expandable annular member (<NUM>) is movable on a tapered outer surface (<NUM>) of the wedge member (<NUM>), the tapered outer surface (<NUM>) is configured to radially expand the expandable annular member (<NUM>) into contact with an inner wall of the second tubular (<NUM>) to create the seal portion and the anchor portion as the expandable annular member (<NUM>) moves from a first position to a second position, and
a gap (<NUM>) defined between a side of the groove (<NUM>) and a side of the seal member (<NUM>), wherein the gap (<NUM>) is configured to close upon expansion of the expandable annular member (<NUM>).