Patent ID: 12215564

DETAILED DESCRIPTION OF THE INVENTION

FIGS.5-12show embodiments of a packer system10according to the present invention. The packer system10comprises a packer mandrel20, an upper support or gage ring30, a seal member40, an upper slip device50, an upper cone60, a lower cone70, a lower slip device80, a setting sleeve90, and a setting piston100. The packer mandrel20has an upper mandrel end22and a lower mandrel end24, and the upper support ring30is positioned at the upper mandrel end22. The seal member40has an upper seal end42and a lower seal end44opposite the upper seal end. The seal member40has a run-in position with a run-in diameter and a set position with a set diameter. The set diameter is larger than the run-in diameter so as to seal against a borehole, while the run-in diameter corresponds to the packer system10being deployed through the borehole to reach a desired location.

The upper slip device50has an upper support ring end52and an upper cone end54opposite the upper support ring end. The upper slip device50is between the upper support ring30and the upper seal end42of the seal member40. The upper slip device50has an initial upper slip position with the seal member40in the run-in position. The initial upper slip position is the retracted position as the narrow configuration of the upper slip device50for deploying the packer system10through the borehole.

The upper cone60has an upper slip end62and an upper sealing end64opposite the upper slip end62. The upper sealing end64is positioned so as to exert pressure at the upper seal end42on the seal member40. The upper slip device50is in sliding engagement with the upper cone60between the initial upper slip position and an upper slip engaged position. The upper slip engaged position is the expanded position, when the seal member40is in the set position.

The lower cone70has a lower slip end72and a lower sealing end74opposite the lower slip end72. The lower sealing end is positioned so as to exert pressure at the lower seal end44on the seal member40.

The lower slip device80has a lower setting sleeve end82, and a lower cone end84opposite the lower setting sleeve end82. The lower slip device80also has an initial lower slip position with the seal member40in the run-in position. The initial lower slip position is the retracted position as the narrow configuration of the lower slip device80for deploying the packer system10through the borehole. The lower slip device80is in sliding engagement with the lower cone70between the initial lower slip position and a lower slip engaged position. The lower slip engaged position is the expanded position with the seal member40in the set position.

FIGS.5-12show the setting sleeve90having a lower cone engagement end92and a setting piston end94opposite the lower cone engagement end92. The setting sleeve90is mounted on the packer mandrel20and between the packer mandrel20and the lower slip device80.

In the present invention, the downhole hydraulic pressure actuates the setting piston100having a setting end102in removeable engagement with the setting piston end94of the setting sleeve90so as to apply pressure on the setting sleeve90to the lower cone70. The lower slip device80is between the setting piston100and the lower cone70.

FIGS.5-11show the setting sleeve90in a bypass position relative to the setting piston100with the setting piston end94of the setting sleeve90removably engaged with the setting piston100.FIG.12shows the setting sleeve90in a released position relative to the setting piston100with the lower slip device80engaged with the setting piston100. In the bypass position of the setting sleeve90ofFIGS.5-11, the setting piston100applies pressure on the setting sleeve90to the lower cone70, the seal member40and the upper cone60. The full pressure of the setting piston100is no longer on the lower slip device80. With the setting sleeve90in the bypass position, the load of the setting piston100bypasses the lower slip device80so that there is less risk of premature expansion of the lower slip device80. The pressure differential is also lower to transition the seal member40to the set position and the upper slip device50to the upper slip engaged position, which are no longer expanded through a partially expanded or fully expanded prior art lower slip device.

In the released position of the setting sleeve90ofFIG.12, the setting piston10applies pressure on the lower slip device80, instead of the lower cone70, the seal member40and the upper cone60through the setting sleeve90. The lower slip device80is in sliding engagement with the lower cone70between the initial lower slip position and lower slip engaged position. The lower slip engaged position is the expanded position, when the seal member40is in the set position. Additionally, the pressure differential to expand the lower slip device80is lower than prior art pressure levels, since the lower slip device80no longer has to be so strong and resistant to pressure in order to avoid premature expansion. The packer system10of the present invention can be set with smaller amounts of pressure and reduce the risk of premature expansion. The lower slip device80is in sliding engagement with the setting sleeve90in the released position. The lower slip device80can slide from the initial lower slip position to lower slip engaged position over both the setting sleeve90and the lower cone70.

In embodiments of the setting sleeve90in the bypass position, the setting piston end94of the setting sleeve90is removably engaged with the setting piston100so as to apply pressure on the setting sleeve90to the lower cone70, the seal member40, and the upper cone60through the lower slip device80. The setting sleeve90extends through the lower slip device80so that the force exerted by the setting piston100is not exerted on the lower slip device80. The setting sleeve90is mounted around the packer mandrel20, and the lower slip device80is mounted around the setting sleeve90. In this concentric relationship, the pressure on the setting sleeve90bypasses the lower slip device80. The present invention includes a concentric relationship and other physical relationships between the lower slip device80and the setting sleeve90to bypass the load of the setting piston100from the lower slip device80.

FIGS.8-12show embodiments of the packer system10with the setting sleeve90being comprised of a release component96on the setting piston end94so as to separate the setting piston100from the setting sleeve90.FIGS.8and10-12show the release component96as a shear pin98or shear screw.FIG.9shows the release component96as a shear ring99. The release component96transitions the setting sleeve90from the bypass position to the released position. The lower slip device80must eventually expand to the lower slip engaged position in order to fully set the packer system10at the desired location in the borehole. The pressure of the setting piston100is still applied to expand the lower slip device80. With the seal member40in the set position and the upper slip device50in the upper slip engaged position, the lower slip device80is the last remaining component to be set in the borehole. The release component96can transition the setting sleeve90from the bypass position to the released position.

In this embodiment, the setting sleeve90in the bypass position relative to the setting piston applies pressure of the setting piston100on the release component96, the setting sleeve90, the lower cone70, the seal member40, and the upper cone60. The full pressure of the setting piston100is exerted on multiple components concurrently. Only a portion of the pressure of the setting piston100is exerted on the release component96in the bypass position. Thus, the release component96is not subject to premature breakage. The seal member40in the set position and the upper slip device50in the upper slip engaged position will resist the pressure of the setting piston100, since these components are now locked in borehole. More of the full pressure of the setting piston100is exerted on the release component96. The portion of pressure from the setting piston100on the release component96increases with the seal member40and the upper slip device50locked in the borehole. This increased pressure is now sufficient to break the release component96. This increased pressure on the release component96is only available, when the seal member40and the upper slip device50are expanded and locked. The risk of premature separation of the setting sleeve90and the setting piston100is significantly reduced and at least controlled to be after the packer system10is ready for any expansion (premature, accidental, or intentional) of the lower slip device80.

FIGS.5,6,8and12show embodiments of the upper support ring30or gage ring having an unlocked position on the packer mandrel20relative to the seal member40and a locked position relative to the seal member40. The packer mandrel20holds the upper support ring30in place on the packer mandrel20, while the seal member40and upper slip device50move relative to the upper support ring30. The pressure of the setting piston100on the setting sleeve90pushes the upper cone60into the upper slip device50because the upper support ring30holds the upper slip device50in place relative to the packer mandrel20. With pressure, the upper slip device50cannot move along the packer mandrel20; thus, the upper slip device50must expand from the initial upper slip position to the upper slip engaged position.

FIGS.5,6and8show the unlocked position with the seal member40in the run-in position and the upper slip device50in the initial upper slip position.FIG.12shows the locked position being closer to the seal member40than the unlocked position. The upper support ring30is in the locked position with the seal member40in the set position and the upper slip device50in the upper slip engaged position. In the present invention, the upper support ring30is in the locked position with both the lower slip device80in the lower slip engaged position and the setting sleeve90in the released position AND the lower slip device80in the initial lower slip position and the setting sleeve90in the bypass position. The setting sleeve90is separated from the setting piston100to transition to the released position, when the seal member40is in the set position, which corresponds to the upper support ring30in the locked position.

The packer system10can also include a hydraulic pressure means for the setting piston100. The downhole hydraulic pressure for the present invention can be generated by the hydraulic pressure means being comprised of a lower support ring110or lower gage ring, an upper piston112, a lower mandrel114, an upper piston housing116, a lower piston118, and a bottom sub120. The lower support ring110is mounted on the packer mandrel20and connected to the setting piston100. The upper piston112is engaged to the setting piston100and blocked by the lower support ring110. The lower mandrel114is connected to lower mandrel end24of the packer mandrel20. The upper piston housing116is mounted around the upper piston112, the packer mandrel20and lower mandrel114. The lower piston118is mounted around the lower mandrel so as to actuate the setting piston100cooperatively with the upper piston112within the cavity formed by the upper piston housing116. The bottom sub120attaches to the lower mandrel118for the drill string to continue. The hydraulic pressure means of the present invention actuates the setting piston100to set the packer system10at the desired location in the borehole.

Embodiments of the present invention include a method for downhole operations with the packer system10. The method includes running the packer system10in a borehole, with the seal member40in the run-in position, the upper slip device50in the initial upper slip position, the lower slip device80in the initial lower slip position, and the setting sleeve90in the bypass position. The packer system10has its smallest diameter in this configuration in order to travel through the borehole. The method includes placing the packer system10at a desired location in the wellbore. At the desired location, the setting piston100applies pressure on the setting sleeve90. The setting sleeve90applies pressure on the lower cone70, the seal member40and the upper cone60with the setting piston100. The seal member40expands from the run-in position to the set position. The upper slip device50slides from the initial upper slip position to the upper slip engaged position. The pressure exerted by the setting sleeve90to the upper cone60pushes the upper cone60into the upper slip device50to expand the upper slip device50. The setting sleeve90remains in the bypass position. Once the seal member40is in the set position and the upper slip device50is in the upper slip engaged position, the setting piston100is separated from the setting sleeve90so as to place the setting sleeve90in the released position. The setting piston100engages the lower slip device80to apply pressure the lower slip device80with the setting sleeve90in the released position. The lower slip device80now slides from the initial lower slip position to the lower slip engaged position with pressure from the setting piston100. Embodiments of the present invention further include the step of performing downhole operations with the seal member40in the set position, the upper slip device50being in the upper slip engaged position, and the lower slip device80in the lower slip engaged position.

Another embodiment of the method of the present invention includesFIGS.8-12showing the setting sleeve90being comprised of a release component96on the setting piston end94. In this embodiment of the method, the step of separating the setting piston100from the setting sleeve90is comprised of shearing the release component96.

Still another embodiment of the method of the present invention includesFIGS.5and8showing the hydraulic pressure means being comprised of a lower support ring110or lower gage ring, an upper piston112, a lower mandrel114, an upper piston housing116, a lower piston118, and a bottom sub120. The lower piston118is mounted around the lower mandrel114so as to actuate the setting piston100cooperatively with the upper piston112within the cavity formed by the upper piston housing116. The step of applying pressure on the setting sleeve90further comprises the steps of building downhole hydraulic pressure with the upper piston112and lower piston118and exerting the hydraulic pressure on the setting piston100. The upper piston112and lower piston118are cooperative generate downhole hydraulic pressure on the setting piston100. It is an object of the present invention to provide a packer system to isolate zones in a wellbore for downhole operations.

The present invention provides a packer system to isolate zones in a wellbore for downhole operations. The packer system and method reliably set the packer system in a location in a controlled and planned manner. The packer system can be set and locked in the location for the performance of a variety of downhole operations. The packer system is set by downhole hydraulic pressure. The setting sleeve of the packer system has a bypass position and a released position to prevent premature expansion of a lower slip device of the packer system. In the present invention, the lower slip device now avoids the fatal premature expansion of the prior art “strong” lower slip device. The present invention also avoids the very high prior art pressure differential needed to expand the seal member and the upper slip device due to the expansion of a prior art “weak” lower slip device. The setting sleeve of the present invention transfers load to a lower cone, a seal member, and an upper cone of the packer system instead of the lower slip device in the bypass position. The seal member can be expanded to the set position, and the upper slip device can be expanded to the upper slip engaged position or expanded position. The setting piston transfers load through the lower slip device and to the lower cone. Then, the lower slip device can be expanded, when the setting sleeve transitions from the bypass position to the released position relative to the setting piston.

The setting sleeve is in removable engagement with a setting piston for applying pressure on the lower cone, the seal member, and the upper cone in the bypass position. In the released position, the setting sleeve is separated from the setting piston so that the setting piston engages the lower slip device. Then, the setting piston can apply pressure on the lower slip device to expand the lower slip device. The downhole hydraulic pressure can now be reliably distributed to the lower cone, the seal member, the upper cone, and then the lower slip device. There can also be a release component on the setting sleeve, which still allows the load bypass through the lower slip device and transfer back to expand the lower slip device. The present invention allows the lower slip device to be fabricated with more standard and conventional materials, instead of specialized and strengthened materials. The lower slip device and the upper slip device can be made of the same materials, instead of the lower slip device requiring special materials for hydraulic pressure setting the packer system. Furthermore, the present invention still avoids the higher pressure differential required of the prior art “weaker” lower slips. The lower slip device is no longer expanded or partially expanded. The seal member and the upper slip device no longer have to be expanded with the additional pressure to expand through an expanded or partially expanded lower slip device. With the setting sleeve and relationship to the setting piston, the seal member and the upper slip device are expanded before the pressure of the setting piston engages the lower slip device and any release component. The present invention resolves the difficulty of premature expansion of the lower slip device without the high pressure differentials required in the prior art.

The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated structures, construction and method can be made without departing from the true spirit of the invention.