US20180238136A1 - Modular seal system - Google Patents

Abstract

A ring seal system includes a first segment having a first support member formed from a first support material, and a first seal portion mounted to the first support. The first seal portion is formed from a first seal material. A second segment includes a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support. The second seal portion is formed from a second seal material distinct from the first seal material. The second segment is operatively connected to the first segment.

Description

BACKGROUND
• Downhole systems rely on a variety of seals to control flow and/or establish flow paths. One form of seal, such as a ring seal, may be selectively positioned along a first portion of a tubular and subsequently shifted to create a barrier. A ring seal may include a metal support, a first elastomer material arranged on one side of the metal support, and a second elastomer material arranged on a second, opposing side of the metal support. The ring seal may be run along a tapered surface of the tubular. Travel along the tapered surface causes the seal to expand and engage an adjacent structure.
• Seals are exposed to a variety of operating conditions. Pressure, temperature, fluids as well as other factors can vary in each formation. Seals are selected to withstand a particular operating environment. Different materials employed in ring seals respond differently to these factors. One material may be better at higher temperature while another material may possess a good response at lower temperatures. Different materials used in the metal support may also possess different qualities such as strength, resilience, and corrosion resistance.
SUMMARY
• A ring seal system includes a first segment having a first support member formed from a first support material, and a first seal portion mounted to the first support. The first seal portion is formed from a first seal material. A second segment includes a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support. The second seal portion is formed from a second seal material distinct from the first seal material. The second segment is operatively connected to the first segment.
• A resource exploration system includes a surface system, and a downhole system operatively connected to the surface system through a system of tubulars. At least one of the system of tubulars supports a ring seal system including a first segment having a first support member formed from a first support material, and a first seal portion mounted to the first support. The first seal portion is formed from a first seal material. A second segment includes a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support. The second seal portion is formed from a second seal material distinct from the first seal material. The second segment is operatively connected to the first segment.
BRIEF DESCRIPTION OF THE DRAWINGS
• Referring now to the drawings wherein like elements are numbered alike in the several Figures:
• FIG. 1 depicts a resource exploration system including a modular seal system, in accordance with an exemplary embodiment;
• FIG. 2 depicts a cross-sectional view of the modular seal system arranged between a first tubular and a second tubular, in accordance with the exemplary embodiment, arranged therebetween;
• FIG. 3 depicts a detail view of the modular seal system ofFIG. 2; and
• FIG. 4 depicts a cross-sectional view of a modular seal system, in accordance with another aspect of an exemplary embodiment, arranged between a first tubular and a second tubular.
DETAILED DESCRIPTION
• A resource exploration system, in accordance with an exemplary embodiment, is indicated generally at2, inFIG. 1.Resource exploration system2 should be understood to include well drilling operations, resource extraction and recovery, CO₂sequestration, and the like.Resource exploration system2 may include asurface system4 operatively connected to adownhole system6.Surface system4 may includepumps8 that may aid in treatment, completion and/or extraction processes, as well as afluid storage zone10.Fluid storage zone10 may contain a gravel pack fluid or slurry (not shown), a fracturing fluid (also not shown), or a treating fluid that may be introduced intodownhole system6.
• Downhole system6 may include a system oftubulars20 that is extended into awellbore21 formed information22. System oftubulars20 may include a first tubular (not separately labeled) which may take the form of anouter tubular26 and a second tubular (also not separately labeled) which may take the form of an inner tubular28. An annular orring seal system34 is arranged between first tubular26 and second tubular28. It is to be understood that the relative position ofring seal system34 may vary. As shown inFIGS. 2 and 3, first tubular26 includes anouter surface39 and aninner surface40. Second tubular28 includes anouter surface portion42 and aninner surface portion43. Second tubular28 is also shown to include acone portion46 having a conical surface portion.48.
• In accordance with an aspect of an exemplary embodiment,ring seal system34 includes afirst segment60, a second segment62 athird segment64, afourth segment66, and afifth segment68. It is to be understood that the number of segments may vary.First segment60 includes afirst support member72 defining an annular or substantially annular ring formed from afirst support material74.First support material74 may take the form of an expandable metal such as, for example, an annealed nickel alloy, 80 ksi 4140, or a nickel based molybdenum or nickel based chromium and molybdenum steel alloys.First support member72 includes afirst base portion76, afirst end portion78.First base portion76 includes afirst recess80. A first O-ring82 is arranged infirst recess80.First end portion78 includes afirst recess portion84. Afirst seal portion86 is arranged infirst recess portion84.First seal portion86 is formed from afirst seal material88.First seal material88 may take the form of, for example, about a 90 durometer perfluoroelastomer (FFKM).
• Second segment62 includes asecond support member92 operatively connected tofirst segment60. The term operatively connected should be understood to describe thatfirst segment60 andsecond segment62 are adjoined or may be connected through mechanical and/or chemical processes.Second support member92 defines annular or substantially annular ring formed from asecond support material94.Second support material94 may take the form of an expandable metal such as, for example, an annealed8620 steel.Second support member92 includes asecond base portion96, and asecond end portion98.Second base portion96 includes asecond recess100. A second O-ring102 is arranged insecond recess100.Second end portion98 includes asecond recess portion104. Asecond seal portion106 is arranged insecond recess portion104.Second seal portion106 is formed from asecond seal material108.Second seal material108 may take the form of, for example, about an 80 durometer fluoroelastomer (FKM).
• Third segment64 includes athird support member112 operatively connected tosecond segment62. It is to be understood that operatively connected tosecond segment62 does not require a direct contact.Third segment64 may be adjoined tofirst segment60 which, in turn, may be adjoined tosecond segment62. Operatively connected should be understood to describe that segments form part of the same annular seal.Third support member112 defines annular or substantially annular ring formed from athird support material114.Third support material114 may take the form of an expandable metal such as, for example, an annealed aluminum alloy.Third support member112 includes athird base portion116, and athird end portion118.Third base portion116 includes athird recess120. A third O-ring122 is arranged inthird recess120.Third end portion118 includes athird recess portion124. Athird seal portion126 is arranged inthird recess portion124.Third seal portion126 is formed from athird seal material128.Third seal material128 may take the form of, for example, about a 70 durometer hydrogenated nitrile butadiene rubber (HNBR).
• Fourth segment66 includes afourth support member132 operatively connected tothird segment64.Fourth support member132 defines annular or substantially annular ring formed from afourth support material134.Fourth support material134 may be the same or substantially the same assecond support material94 or may be formed from a different expandable metal depending upon desired operational characteristics.Fourth support member132 includes afourth base portion136, and afourth end portion138.Fourth base portion136 includes afourth recess140. A fourth O-ring142 is arranged infourth recess140.Fourth end portion138 includes afourth recess portion144. Afourth seal portion146 is arranged infourth recess portion144.Fourth seal portion146 is formed from afourth seal material148.Fourth seal material148 may be the same as or substantially the same assecond seal material108 or may take on another form depending upon desired sealing characteristics.
• Fifth segment68 includes afifth support member152 operatively connected tofourth segment66.Fifth support member152 defines annular or substantially annular ring formed from afifth support material154.Fifth support material154 may be the same or substantially the same asfirst support material74 or may be formed from a different expandable metal depending upon desired operational characteristics.Fifth support member152 includes afifth base portion156, and afifth end portion158.Fifth base portion156 includes afifth recess160. A fifth O-ring162 is arranged infifth recess160.Fifth end portion158 includes afifth recess portion164. Afifth seal portion166 is arranged infifth recess portion164.Fifth seal portion166 is formed from afifth seal material168.Fifth seal material168 may be the same as or substantially the same asfirst seal material88 or may take on another form depending upon desired sealing characteristics.
• In accordance with an exemplary aspect, segments may include additional features such as shown inFIG. 4. For example, afirst segment190 includes afirst support member192 that may be formed from afirst support material194 such as described above.First segment190 includes atab196 extending axially outwardly fromfirst support member192. Asecond segment200 includes asecond support member202 that may be formed from asecond support material204 such as described above.Second segment200 includes arecess206 extending axially inwardly tosecond support member202.Tab196 may extend intorecess206 and mechanically connect withsecond segment200. Additionally,second support member202 may include anend portion208 provided with arecess portion210.Recess portion210 receives and supports aseal portion212. In the exemplary embodiment shown, arib214 projects radially outwardly ofend portion208.Rib214 promotes and enhances retention ofseal portion212.
• It is to be understood that exemplary embodiments describe a composite annular seal formed from various materials that may be tailored to specific downhole applications. Portions or segments of the seal may expand at different rates, seal at different temperatures and/or be capable of withstanding different pressures. In this manner, the seal may readily adapt to changing downhole conditions and reduce failure modes that could otherwise require costly repair, removal and maintenance. Additionally, it is to be understood that the number of segments forming the composite annular seal may vary.
• The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.
Embodiment 1
• A ring seal system comprising: a first segment including a first support member formed from a first support material, and a first seal portion mounted to the first support, the first seal portion being formed from a first seal material; and a second segment including a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support, the second seal portion being formed from a second seal material distinct from the first seal material, the second segment being operatively connected to the first segment.
Embodiment 2
• The ring seal system according to embodiment 1, further comprising: a third segment including a third support member formed from a third support material that is distinct from at least one of the first support material and the second support material, and a third seal portion mounted to the third support, the third seal material being formed from a third seal material that is distinct from at least one of the first seal material and the second seal material, the third segment being operatively connected to at least one of the first segment and the second segment.
Embodiment 3
• The ring seal system according toembodiment 2, wherein the third support material is distinct from each of the first support material and the second support material.
Embodiment 4
• The ring seal system according toembodiment 2, wherein the third seal material is distinct from each of the first seal material and the second seal material.
Embodiment 5
• The ring seal system according toembodiment 2, wherein the second segment directly abuts the first segment and the third segment directly abuts the second segment.
Embodiment 6
• The ring seal system according to embodiment 5, further comprising: a fourth segment including a fourth support member formed from a fourth support material that is similar to the second support material, and a fourth seal portion mounted to the fourth support, the fourth seal portion being formed from a fourth seal material that is similar to the second seal material, the fourth segment directly abutting the third segment.
Embodiment 7
• The ring seal system according toembodiment 6, further comprising: a fifth segment including a fifth support member formed from a fifth support material that is similar to the first support material, and a fifth seal portion mounted to the fifth support, the fifth seal portion being formed from a fifth seal material that is similar to the first seal material, the fifth segment directly abutting the fourth segment.
Embodiment 8
• The ring seal system according to embodiment 1, wherein the second segment is mechanically linked to the first segment.
Embodiment 9
• A resource exploration system comprising: a surface system; and a downhole system operatively connected to the surface system through a system of tubulars, at least one of the system of tubulars supporting a ring seal system comprising: a first segment including a first support member formed from a first support material, and a first seal portion mounted to the first support, the first seal portion being formed from a first seal material; and a second segment including a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support, the second seal portion being formed from a second seal material distinct from the first seal material, the second segment being operatively connected to the first segment.
Embodiment 10
• The resource exploration system according to embodiment 9, further comprising: a third segment including a third support member formed from a third support material that is distinct from at least one of the first support material and the second support material, and a third seal portion mounted to the third support, the third seal material being formed from a third seal material that is distinct from at least one of the first seal material and the second seal material, the third segment being operatively connected to at least one of the first segment and the second segment.
Embodiment 11
• The resource exploration system according toembodiment 10, wherein the third support material is distinct from each of the first support material and the second support material.
Embodiment 12
• The resource exploration system according toembodiment 10, wherein the third seal material is distinct from each of the first seal material and the second seal material.
Embodiment 13
• The resource exploration system according toembodiment 10, wherein the second segment directly abuts the first segment and the third segment directly abuts the second segment.
Embodiment 14
• The resource exploration system according to embodiment 13, further comprising: a fourth segment including a fourth support member formed from a fourth support material that is similar to the second support material, and a fourth seal portion mounted to the fourth support, the fourth seal portion being formed from a fourth seal material that is similar to the second seal material, the fourth segment directly abutting the third segment.
Embodiment 15
• The resource exploration system according to embodiment 14, further comprising: a fifth segment including a fifth support member formed from a fifth support material that is similar to the first support material, and a fifth seal portion mounted to the fifth support, the fifth seal portion being formed from a fifth seal material that is similar to the first seal material, the fifth segment directly abutting the fourth segment.
• The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value.
• While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.

Claims (15)

1. A ring seal system comprising:

a first segment including a first support member formed from a first support material, and a first seal portion mounted to the first support, the first seal portion being formed from a first seal material; and

a second segment including a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support, the second seal portion being formed from a second seal material distinct from the first seal material, the second segment being operatively connected to the first segment.

2. The ring seal system according toclaim 1, further comprising: a third segment including a third support member formed from a third support material that is distinct from at least one of the first support material and the second support material, and a third seal portion mounted to the third support, the third seal material being formed from a third seal material that is distinct from at least one of the first seal material and the second seal material, the third segment being operatively connected to at least one of the first segment and the second segment.

3. The ring seal system according toclaim 2, wherein the third support material is distinct from each of the first support material and the second support material.

4. The ring seal system according toclaim 2, wherein the third seal material is distinct from each of the first seal material and the second seal material.

5. The ring seal system according toclaim 2, wherein the second segment directly abuts the first segment and the third segment directly abuts the second segment.

6. The ring seal system according toclaim 5, further comprising: a fourth segment including a fourth support member formed from a fourth support material that is similar to the second support material, and a fourth seal portion mounted to the fourth support, the fourth seal portion being formed from a fourth seal material that is similar to the second seal material, the fourth segment directly abutting the third segment.

7. The ring seal system according toclaim 6, further comprising: a fifth segment including a fifth support member formed from a fifth support material that is similar to the first support material, and a fifth seal portion mounted to the fifth support, the fifth seal portion being formed from a fifth seal material that is similar to the first seal material, the fifth segment directly abutting the fourth segment.

8. The ring seal system according toclaim 1, wherein the second segment is mechanically linked to the first segment.

9. A resource exploration system comprising:

a surface system; and

a downhole system operatively connected to the surface system through a system of tubulars, at least one of the system of tubulars supporting a ring seal system comprising:

a first segment including a first support member formed from a first support material, and a first seal portion mounted to the first support, the first seal portion being formed from a first seal material; and

a second segment including a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support, the second seal portion being formed from a second seal material distinct from the first seal material, the second segment being operatively connected to the first segment.

10. The resource exploration system according toclaim 9, further comprising: a third segment including a third support member formed from a third support material that is distinct from at least one of the first support material and the second support material, and a third seal portion mounted to the third support, the third seal material being formed from a third seal material that is distinct from at least one of the first seal material and the second seal material, the third segment being operatively connected to at least one of the first segment and the second segment.

11. The resource exploration system according toclaim 10, wherein the third support material is distinct from each of the first support material and the second support material.

12. The resource exploration system according toclaim 10, wherein the third seal material is distinct from each of the first seal material and the second seal material.

13. The resource exploration system according toclaim 10, wherein the second segment directly abuts the first segment and the third segment directly abuts the second segment.

14. The resource exploration system according toclaim 13, further comprising: a fourth segment including a fourth support member formed from a fourth support material that is similar to the second support material, and a fourth seal portion mounted to the fourth support, the fourth seal portion being formed from a fourth seal material that is similar to the second seal material, the fourth segment directly abutting the third segment.

15. The resource exploration system according toclaim 14, further comprising: a fifth segment including a fifth support member formed from a fifth support material that is similar to the first support material, and a fifth seal portion mounted to the fifth support, the fifth seal portion being formed from a fifth seal material that is similar to the first seal material, the fifth segment directly abutting the fourth segment.

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