Debris protection and retrievability system for bridge plugs and packers
A seal apparatus for use as sealing devices for downhole applications in a wellbore, such as packers and bridge plugs, includes a seal element formed from an elastomeric material. The seal apparatus may include one or more end pieces, referred to as extraction limiting assemblies, which are provided to limit extrusion of the sealing element in direction(s) other than in a radial direction outward from the longitudinal axis of the tool body of the seal apparatus. The end pieces may include components included in a fabric barriers sleeve that encases components of the end caps, the fabric reinforcement barriers allowing for the expansion and contraction of the end caps and the sealing element but limiting or completely blocking debris from entering into any portion of the end caps.
1 . An apparatus comprising:
a seal apparatus configured to be positioned downhole within a wellbore, the seal apparatus comprising a sealing element configured to form a seal between the sealing element and a surface positioned adjacent to the seal apparatus when the sealing element is actuated into a sealing configuration,
the seal apparatus further comprising at least one extrusion limitation assembly positioned at an end of the sealing element, the extrusion limitation assembly configured to limit or eliminate a lateral extrusion of the sealing element while the sealing element is actuated into the sealing configuration, the at least one extrusion limitation assembly having a plurality of radially expandable components that are completely enclosed in a fabric barrier sleeve configured to block debris from coming into contact with the plurality of radially expandable components.
2 . The apparatus of claim 1 , wherein the fabric barrier sleeve comprises woven carbon fiber infused with an elastomeric material.
3 . The apparatus of claim 1 , wherein the plurality of radially expandable components comprises:
a metal expandable ring having a plurality of slots extending radially and positioned around a circumference of the metal expandable ring;
an inner row of wedges positioned along a side of the metal expandable ring and arranged around the circumference of the metal expandable ring; and
an outer row of wedges positioned on the side of the metal expandable ring and interspaced between each of the wedges of the inner row of wedges.
4 . The apparatus of claim 1 , wherein the sealing element further comprises a wire reinforcement structure embedded within the sealing element.
5 . The apparatus of claim 4 , wherein the wire reinforcement structure includes:
a first ring embedded within a pull ridge positioned at a proximal end of the sealing element;
a second ring embedded within the proximal end of a main body of the sealing element; and
a plurality of reinforcement wires extending between and coupled to each of the first ring and the second ring.
6 . The apparatus of claim 1 , wherein the seal apparatus further comprises a fabric reinforcement layer fused onto one or more outer surfaces of the sealing element.
7 . The apparatus of claim 6 , wherein the fabric reinforcement layer comprises a distal end that overlaps onto a proximal end of a main body of the sealing element.
8 . The apparatus of claim 6 , wherein the fabric reinforcement layer encircles a proximal portion of the sealing element, and is routed to extend over a proximal end of a main body of the sealing element, underneath a proximal extrusion limitation assembly, along a narrowed portion of the sealing element, and over a pull ridge positioned at a proximal end of the sealing element.
9 . The apparatus of claim 1 , wherein the seal apparatus further comprises one or more debris barriers configured to be actuatable to close off a portion of an annulus that is positioned adjacent to the sealing element, the debris barriers configured to be actuated to block debris from entering into the portion of the annulus positioned adjacent to the sealing element.
10 . The apparatus of claim 9 , wherein each of the one or more debris barriers comprise a ring shaped barrier that encircles a tool body of the seal apparatus and is positioned longitudinally either proximally or distally of the sealing element.
11 . The apparatus of claim 1 , wherein the plurality of radially expandable components being completely enclosed in the fabric barrier sleeve comprises the fabric barrier sleeve enclosing a distal side of the at least one extrusion limitation assembly, a proximal side of the at least one extrusion limitation assembly, an outer side of the at least one extrusion limitation assembly, and an inner side of the at least one extrusion limitation assembly.
12 . The apparatus of claim 1 , wherein the extrusion limitation assembly has an annular shape and the fabric barrier sleeve has an axially continuous surface.
13 . A system comprising:
a bridge plug configured to be positioned within a section of production tubing extending within a wellbore, the bridge plug comprising a seal apparatus including a sealing element configured to form a seal between the seal apparatus and an interior surface of the section of production tubing; and
the seal apparatus further comprising at least one extrusion limitation assembly positioned at an end of the sealing element, the extrusion limitation assembly configured to limit or eliminate a lateral extrusion of the sealing element while the sealing element is actuated into a sealing configuration, the at least one extrusion limitation assembly having a plurality of radially expandable components that are completely enclosed in a fabric barrier sleeve configured to block debris from coming into contact with the plurality of radially expandable components.
14 . The system of claim 13 , wherein the fabric barrier sleeve comprises woven carbon fiber infused with an elastomeric material.
15 . The system of claim 13 , wherein the sealing element further comprises a wire reinforcement structure embedded within the sealing element.
16 . The system of claim 13 , wherein the seal apparatus further comprises a fabric reinforcement layer fused onto one or more outer surfaces of the sealing element.
17 . The system of claim 13 , wherein the seal apparatus further comprises one or more debris barriers configured to be actuatable to close off a portion of an annulus that is positioned adjacent to the sealing element, the debris barriers configured to be actuated to block debris from entering into the portion of the annulus positioned adjacent to the sealing element.
18 . A method comprising:
positioning a seal apparatus comprising a sealing element in an unactuated configuration at a location downhole within a wellbore,
the sealing element configured to form a seal between the sealing element and a surface positioned adjacent to the sealing element when the sealing element is actuated into a sealing configuration,
the seal apparatus further comprising at least one extrusion limitation assembly positioned at an end of the sealing element, the extrusion limitation assembly configured to limit or eliminate a lateral extrusion of the sealing element while the sealing element is actuated into the sealing configuration, the at least one extrusion limitation assembly having a plurality of radially expandable components that are completely enclosed in a fabric barrier sleeve configured to block debris from coming into contact with the plurality of radially expandable components; and
actuating the sealing element by applying a laterally compressive force to the sealing element, the laterally compressive force expanding the sealing element in a radially outward direction to form the seal between a tool body of the seal apparatus and the surface positioned adjacent to the sealing element.
19 . The method of claim 18 , further comprising:
deactuating the seal apparatus to allow the sealing element to return to the unactuated configuration; and
retrieving the seal apparatus from the wellbore.
20 . The method of claim 18 , wherein the sealing element further comprises a wire reinforcement structure embedded within the sealing element.
21 . The method of claim 18 , wherein the seal apparatus further comprises a fabric reinforcement layer fused onto one or more outer surfaces of the sealing element.
22 . The method of claim 18 , wherein the seal apparatus further comprises one or more debris barriers configured to be actuatable to close off a portion of an annulus that is positioned adjacent to the sealing element, the debris barriers configured to be actuated to block debris from entering into the portion of the annulus positioned adjacent to the sealing element.