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US20250043654A1 - Sealing assembly employing a cylindrical extrusion limiter - Google Patents

Sealing assembly employing a cylindrical extrusion limiter Download PDF

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Publication number
US20250043654A1
US20250043654A1 US18/494,395 US202318494395A US2025043654A1 US 20250043654 A1 US20250043654 A1 US 20250043654A1 US 202318494395 A US202318494395 A US 202318494395A US 2025043654 A1 US2025043654 A1 US 2025043654A1
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United States
Prior art keywords
extrusion limiter
sealing element
radially
cylindrical extrusion
recited
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Application number
US18/494,395
Inventor
Adam J. Milne
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Halliburton Energy Services Inc
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Halliburton Energy Services Inc
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Publication date
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Priority to US18/494,395 priority Critical patent/US20250043654A1/en
Assigned to HALLIBURTON ENERGY SERVICES, INC. reassignment HALLIBURTON ENERGY SERVICES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MILNE, ADAM J.
Priority to PCT/US2023/035989 priority patent/WO2025029269A1/en
Priority to FR2404573A priority patent/FR3151872A1/en
Publication of US20250043654A1 publication Critical patent/US20250043654A1/en
Pending legal-status Critical Current

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    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00Sealing or packing boreholes or wells
    • E21B33/10Sealing or packing boreholes or wells in the borehole
    • E21B33/12Packers; Plugs
    • E21B33/128Packers; Plugs with a member expanded radially by axial pressure

Definitions

  • Wellbores are drilled into the earth for a variety of purposes including accessing hydrocarbon bearing formations.
  • a variety of downhole tools may be used within a wellbore in connection with accessing and extracting such hydrocarbons. Throughout the process, it may become necessary to isolate sections of the wellbore in order to create pressure zones.
  • Downhole tools such as hydraulic fracturing (“frac”) plugs, bridge plugs, packers, and other suitable tools, may be used to isolate wellbore sections.
  • frac hydraulic fracturing
  • Downhole tools such as frac plugs
  • a conveyance such as a wireline, work string or production tubing.
  • Such tools typically have either an internal or external setting tool, which is used to set the downhole tool within the wellbore and hold the tool in place.
  • the downhole tools allow fluid communication between sections of the wellbore above the plug and below the plug until another downhole tool, such as a ball, is pumped down to seat in the plug and interrupt fluid communication through the plug and a sealing assembly, which can be made of rubber and extends outwards to seal off the flow of liquid around the downhole tool.
  • FIG. 1 illustrates a schematic view of a well system designed, manufactured and operated according to one or more embodiments disclosed herein;
  • FIGS. 2 A through 2 H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more embodiments of the disclosure
  • FIGS. 3 A through 3 H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure
  • FIGS. 4 A through 4 H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure.
  • FIGS. 5 A through 5 E illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure.
  • connection Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described.
  • use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” “downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation.
  • any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis.
  • use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.
  • Sealing elements are traditionally a critical part of a sealing assembly.
  • the present disclosure has recognized that sealing elements tend to have difficulties when the expansion ratio (e.g., the distance the sealing elements must move from their radially retracted state to their radially expanded state to engage with a bore, such as a wellbore, tubular, casing, etc.) is large.
  • the present disclosure has recognized that such sealing elements often experience challenges in open-hole conditions that require significant expansion ratios. For example, due to the large extrusion gap in certain conditions, when the sealing element expands, it will often lose its axial stiffness and escape the desired load path.
  • the cylindrical extrusion limiter in accordance with this embodiment, is configured to break (e.g., break to form first and second separate extrusion limiting rings) to deploy from an undeployed state to a deployed state as the sealing element moves from a radially retracted state to a radially expanded state.
  • the cylindrical extrusion limiter is located radially about a centerpoint of the sealing element.
  • the cylindrical extrusion limiter is located radially about at least 60 percent of the sealing element, if not at least 80 percent, if not at least 90 percent, if not at least 95 percent.
  • the cylindrical extrusion limiter is located radially about an entirety of the sealing element.
  • the extrusion limiter is located radially about a centerpoint of the sealing element, but not located about an entirety of the sealing element.
  • separate uphole and downhole retaining rings may overlap radially outside of the extrusion limiter, thus creating a three-piece design.
  • the cylindrical extrusion limiter in at least one embodiment, includes an extrusion limiter body having a weakened region proximate a midpoint thereof.
  • the weakened region in at least one embodiment, is a circumferential notch located around an inside radial surface of the extrusion limiter body.
  • the weakened region in at least one other embodiment, is a circumferential notch located around an outside radial surface of the extrusion limiter body.
  • the weakened region in at least another embodiment, is a series of holes extending entirely through a thickness of the extrusion limiter body. In at least one embodiment, the series of holes are a series of slots extending entirely through the thickness of the extrusion limiter body.
  • the weakened region in at least one embodiment, is configured to remain intact prior to setting the sealing element, but once enough axial compression is imparted upon the sealing element break resulting in first and second separate extrusion limiting rings.
  • FIG. 1 illustrated is an elevation view of a well system 100 in which a wellbore sealing system 135 according to an example of the present disclosure may be implemented.
  • FIG. 1 depicts a land-based well system 100
  • a representative wellbore 110 is shown, having been drilled through one or more subterranean formations 115 .
  • FIG. 1 shows a straight, vertical portion of the wellbore 110 , but it will be understood that directional drilling techniques may be implemented, such as using a rotary steerable system providing directional control to deviate from vertical and achieve any desired wellbore path.
  • a tubular, typically metallic casing 120 is cemented in place to reinforce the wellbore 110 .
  • the inner surface of the casing 120 when present, may functionally define an inner surface of the wellbore 110 .
  • the wellbore sealing system 135 is typically used to seal off the wellbore 110 by sealing against the inner diameter (ID) of the casing 120 .
  • the wellbore sealing system 135 in at least one embodiment includes a sealing assembly 150 , shown in FIG. 1 in a run-in-hole (RIH) condition prior to being set by a setting tool 140 .
  • the sealing assembly 150 is run into the wellbore 110 on a conveyance, which in this example includes a tubing string 130 , but could alternatively include a coiled tubing, wireline, or other conveyance.
  • the tubing string 130 may extend to a wellhead at the ground level 125 (e.g., “surface”) of the well system 100 , for carrying produced fluids from the hydrocarbon bearing formation to the surface.
  • the setting tool 140 includes an actuatable element, such as a sleeve 145 , for applying a large axial setting force (e.g., hydraulically) to set the sealing assembly 150 , for example once the sealing assembly 150 is positioned at a desired location within the wellbore 110 .
  • Setting the sealing assembly 150 squeezes the components (e.g., collar sleeves, scaling element(s), etc.) of the sealing assembly 150 together axially, which may both anchor the sealing assembly 150 in the casing 120 and seal against the casing 120 .
  • the scaling assembly 150 may be set in the axial position shown to sealingly isolate an uphole portion of the wellbore 110 from a downhole portion of the wellbore 110 .
  • the scaling assembly 150 may be a hydraulic fracturing plug (i.e., frac plug) used to plug the wellbore 110 prior to performing a hydraulic fracturing operation in the uphole portion of the wellbore 110 .
  • the sealing assembly 150 is a packer. The various configurations discussed below may allow the sealing assembly 150 to be set within a larger diameter and/or within a larger range of diameters than might ordinarily be practicable for a conventional tool.
  • the sealing system 150 includes a cylindrical extrusion limiter 155 , for example positioned radially about a sealing element.
  • the cylindrical extrusion limiter 155 is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
  • FIGS. 2 A through 2 H illustrated are different cross-sectional views of various deployment states of a sealing assembly 200 designed, manufactured and/or operated according to one or more embodiments of the disclosure.
  • FIGS. 2 A through 2 F illustrate the sealing assembly 200 in a run-in-hole state (e.g., undeployed state), whereas FIGS. 2 G and 2 H illustrate the sealing assembly 200 in a deployed state.
  • the sealing assembly 200 includes a mandrel 210 .
  • the mandrel 210 in one or more embodiments, is a fixed mandrel 210 , and thus remains with the sealing assembly 200 regardless of deployment state.
  • the mandrel 210 is a removable mandrel 210 , and thus may be removed.
  • a sealing element 220 is positioned about the mandrel 210 . While a single sealing element 220 is illustrated in FIGS. 2 A through 2 H , other embodiments may exist wherein multiple sealing elements are employed. In accordance with one embodiment of the disclosure, the sealing element 220 is an elastomeric sealing element. Further to this one embodiment, the sealing element 220 may be a non-swellable sealing element.
  • a first collar sleeve 230 is coupled proximate a first end 225 a of the sealing element 220
  • a second collar sleeve 235 is coupled proximate a second end 225 b of the sealing element 220
  • the first and second collar sleeves 230 , 235 are configured to axially translate relative to one another along the mandrel 210 to move the sealing element 220 between a radially retracted state (e.g., that shown in FIG. 2 C ) a radially expanded state (e.g., that shown in FIG. 2 G ).
  • angled surfaces of the first and second collar sleeves 230 , 235 may engage with angled surfaces of the sealing element 220 , such that the sealing element 220 is forced radially outward when the first and second collar sleeves 230 , 235 move relative to one another.
  • the sealing assembly 200 may additionally include a cylindrical extrusion limiter 240 positioned radially about a centerpoint of the sealing element 220 .
  • the cylindrical extrusion limiter 240 is configured to break to deploy from an undeployed state to a deployed state (e.g., break to form first and second separate extrusion limiting rings 240 a , 240 b ) as the sealing element 220 moves from the radially retracted state to the radially expanded state.
  • the cylindrical extrusion limiter 240 includes an extrusion limiter body 242 having a weakened region 244 .
  • the weakened region 244 is located substantially proximate a midpoint of the extrusion limiter body 242 .
  • the phrase “substantially proximate,” as used herein with reference to the midpoint of the extrusion limiter body 242 means that the weakened region 244 is located within 20 percent of the midpoint of the extrusion limiter body 242 .
  • the weakened region 244 is located ideally proximate a midpoint thereof, wherein the phrase “ideally proximate” means that the weakened region 244 is located within 5 percent of the midpoint of the extrusion limiter body 242 . In yet another embodiment, the weakened region 244 is located at exactly the midpoint, which means that the weakened region 244 is located within 1 percent of the midpoint of the extrusion limiter body 242 .
  • the weakened region 244 may take on many different sizes, shapes and/or styles and remain within the scope of the present disclosure. In the illustrated embodiment of FIGS. 2 A through 2 F , however, the weakened region 244 is a circumferential notch 246 located around an inside radial surface of the extrusion limiter body 242 . The circumferential notch 246 , in the illustrated embodiment, might not extend entirely through a thickness of the extrusion limiter body 242 . While the embodiment of FIGS.
  • FIGS. 2 A through 2 F illustrates that a single notch 246 extends circumferentially around an entire inside radial surface of the extrusion limiter body 242
  • other embodiments may exist wherein one or more circumferential notches 246 extend around only a portion of the inside radial surface of the extrusion limiter body 242 .
  • the embodiment of FIGS. 2 A through 2 F illustrates that the circumferential notch 246 is located around an inside radial surface
  • the weakened region 244 is a circumferential notch located around an outside radial surface of the extrusion limiter body 242 .
  • the cylindrical extrusion limiter 240 may comprise many different materials and remain within the scope of the disclosure. In at least one embodiment, however, the cylindrical extrusion limiter 240 comprises a deployable ductile metal, such as AISI 1018 steel or SAE 316L grade stainless steel. In yet another embodiment, the cylindrical extrusion limiter 240 comprises a dissolvable or corrodible material. In even yet another embodiment, the cylindrical extrusion limiter 240 comprises a deployable plastic, polymer or composite. For example, in at least one embodiment, at least a portion of the cylindrical extrusion limiter 240 comprises a material having a yield strength of 40 ksi or less, if not 30 ksi or less.
  • the cylindrical extrusion limiter 240 may cover varying amounts of the sealing element 220 .
  • the cylindrical extrusion limiter 240 is located radially about at least 60 percent of the sealing element 220 .
  • the cylindrical extrusion limiter 240 is located radially about at least 80 percent of the sealing element 220 , if not at least 90 percent, if not at least 95 percent.
  • the cylindrical extrusion limiter 240 is located radially about an entirety of the sealing element, such as is shown in FIGS. 2 A through 2 F .
  • the sealing assembly 200 may additionally include one or more anchoring systems 250 .
  • a first anchoring system 250 a and a second anchoring system 250 b are included with the sealing assembly 200 to secure the sealing assembly 200 downhole.
  • the first anchoring system 250 a is engaged with an outer taper face 230 a of the first collar sleeve 230
  • the second anchoring system 250 b is engaged with an outer taper face 235 a of the second collar sleeve 235 .
  • the same axial setting force provided by a setting tool to deploy the sealing element 220 into sealing engagement with the bore may also be used to deploy the first and second anchoring systems 250 a , 250 b into sealing engagement with the bore.
  • a lower end of the sealing assembly 200 also includes a muleshoe 260 that protects certain other features of the sealing assembly 200 as it is run-in-hole.
  • the muleshoe 260 also allows the sealing assembly 200 to pass through other tools, casing joints, or anything with an upset that may otherwise cause the sealing assembly 200 to get stuck.
  • FIGS. 2 G and 2 H illustrated is the sealing assembly 200 in the deployed state. Accordingly, the sealing element 220 has moved from the radially retraced state (e.g., illustrated in FIGS. 2 A through 2 F ) to the radially expanded state. Additionally, the cylindrical extrusion limiter 240 has broken, thus resulting in the first and second separate extrusion limiting rings 240 a , 240 b .
  • the first and second separate extrusion limiting rings 240 a , 240 b may deform and/or deploy to create a barrier that prevents extrusion of the sealing element 220 when deployed.
  • first and second separate extrusion limiting rings 340 a , 340 b result.
  • the first and second separate extrusion limiting rings 340 a , 340 b may deform and/or deploy to create a barrier that prevents extrusion of the sealing element 220 when deployed.
  • the weakened region 444 is a series of holes 446 extending entirely through the extrusion limiter body 442 .
  • the series of holes 446 are a series of slots extending entirely through the extrusion limiter body. Nevertheless, any number, size, shape, location and/or spacing of the series of holes 446 may be used and remain within the scope of the disclosure.
  • this three-piece cylindrical extrusion limiter 540 could include a central cylindrical extrusion limiter 540 a , but may also include separate uphole and downhole retaining rings 540 b , 540 c overlapping radially outside of the central cylindrical extrusion limiter 540 a .
  • Aspects disclosed herein include:
  • a sealing assembly including: 1) a mandrel; 2) a scaling element positioned about the mandrel; 3) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; 4) a first collar sleeve coupled proximate a first end of the sealing element; and 5) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
  • a well system including: 1) a wellbore located in a subterranean formation; and 2) a sealing assembly positioned in the wellbore, the sealing assembly including: a) a mandrel; b) a sealing element positioned about the mandrel; c) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; d) a first collar sleeve coupled proximate a first end of the sealing element; and 3) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
  • a method including: 1) positioning a sealing assembly within a wellbore located in a subterranean formation, the sealing assembly including: a) a mandrel; b) a sealing element positioned about the mandrel; c) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; d) a first collar sleeve coupled proximate a first end of the sealing element; and 3) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.; and 2) moving the sealing element from the radially retracted state
  • aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region substantially proximate a midpoint thereof. Element 2: wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region ideally proximate a midpoint thereof. Element 3: wherein the weakened region is a circumferential notch located around an inside radial surface of the extrusion limiter body. Element 4: wherein the weakened region is a circumferential notch located around an outside radial surface of the extrusion limiter body.
  • Element 5 wherein the weakened region is a series of holes extending entirely through a thickness of the extrusion limiter body.
  • Element 6 wherein the weakened region is a series of slots extending entirely through a thickness of the extrusion limiter body.
  • Element 7 wherein the cylindrical extrusion limiter is located radially about an entirety of the sealing element.
  • Element 8 wherein the cylindrical extrusion limiter is located radially about at least 60 percent of the sealing element.
  • cylindrical extrusion limiter is a three-piece cylindrical extrusion limiter located radially about a centerpoint of the sealing element, the three-piece cylindrical extrusion limiter including a central cylindrical extrusion limiter, and separate uphole and downhole retaining rings overlapping radially outside of the central cylindrical extrusion limiter.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Earth Drilling (AREA)
  • Gasket Seals (AREA)

Abstract

Provided is a sealing assembly, a well system, and a method. The sealing assembly, in one aspect, includes a mandrel, and a sealing element positioned about the mandrel. The sealing element, in this aspect, includes a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element. The sealing assembly, according to this aspect, further includes a first collar sleeve coupled proximate a first end of the sealing element, and a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.

Description

    CROSS-REFERENCE TO RELATED APPLICATION
  • This application claims the benefit of U.S. Provisional Application Ser. No. 63/516,951, filed on Aug. 1, 2023, entitled “SEALING ASSEMBLY EMPLOYING A CYLINDRICAL EXTRUSION LIMITER,” commonly assigned with this application and incorporated herein by reference in its entirety.
  • BACKGROUND
  • Wellbores are drilled into the earth for a variety of purposes including accessing hydrocarbon bearing formations. A variety of downhole tools may be used within a wellbore in connection with accessing and extracting such hydrocarbons. Throughout the process, it may become necessary to isolate sections of the wellbore in order to create pressure zones. Downhole tools, such as hydraulic fracturing (“frac”) plugs, bridge plugs, packers, and other suitable tools, may be used to isolate wellbore sections.
  • Downhole tools, such as frac plugs, are commonly run into the wellbore on a conveyance such as a wireline, work string or production tubing. Such tools typically have either an internal or external setting tool, which is used to set the downhole tool within the wellbore and hold the tool in place. Once in place, the downhole tools allow fluid communication between sections of the wellbore above the plug and below the plug until another downhole tool, such as a ball, is pumped down to seat in the plug and interrupt fluid communication through the plug and a sealing assembly, which can be made of rubber and extends outwards to seal off the flow of liquid around the downhole tool.
  • BRIEF DESCRIPTION
  • Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
  • FIG. 1 illustrates a schematic view of a well system designed, manufactured and operated according to one or more embodiments disclosed herein;
  • FIGS. 2A through 2H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more embodiments of the disclosure;
  • FIGS. 3A through 3H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure;
  • FIGS. 4A through 4H illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure; and
  • FIGS. 5A through 5E illustrate different cross-sectional views of various deployment states of a sealing assembly designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure.
  • DETAILED DESCRIPTION
  • In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms.
  • Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.
  • Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” “downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis. Unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.
  • Sealing elements are traditionally a critical part of a sealing assembly. The present disclosure, however, has recognized that sealing elements tend to have difficulties when the expansion ratio (e.g., the distance the sealing elements must move from their radially retracted state to their radially expanded state to engage with a bore, such as a wellbore, tubular, casing, etc.) is large. Specifically, the present disclosure has recognized that such sealing elements often experience challenges in open-hole conditions that require significant expansion ratios. For example, due to the large extrusion gap in certain conditions, when the sealing element expands, it will often lose its axial stiffness and escape the desired load path.
  • Given the foregoing recognitions, the present disclosure proposes inserting a cylindrical extrusion limiter radially about the sealing element. The cylindrical extrusion limiter, in accordance with this embodiment, is configured to break (e.g., break to form first and second separate extrusion limiting rings) to deploy from an undeployed state to a deployed state as the sealing element moves from a radially retracted state to a radially expanded state. In at least one embodiment, the cylindrical extrusion limiter is located radially about a centerpoint of the sealing element. In at least one other embodiment, the cylindrical extrusion limiter is located radially about at least 60 percent of the sealing element, if not at least 80 percent, if not at least 90 percent, if not at least 95 percent. In yet another embodiment, the cylindrical extrusion limiter is located radially about an entirety of the sealing element.
  • In even yet another embodiment, the extrusion limiter is located radially about a centerpoint of the sealing element, but not located about an entirety of the sealing element. In accordance with this embodiment, separate uphole and downhole retaining rings may overlap radially outside of the extrusion limiter, thus creating a three-piece design.
  • The cylindrical extrusion limiter, in at least one embodiment, includes an extrusion limiter body having a weakened region proximate a midpoint thereof. The weakened region, in at least one embodiment, is a circumferential notch located around an inside radial surface of the extrusion limiter body. The weakened region, in at least one other embodiment, is a circumferential notch located around an outside radial surface of the extrusion limiter body. The weakened region, in at least another embodiment, is a series of holes extending entirely through a thickness of the extrusion limiter body. In at least one embodiment, the series of holes are a series of slots extending entirely through the thickness of the extrusion limiter body. The weakened region, in at least one embodiment, is configured to remain intact prior to setting the sealing element, but once enough axial compression is imparted upon the sealing element break resulting in first and second separate extrusion limiting rings.
  • Turning to FIG. 1 , illustrated is an elevation view of a well system 100 in which a wellbore sealing system 135 according to an example of the present disclosure may be implemented. Although FIG. 1 depicts a land-based well system 100, those skilled in the art will also appreciate that aspects of this disclosure may be applied to other well sites including offshore, fixed or floating platform, subsea, and/or other kinds of well operations. A representative wellbore 110 is shown, having been drilled through one or more subterranean formations 115. FIG. 1 shows a straight, vertical portion of the wellbore 110, but it will be understood that directional drilling techniques may be implemented, such as using a rotary steerable system providing directional control to deviate from vertical and achieve any desired wellbore path. A tubular, typically metallic casing 120 is cemented in place to reinforce the wellbore 110. For purposes of this disclosure, the inner surface of the casing 120, when present, may functionally define an inner surface of the wellbore 110. The wellbore sealing system 135 is typically used to seal off the wellbore 110 by sealing against the inner diameter (ID) of the casing 120.
  • The wellbore sealing system 135 in at least one embodiment includes a sealing assembly 150, shown in FIG. 1 in a run-in-hole (RIH) condition prior to being set by a setting tool 140. The sealing assembly 150 is run into the wellbore 110 on a conveyance, which in this example includes a tubing string 130, but could alternatively include a coiled tubing, wireline, or other conveyance. The tubing string 130 may extend to a wellhead at the ground level 125 (e.g., “surface”) of the well system 100, for carrying produced fluids from the hydrocarbon bearing formation to the surface.
  • The setting tool 140, in one embodiment, includes an actuatable element, such as a sleeve 145, for applying a large axial setting force (e.g., hydraulically) to set the sealing assembly 150, for example once the sealing assembly 150 is positioned at a desired location within the wellbore 110. Setting the sealing assembly 150 squeezes the components (e.g., collar sleeves, scaling element(s), etc.) of the sealing assembly 150 together axially, which may both anchor the sealing assembly 150 in the casing 120 and seal against the casing 120. For instance, the scaling assembly 150 may be set in the axial position shown to sealingly isolate an uphole portion of the wellbore 110 from a downhole portion of the wellbore 110. In some examples, the scaling assembly 150 may be a hydraulic fracturing plug (i.e., frac plug) used to plug the wellbore 110 prior to performing a hydraulic fracturing operation in the uphole portion of the wellbore 110. In yet another embodiment, the sealing assembly 150 is a packer. The various configurations discussed below may allow the sealing assembly 150 to be set within a larger diameter and/or within a larger range of diameters than might ordinarily be practicable for a conventional tool.
  • In the illustrated embodiment, the sealing system 150 includes a cylindrical extrusion limiter 155, for example positioned radially about a sealing element. As will be discussed in detail below, the cylindrical extrusion limiter 155 is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
  • Turning now to FIGS. 2A through 2H, illustrated are different cross-sectional views of various deployment states of a sealing assembly 200 designed, manufactured and/or operated according to one or more embodiments of the disclosure. FIGS. 2A through 2F illustrate the sealing assembly 200 in a run-in-hole state (e.g., undeployed state), whereas FIGS. 2G and 2H illustrate the sealing assembly 200 in a deployed state. In the illustrated embodiments, the sealing assembly 200 includes a mandrel 210. The mandrel 210, in one or more embodiments, is a fixed mandrel 210, and thus remains with the sealing assembly 200 regardless of deployment state. In yet another embodiment, the mandrel 210 is a removable mandrel 210, and thus may be removed.
  • In the illustrated embodiment, a sealing element 220 is positioned about the mandrel 210. While a single sealing element 220 is illustrated in FIGS. 2A through 2H, other embodiments may exist wherein multiple sealing elements are employed. In accordance with one embodiment of the disclosure, the sealing element 220 is an elastomeric sealing element. Further to this one embodiment, the sealing element 220 may be a non-swellable sealing element.
  • In the illustrated embodiment, a first collar sleeve 230 is coupled proximate a first end 225 a of the sealing element 220, and a second collar sleeve 235 is coupled proximate a second end 225 b of the sealing element 220. In at least one embodiment, the first and second collar sleeves 230, 235 are configured to axially translate relative to one another along the mandrel 210 to move the sealing element 220 between a radially retracted state (e.g., that shown in FIG. 2C) a radially expanded state (e.g., that shown in FIG. 2G). For example, in at least one embodiment, angled surfaces of the first and second collar sleeves 230, 235 may engage with angled surfaces of the sealing element 220, such that the sealing element 220 is forced radially outward when the first and second collar sleeves 230, 235 move relative to one another.
  • The sealing assembly 200, in the illustrated embodiment, may additionally include a cylindrical extrusion limiter 240 positioned radially about a centerpoint of the sealing element 220. In accordance with one or more embodiments, the cylindrical extrusion limiter 240 is configured to break to deploy from an undeployed state to a deployed state (e.g., break to form first and second separate extrusion limiting rings 240 a, 240 b) as the sealing element 220 moves from the radially retracted state to the radially expanded state.
  • In at least one embodiment, the cylindrical extrusion limiter 240 includes an extrusion limiter body 242 having a weakened region 244. In one or more embodiments, the weakened region 244 is located substantially proximate a midpoint of the extrusion limiter body 242. The phrase “substantially proximate,” as used herein with reference to the midpoint of the extrusion limiter body 242, means that the weakened region 244 is located within 20 percent of the midpoint of the extrusion limiter body 242. In yet another embodiment, the weakened region 244 is located ideally proximate a midpoint thereof, wherein the phrase “ideally proximate” means that the weakened region 244 is located within 5 percent of the midpoint of the extrusion limiter body 242. In yet another embodiment, the weakened region 244 is located at exactly the midpoint, which means that the weakened region 244 is located within 1 percent of the midpoint of the extrusion limiter body 242.
  • The weakened region 244 may take on many different sizes, shapes and/or styles and remain within the scope of the present disclosure. In the illustrated embodiment of FIGS. 2A through 2F, however, the weakened region 244 is a circumferential notch 246 located around an inside radial surface of the extrusion limiter body 242. The circumferential notch 246, in the illustrated embodiment, might not extend entirely through a thickness of the extrusion limiter body 242. While the embodiment of FIGS. 2A through 2F illustrates that a single notch 246 extends circumferentially around an entire inside radial surface of the extrusion limiter body 242, other embodiments may exist wherein one or more circumferential notches 246 extend around only a portion of the inside radial surface of the extrusion limiter body 242. Furthermore, while the embodiment of FIGS. 2A through 2F illustrates that the circumferential notch 246 is located around an inside radial surface, in one or more other embodiments the weakened region 244 is a circumferential notch located around an outside radial surface of the extrusion limiter body 242.
  • The cylindrical extrusion limiter 240 may comprise many different materials and remain within the scope of the disclosure. In at least one embodiment, however, the cylindrical extrusion limiter 240 comprises a deployable ductile metal, such as AISI 1018 steel or SAE 316L grade stainless steel. In yet another embodiment, the cylindrical extrusion limiter 240 comprises a dissolvable or corrodible material. In even yet another embodiment, the cylindrical extrusion limiter 240 comprises a deployable plastic, polymer or composite. For example, in at least one embodiment, at least a portion of the cylindrical extrusion limiter 240 comprises a material having a yield strength of 40 ksi or less, if not 30 ksi or less.
  • The cylindrical extrusion limiter 240, depending on the design of the sealing assembly 200, may cover varying amounts of the sealing element 220. For example, in at least one embodiment, the cylindrical extrusion limiter 240 is located radially about at least 60 percent of the sealing element 220. In yet another embodiment, the cylindrical extrusion limiter 240 is located radially about at least 80 percent of the sealing element 220, if not at least 90 percent, if not at least 95 percent. In yet another embodiment, the cylindrical extrusion limiter 240 is located radially about an entirety of the sealing element, such as is shown in FIGS. 2A through 2F.
  • The sealing assembly 200, in the illustrated embodiment, may additionally include one or more anchoring systems 250. In the illustrated embodiment, a first anchoring system 250 a and a second anchoring system 250 b are included with the sealing assembly 200 to secure the sealing assembly 200 downhole. In the illustrated embodiment, the first anchoring system 250 a is engaged with an outer taper face 230 a of the first collar sleeve 230, and the second anchoring system 250 b is engaged with an outer taper face 235 a of the second collar sleeve 235. Thus, the same axial setting force provided by a setting tool to deploy the sealing element 220 into sealing engagement with the bore may also be used to deploy the first and second anchoring systems 250 a, 250 b into sealing engagement with the bore.
  • In one or more embodiments, a lower end of the sealing assembly 200 also includes a muleshoe 260 that protects certain other features of the sealing assembly 200 as it is run-in-hole. The muleshoe 260 also allows the sealing assembly 200 to pass through other tools, casing joints, or anything with an upset that may otherwise cause the sealing assembly 200 to get stuck.
  • Turning to FIGS. 2G and 2H, illustrated is the sealing assembly 200 in the deployed state. Accordingly, the sealing element 220 has moved from the radially retraced state (e.g., illustrated in FIGS. 2A through 2F) to the radially expanded state. Additionally, the cylindrical extrusion limiter 240 has broken, thus resulting in the first and second separate extrusion limiting rings 240 a, 240 b. The first and second separate extrusion limiting rings 240 a, 240 b, as shown, may deform and/or deploy to create a barrier that prevents extrusion of the sealing element 220 when deployed.
  • Turning now to FIGS. 3A through 3H, illustrated are different cross-sectional views of various deployment states of a sealing assembly 300 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 300 of FIGS. 3A through 3H is similar in many respects to the sealing assembly 200 of FIGS. 2A through 2H. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 300 differs, for the most part, from the scaling assembly 200 in that the sealing assembly 300 employs a cylindrical extrusion limiter 340 including an extrusion limiter body 342 with a weakened region 344 that does not wrap around the sealing element 220. Once the cylindrical extrusion limiter 340 has broken, first and second separate extrusion limiting rings 340 a, 340 b result. The first and second separate extrusion limiting rings 340 a, 340 b, as shown, may deform and/or deploy to create a barrier that prevents extrusion of the sealing element 220 when deployed.
  • Turning now to FIGS. 4A through 4H, illustrated are different cross-sectional views of various deployment states of a sealing assembly 400 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 400 of FIGS. 4A through 4H is similar in many respects to the sealing assembly 300 of FIGS. 3A through 3H. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 400 differs, for the most part, from the scaling assembly 300 in that the sealing assembly 400 employs a cylindrical extrusion limiter 440, having a weakened region 444 substantially proximate a midpoint thereof. Moreover, in at least this embodiment, the weakened region 444 is a series of holes 446 extending entirely through the extrusion limiter body 442. In the illustrated embodiment, the series of holes 446 are a series of slots extending entirely through the extrusion limiter body. Nevertheless, any number, size, shape, location and/or spacing of the series of holes 446 may be used and remain within the scope of the disclosure.
  • Turning now to FIGS. 5A through 5E, illustrated are different cross-sectional views of various deployment states of a sealing assembly 500 designed, manufactured and/or operated according to one or more alternative embodiments of the disclosure. The sealing assembly 500 of FIGS. 5A through 5E is similar in many respects to the sealing assembly 200 of FIGS. 2A through 2H. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The sealing assembly 500 differs, for the most part, from the sealing assembly 200 in that the sealing assembly 500 employs a three-piece cylindrical extrusion limiter 540. For example, this three-piece cylindrical extrusion limiter 540 could include a central cylindrical extrusion limiter 540 a, but may also include separate uphole and downhole retaining rings 540 b, 540 c overlapping radially outside of the central cylindrical extrusion limiter 540 a. Aspects disclosed herein include:
  • A. A sealing assembly, the sealing assembly including: 1) a mandrel; 2) a scaling element positioned about the mandrel; 3) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; 4) a first collar sleeve coupled proximate a first end of the sealing element; and 5) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
  • B. A well system, the well system including: 1) a wellbore located in a subterranean formation; and 2) a sealing assembly positioned in the wellbore, the sealing assembly including: a) a mandrel; b) a sealing element positioned about the mandrel; c) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; d) a first collar sleeve coupled proximate a first end of the sealing element; and 3) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
  • C. A method, the method including: 1) positioning a sealing assembly within a wellbore located in a subterranean formation, the sealing assembly including: a) a mandrel; b) a sealing element positioned about the mandrel; c) a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element; d) a first collar sleeve coupled proximate a first end of the sealing element; and 3) a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.; and 2) moving the sealing element from the radially retracted state to the radially expanded state, the moving causing the cylindrical extrusion limiter to break deploy from the undeployed state to the deployed state.
  • Aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region substantially proximate a midpoint thereof. Element 2: wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region ideally proximate a midpoint thereof. Element 3: wherein the weakened region is a circumferential notch located around an inside radial surface of the extrusion limiter body. Element 4: wherein the weakened region is a circumferential notch located around an outside radial surface of the extrusion limiter body. Element 5: wherein the weakened region is a series of holes extending entirely through a thickness of the extrusion limiter body. Element 6: wherein the weakened region is a series of slots extending entirely through a thickness of the extrusion limiter body. Element 7: wherein the cylindrical extrusion limiter is located radially about an entirety of the sealing element. Element 8: wherein the cylindrical extrusion limiter is located radially about at least 60 percent of the sealing element. Element 9: wherein the cylindrical extrusion limiter is a three-piece cylindrical extrusion limiter located radially about a centerpoint of the sealing element, the three-piece cylindrical extrusion limiter including a central cylindrical extrusion limiter, and separate uphole and downhole retaining rings overlapping radially outside of the central cylindrical extrusion limiter.
  • Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.

Claims (21)

What is claimed is:
1. A sealing assembly, comprising:
a mandrel;
a sealing element positioned about the mandrel;
a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element;
a first collar sleeve coupled proximate a first end of the sealing element; and
a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
2. The sealing assembly as recited in claim 1, wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region substantially proximate a midpoint thereof.
3. The sealing assembly as recited in claim 1, wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region ideally proximate a midpoint thereof.
4. The sealing assembly as recited in claim 1, wherein the weakened region is a circumferential notch located around an inside radial surface of the extrusion limiter body.
5. The sealing assembly as recited in claim 1, wherein the weakened region is a circumferential notch located around an outside radial surface of the extrusion limiter body.
6. The sealing assembly as recited in claim 1, wherein the weakened region is a series of holes extending entirely through a thickness of the extrusion limiter body.
7. The sealing assembly as recited in claim 1, wherein the weakened region is a series of slots extending entirely through a thickness of the extrusion limiter body.
8. The sealing assembly as recited in claim 1, wherein the cylindrical extrusion limiter is located radially about an entirety of the sealing element.
9. The sealing assembly as recited in claim 1, wherein the cylindrical extrusion limiter is located radially about at least 60 percent of the sealing element.
10. The sealing assembly as recited in claim 9, wherein the cylindrical extrusion limiter is a three-piece cylindrical extrusion limiter located radially about a centerpoint of the sealing element, the three-piece cylindrical extrusion limiter including a central cylindrical extrusion limiter, and separate uphole and downhole retaining rings overlapping radially outside of the central cylindrical extrusion limiter.
11. A well system, comprising:
a wellbore located in a subterranean formation; and
a sealing assembly positioned in the wellbore, the sealing assembly including:
a mandrel;
a sealing element positioned about the mandrel;
a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element;
a first collar sleeve coupled proximate a first end of the sealing element; and
a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state.
12. The well system as recited in claim 11, wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region substantially proximate a midpoint thereof.
13. The well system as recited in claim 11, wherein the cylindrical extrusion limiter includes an extrusion limiter body having a weakened region ideally proximate a midpoint thereof.
14. The well system as recited in claim 11, wherein the weakened region is a circumferential notch located around an inside radial surface of the extrusion limiter body.
15. The well system as recited in claim 11, wherein the weakened region is a circumferential notch located around an outside radial surface of the extrusion limiter body.
16. The well system as recited in claim 11, wherein the weakened region is a series of holes extending entirely through the extrusion limiter body.
17. The well system as recited in claim 11, wherein the weakened region is a series of slots extending entirely through the extrusion limiter body.
18. The well system as recited in claim 11, wherein the cylindrical extrusion limiter is located radially about an entirety of the sealing element.
19. The well system as recited in claim 11, wherein the cylindrical extrusion limiter is located radially about at least 60 percent of the sealing element.
20. The well system as recited in claim 19, wherein the cylindrical extrusion limiter is a three-piece cylindrical extrusion limiter located radially about a centerpoint of the sealing element, the three-piece cylindrical extrusion limiter including a central cylindrical extrusion limiter, and separate uphole and downhole retaining rings overlapping radially outside of the central cylindrical extrusion limiter.
21. A method, comprising:
positioning a sealing assembly within a wellbore located in a subterranean formation, the sealing assembly including:
a mandrel;
a sealing element positioned about the mandrel;
a cylindrical extrusion limiter positioned radially about a centerpoint of the sealing element;
a first collar sleeve coupled proximate a first end of the sealing element; and
a second collar sleeve coupled proximate a second end of the sealing element, wherein the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state, and further wherein the cylindrical extrusion limiter is configured to break to deploy from an undeployed state to a deployed state as the sealing element moves from the radially retracted state to the radially expanded state; and
moving the sealing element from the radially retracted state to the radially expanded state, the moving causing the cylindrical extrusion limiter to break deploy from the undeployed state to the deployed state.
US18/494,395 2023-08-01 2023-10-25 Sealing assembly employing a cylindrical extrusion limiter Pending US20250043654A1 (en)

Priority Applications (3)

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US18/494,395 US20250043654A1 (en) 2023-08-01 2023-10-25 Sealing assembly employing a cylindrical extrusion limiter
PCT/US2023/035989 WO2025029269A1 (en) 2023-08-01 2023-10-26 A sealing assembly employing a cylindrical extrusion limiter
FR2404573A FR3151872A1 (en) 2023-08-01 2024-04-30 A SEALING ASSEMBLY USING A CYLINDRICAL EXTRUSION LIMITER

Applications Claiming Priority (2)

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US202363516951P 2023-08-01 2023-08-01
US18/494,395 US20250043654A1 (en) 2023-08-01 2023-10-25 Sealing assembly employing a cylindrical extrusion limiter

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Publication number Priority date Publication date Assignee Title
US20050171248A1 (en) * 2004-02-02 2005-08-04 Yanmei Li Hydrogel for use in downhole seal applications
US7810558B2 (en) * 2004-02-27 2010-10-12 Smith International, Inc. Drillable bridge plug
US7661471B2 (en) * 2005-12-01 2010-02-16 Baker Hughes Incorporated Self energized backup system for packer sealing elements
CA3005540C (en) * 2012-08-27 2020-03-31 Halliburton Energy Services, Inc. Constructed annular safety valve element package
RO132929A2 (en) * 2016-01-11 2018-11-29 Halliburton Energy Services Inc. Extrusion limiting ring for wellbore isolation devices

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Owner name: HALLIBURTON ENERGY SERVICES, INC., TEXAS

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MILNE, ADAM J.;REEL/FRAME:065342/0799

Effective date: 20231024