Isolation device and method

Abstract

An isolation device that has a metal bladder that is deformed downhole, such as by hydroforming. Certain aspects of the present invention include methods for implementing and using the isolation device, manufacturing techniques for making the device, sleeve properties and other device components. It is emphasized that this abstract is provided to comply with the rules requiring an abstract, which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

1 . A well isolation device, comprising: 
 a base pipe;    a tubular sleeve formed of a metal material and having end portions;    a seal between each of the end portions of the sleeve and the base pipe;    the base pipe, the sleeve, and the seals defining a cavity;    a fluid passageway in communication with the cavity;    the sleeve is inflatable from a retracted state to an inflated state in response to application of pressurized fluid in the cavity.    
   
   
       2 . The well isolation device of  claim 1 , further comprising: 
 a valve in the fluid passageway configured to substantially maintain the pressurized fluid in the cavity.    
   
   
       3 . The well isolation device of  claim 2 , wherein the valve is a check valve.  
   
   
       4 . The well isolation device of  claim 2 , wherein the valve is an inflation valve.  
   
   
       5 . The well isolation device of  claim 1 , wherein the fluid passageway communicates with one of a well annulus, an interior of the base pipe, and a control line.  
   
   
       6 . The well isolation device of  claim 1 , further comprising a stiffening ring on the end portion of the sleeve.  
   
   
       7 . The well isolation device of  claim 1 , further comprising a jacket on the sleeve.  
   
   
       8 . The well isolation device of  claim 7 , wherein the jacket comprises a sealing material.  
   
   
       9 . The well isolation device of  claim 7 , further comprising: 
 a central portion of the sleeve between the end portions having a smaller diameter than the end portions; and    the jacket is on the central portion.    
   
   
       10 . The well isolation device of  claim 1 , wherein the end portions of the sleeve are fixed positionally relative to the base pipe.  
   
   
       11 . The well isolation device of  claim 1 , wherein: 
 a first of the end portions of the sleeve is fixed positionally relative to the base pipe;    a second of the end portions of the sleeve may move axially relative to the base pipe.    
   
   
       12 . The well isolation device of  claim 11 , further comprising a ratchet adapted to restrict the motion of the second of the end portions to one direction.  
   
   
       13 . The well isolation device of  claim 1 , wherein the sleeve is plastically deformed during inflation.  
   
   
       14 . The well isolation device of  claim 1 , wherein the sleeve comprises a material having a strain of greater than 10%.  
   
   
       15 . The well isolation device of  claim 1 , wherein the sleeve comprises a material having a yield stress of less than or equal to 60 ksi.  
   
   
       16 . The well isolation device of  claim 1 , wherein the sleeve is formed of a material selected from low carbon steel, normalized low alloy steel, austenitic stainless steel alloy in the annealed condition, and austenitic nickel alloy.  
   
   
       17 . The well isolation device of  claim 1 , further comprising a fluid passageway providing fluid communication between the cavity and the well annulus.  
   
   
       18 . The well isolation device of  claim 1 , further comprising a valve in the second fluid passageway adapted to selectively establish communication between the well annulus and the cavity.  
   
   
       19 . The well isolation device of  claim 1 , further comprising a valve adapted to selectively establish communication between a well annulus and the cavity.  
   
   
       20 . The well isolation device of  claim 19 , wherein the valve is positioned in the fluid passageway.  
   
   
       21 . The well isolation device of  claim 19 , wherein the valve comprises: 
 a piston adapted to selectively permit and restrict tubing pressure into the cavity; and    a rupture disk adapted to selectively permit communication from a well annulus to the cavity.    
   
   
       22 . The well isolation device of  claim 1 , further comprising an inflation material in the cavity.  
   
   
       23 . The well isolation device of  claim 22 , wherein the inflation material comprises a swelling elastomer.  
   
   
       24 . The well isolation device of  claim 22 , wherein the inflation material comprises a two-part foam.  
   
   
       25 . The well isolation device of  claim 1 , wherein the tubular sleeve is corrugated.  
   
   
       26 . A well isolation device, comprising: 
 a metal bladder mounted to a base pipe;    the metal bladder is inflatable from a retracted state to an inflated state in response to application of pressurized fluid through a fluid inlet; and    a valve in the fluid inlet configured to substantially maintain the pressure in the bladder.    
   
   
       27 . The well isolation device of  claim 26 , further comprising an elastomeric jacket on an exterior surface of the bladder.  
   
   
       28 . The well isolation device of  claim 26 , wherein the bladder has an end that is free to move axially relative to the base pipe.  
   
   
       29 . The well isolation device of  claim 28 , further comprising a ratchet adapted to restrict the motion of the end to one direction.  
   
   
       30 . The well isolation device of  claim 26 , wherein the bladder comprises a material having a strain of greater than 10%.  
   
   
       31 . The well isolation device of  claim 26 , wherein the bladder comprises a material having a yield stress of less than 60 ksi.  
   
   
       32 . The well isolation device of  claim 26 , further comprising a valve adapted to selectively establish communication between a well annulus and an interior of the bladder.  
   
   
       33 . The well isolation device of  claim 26 , further comprising an inflation material in the bladder.  
   
   
       34 . The well isolation device of  claim 33 , wherein the inflation material comprises a swelling elastomer.  
   
   
       35 . The well isolation device of  claim 33 , wherein the inflation material comprises a two-part foam.  
   
   
       36 . The well isolation device of  claim 33 , wherein the metal bladder is corrugated.  
   
   
       37 . A method of providing annular isolation in a well, comprising: 
 hydroforming a metal bladder between a base pipe and an outer well conduit using pressurized well fluid; and    maintaining the pressure in the bladder using a valve.    
   
   
       38 . The method of  claim 37 , further comprising improving collapse resistance of the bladder with pressurized fluid in the bladder.  
   
   
       39 . The method of  claim 37 , further comprising establishing fluid communication between an interior of the bladder and a well annulus.  
   
   
       40 . The method of  claim 37 , further comprising allowing one end of the bladder to move axially in one direction relative to the base pipe.  
   
   
       41 . The method of  claim 37 , further comprising providing an inflation material in the bladder.  
   
   
       42 . A packer element, comprising a metal sleeve packer element comprising a material having a strain of greater than 10%.  
   
   
       43 . The packer element of  claim 42 , wherein the sleeve packer element comprises a material having a yield stress of less than 60 ksi.  
   
   
       44 . The packer element of  claim 42 , wherein the sleeve is formed of a material selected from low carbon steel, normalized low alloy steel, austenitic stainless steel alloy in the annealed condition, and austenitic nickel alloy.  
   
   
       45 . The packer element of  claim 42 , wherein the sleeve packer element is corrugated.  
   
   
       46 . A well isolation device having an inflatable bladder, comprising: 
 a first valve adapted to selectively establish fluid communication between a source of inflation pressure and an interior cavity of the bladder;    a second valve adapted to selectively establish communication between a well annulus and the interior cavity of the bladder.    
   
   
       47 . The well isolation device of  claim 46 , wherein the source of inflation pressure is a tubing pressure.  
   
   
       48 . The well isolation device of  claim 46 , wherein the source of inflation pressure is an annulus pressure.  
   
   
       49 . The well isolation device of  claim 46 , wherein the source of inflation pressure is a control line pressure.  
   
   
       50 . The well isolation device of  claim 46 , wherein the first valve comprises a piston adapted to selectively permit and restrict fluid flow between from the source of inflation pressure into the interior cavity.  
   
   
       51 . The well isolation device of  claim 50 , further comprising: 
 a spring that biases the piston to a closed position; and    a J-slot mechanism that selectively holds the piston in an open position.    
   
   
       52 . The well isolation device of  claim 50 , wherein the piston has a backside referenced to a well pressure.  
   
   
       53 . The well isolation device of  claim 46 , wherein the second valve comprises a rupture disk adapted to selectively permit communication from a well annulus to the cavity.  
   
   
       54 . The well isolation device of  claim 46 , wherein the valve further comprises a check valve adapted to equalize the pressure between the interior cavity and the well annulus as the well isolation device is run in a well.  
   
   
       55 . The well isolation device of  claim 46 , wherein the first valve is an electric valve.  
   
   
       56 . The well isolation device of  claim 46 , wherein the second valve is an electric valve.  
   
   
       57 . A method of energizing a well isolation device having a bladder that is positioned in a well, comprising: 
 inflating the bladder of the well isolation device;    closing an inflation inlet of the well isolation device;    establishing fluid communication between an interior of the bladder and a well annulus.    
   
   
       58 . The method of  claim 57 , further comprising: 
 rupturing a rupture disk to establish fluid communication between an interior of the bladder and the well annulus.    
   
   
       59 . The method of  claim 57 , further comprising: 
 equalizing the pressure between the interior of the bladder and the well annulus as the well isolation device is run in the well.    
   
   
       60 . The method of  claim 57 , wherein the establishing step further comprises establishing fluid communication with a high-pressure side of the well annulus.  
   
   
       61 . A well isolation device, comprising: 
 an inflatable bladder having an interior, the inflatable bladder adapted for inflation from a retracted state to an inflated state;    a valve adapted to selectively provide fluid communication between a well annulus and the interior of the inflatable bladder.    
   
   
       62 . The well isolation device of  claim 61 , wherein the valve comprises a rupture disk.  
   
   
       63 . The well isolation device of  claim 61 , wherein the valve comprises an electric valve.  
   
   
       64 . The well isolation device of  claim 61 , wherein the valve further comprises a valve component adapted to selectively establish fluid communication between a source of inflation pressure the interior of the inflatable bladder.  
   
   
       65 . A method of manufacturing an isolation device, comprising: 
 forming a metal plate into a tubular sleeve;    placing the sleeve onto a base pipe;    connecting and sealing opposing end portions of the sleeve to the base pipe.