Downhole sealing using settable material in an elastic membrane

Abstract

A rubber pocket is described that is suitable for use on tubing, such as a packer-type seal, on casing, such as a cement-type seal, or on liners. The rubber pocket may contain cement particles, rubber particles, swellable particles, cement filled rubber particles, cement filled swellable particles, calcium oxide, magnesium oxide, magnesium sulfate, iron (III) oxide, calcium sulfoaluminate, clay, magnetic particles and/or reactants such as crosslinkers, retardants or epoxy. The particles may be bulk spheres, bulk fibers, hollow spheres, hollow fibers, etc. The rubber pocket or bladder may also be fully or partially filled with fluids such as polymer reactants. The pocket may also be empty or contain a small volume of reactants. The slurry or epoxy or other type of fluid and granular solid or injectable matter can be injected after the completion positioning downhole.

What is claimed is: 
     
         1 . A sealing system for use in downhole sealing applications, the system comprising:
 an elastic membrane adapted to be deployed downhole; and   a settable material housed within the elastic membrane prior to deployment of the membrane downhole, wherein the settable material is adapted to, when positioned downhole, set into an expanded solid form within the elastic membrane so as to form a sealing function when the system is positioned downhole.   
     
     
         2 . A system according to  claim 1  wherein the settable material includes cement particles. 
     
     
         3 . A system according to  claim 1  wherein the settable material is a granular material. 
     
     
         4 . A system according to  claim 1  wherein the settable material includes one or more types of material selected from a group consisting of: rubber particles, water swellable particles, oil swellable particles, cement filled rubber particles, cement filled swellable particles, epoxy particles, calcium oxide, magnesium oxide, magnesium sulfate, iron (III) oxide, calcium sulfoaluminate, clay, and magnetic particles. 
     
     
         5 . A system according to  claim 1  wherein the settable material includes one or more types of material selected from a group consisting of: bulk spheres, bulk fibers, hollow spheres and hollow fibers. 
     
     
         6 . A system according to  claim 1  wherein the settable material is a pliable solid. 
     
     
         7 . A system according to  claim 1  wherein the settable material is fluid. 
     
     
         8 . A system according to  claim 1  wherein the settable material is expanded upon exposure of the settable material to an introduced fluid. 
     
     
         9 . A system according to  claim 8  wherein the introduced fluid is pumped from the surface or from a downhole tool, through one or more orifices to make contact with the settable material. 
     
     
         10 . A system according to  claim 8  wherein the introduced fluid is diffused from a downhole environment through the elastic membrane to make contact with the settable material. 
     
     
         11 . A system according to  claim 8  wherein the introduced fluid is water. 
     
     
         12 . A system according to  claim 8  wherein the introduced fluid is oil. 
     
     
         13 . A system according to  claim 1  wherein the settable material is expanded and/or set upon exposure to a temperature change and/or a magnetic field. 
     
     
         14 . A system according to  claim 1  further comprising a reactant material adapted to aid in triggering the expanding and/or setting of the settable material. 
     
     
         15 . A system according to  claim 14  wherein the reactant material is of a type selected from a group consisting of: crosslinkers, retardants, epoxy, and amine hardener. 
     
     
         16 . A system according to  claim 1  wherein the elastic membrane is adapted to expand by at least 100% in size. 
     
     
         17 . A system according to  claim 1  wherein the system is adapted for use in an external casing packer. 
     
     
         18 . A system according to  claim 1  wherein the elastic material is a rubber material. 
     
     
         19 . A method for sealing downhole comprising:
 deploying an elastic membrane downhole, the membrane containing a settable material prior to deployment;   expanding the settable material within the membrane while downhole; and   setting the expanded settable material within the membrane so as to form a solid mass within the elastic membrane thereby forming a downhole seal.   
     
     
         20 . A method according to  claim 19  further comprising injecting a resin into the elastic membrane while downhole. 
     
     
         21 . A method according to  claim 20  wherein the resin is of a type selected from a group consisting of classical epoxy resin, fatty acid oligomers and polyols. 
     
     
         22 . A method according to  claim 19  further comprising injecting an initiator and/or hardener into the elastic membrane while downhole. 
     
     
         23 . A method according to  claim 22  wherein the initiators and/or hardeners are of a type selected from a group consisting of: urea, secondary amines and isocyanate. 
     
     
         24 . A method according to  claim 19  wherein the settable material is a granular material. 
     
     
         25 . A method according to  claim 19  further comprising introducing a fluid to make contact with the settable material to facilitate the expanding and/or setting of the settable material. 
     
     
         26 . A method according to  claim 25  wherein the introduced fluid is oil or water diffused through the elastic membrane. 
     
     
         27 . A method according to  claim 25  wherein the introduced fluid is oil or water pumped from the surface. 
     
     
         28 . A method according to  claim 19  further comprising exposing the settable material to heat and/or a magnetic field to facilitate the expanding and/or setting of the settable material.