Downhole Check Valve Assembly with a Swellable Element Mechanism

Abstract

Valve systems and methods for inserting the valve system into a casing for a downhole environment are provided. The valve system includes a mandrel, a check valve assembly, and a sealing element containing swellable polymeric material. The check valve assembly is coupled to the mandrel and operable to provide a fluid flow only in a primary direction through a passageway of the mandrel. The sealing element is located on an outer surface of the mandrel. In some examples, the sealing element includes slip buttons or other gripping elements located on the swellable polymeric material.

What is claimed is: 
     
         1 . A valve system insertable into a casing used in a downhole environment, comprising:
 a mandrel comprising a passageway therethrough;   a check valve assembly coupled to the mandrel and operable to provide a fluid flow only in a primary direction through the passageway; and   a sealing element located on an outer surface of the mandrel and comprising a swellable polymeric material expandable into sealing engagement with an inner surface of the casing.   
     
     
         2 . The valve system of  claim 1 , wherein an outer surface of the sealing element comprises gripping elements for gripping the inner surface of the casing. 
     
     
         3 . The valve system of  claim 2 , wherein the gripping elements are located on the swellable polymeric material. 
     
     
         4 . The valve system of  claim 2 , wherein the gripping elements comprise slip buttons, teeth, or a combination thereof. 
     
     
         5 . The valve system of  claim 4 , wherein the gripping elements comprise a material selected from the group consisting of ceramic, metal, metal carbide, thermoplastic, and combinations thereof. 
     
     
         6 . The valve system of  claim 1 , wherein the swellable polymeric material is expandable upon contact with an aqueous fluid. 
     
     
         7 . The valve system of  claim 1 , wherein the swellable polymeric material is expandable upon contact with an organic fluid. 
     
     
         8 . The valve system of  claim 1 , wherein the swellable polymeric material comprises a swellable elastomer. 
     
     
         9 . The valve system of  claim 1 , wherein the swellable polymeric material comprises a rubber selected from the group consisting of ethylene propylene diene monomer (EPDM) rubber, ethylene propylene monomer rubber, ethylene-propylene-copolymer rubber, ethylene propylene-diene terpolymer rubber, ethylene vinyl acetate rubber, polynorbornene rubber, styrene butadiene rubber (SBR), hydrogenized acrylonitrile butadiene rubber, acrylonitrile butadiene rubber, isoprene rubber, butyl rubber, halogenated butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chloroprene rubber, chlorinated polyethylene (CPE) rubber, silicone rubber, natural rubber, crosslinks thereof, and any combination thereof. 
     
     
         10 . The valve system of  claim 1 , wherein the swellable polymeric material comprises a compound selected from the group consisting of methyl methacrylate, polyvinyl chloride (PVC), ethylacetate, acrylonitrile, and any combination thereof. 
     
     
         11 . The valve system of  claim 1 , wherein the swellable polymeric material circumscribes around at least a portion of the mandrel. 
     
     
         12 . A valve system insertable into a casing used in a downhole environment, comprising:
 a mandrel comprising a passageway therethrough;   a check valve assembly coupled to the mandrel and operable to provide a fluid flow only in a primary direction through the passageway;   a sealing element located on an outer surface of the mandrel, wherein the sealing element comprises:
 a swellable polymeric material circumscribing around at least a portion of the mandrel; and 
 slip buttons located on the swellable polymeric material. 
   
     
     
         13 . The valve system of  claim 12 , wherein the slip buttons comprise a material selected from the group consisting of ceramic, metal, metal carbide, thermoplastic, and combinations thereof. 
     
     
         14 . The valve system of  claim 12 , wherein the swellable polymeric material is expandable into sealing engagement with an inner surface of the casing upon contact with an aqueous fluid, an organic fluid, or a combination thereof. 
     
     
         15 . The valve system of  claim 12 , wherein the swellable polymeric material comprises a rubber selected from the group consisting of ethylene propylene diene monomer (EPDM) rubber, ethylene propylene monomer rubber, ethylene-propylene-copolymer rubber, ethylene propylene-diene terpolymer rubber, ethylene vinyl acetate rubber, polynorbornene rubber, styrene butadiene rubber (SBR), hydrogenized acrylonitrile butadiene rubber, acrylonitrile butadiene rubber, isoprene rubber, butyl rubber, halogenated butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chloroprene rubber, chlorinated polyethylene (CPE) rubber, silicone rubber, natural rubber, crosslinks thereof, and any combination thereof, and wherein the swellable polymeric material comprises a compound selected from the group consisting of methyl methacrylate, polyvinyl chloride (PVC), ethylacetate, acrylonitrile, and any combination thereof. 
     
     
         16 . A method for installing a valve system into a casing used in a downhole environment, comprising:
 inserting the valve system into the casing, wherein the valve system comprises:
 a mandrel comprising a passageway therethrough; 
 a check valve assembly coupled to the mandrel and operable to provide a fluid flow only in a primary direction through the passageway; and 
 a sealing element located on an outer surface of the mandrel and comprising a swellable polymeric material; and 
   connecting the valve system to an inner surface of the casing by exposing the swellable polymeric material to a fluid and expanding the swellable polymeric material into sealing engagement with the inner surface of the casing; and   placing the casing and the valve system into a wellbore within the downhole environment.   
     
     
         17 . The method of  claim 16 , wherein connecting the valve system to the inner surface of the casing is conducted above ground prior to placing the casing into the downhole environment, and wherein the valve system prevents wellbore fluid from entering the casing when in the wellbore. 
     
     
         18 . The method of  claim 16 , further comprising cementing the casing in the wellbore by injecting cement from the ground surface through the inside of the casing, out the valve system, and back up the wellbore outside of the casing. 
     
     
         19 . The method of  claim 16 , wherein an outer surface of the sealing element comprises gripping elements for gripping the inner surface of the casing, wherein the gripping elements comprise slip buttons, teeth, or a combination thereof, and wherein the gripping elements comprise a material selected from the group consisting of ceramic, metal, metal carbide, thermoplastic, and combinations thereof. 
     
     
         20 . The method of  claim 16 , wherein the swellable polymeric material is expanded by contacting the swellable polymeric material with the fluid, and wherein the fluid comprises an aqueous fluid, an organic fluid, or a combination thereof.