Big gap element sealing system

A sealing system for use in a downhole tool, the downhole tool being disposed in a casing such that a gap is formed between the downhole tool and the casing, the sealing system comprising:

• a packing element with a first end and a second end, the packing element disposed on a mandrel and having a pre-set cross-sectional thickness that is less than a cross-sectional thickness of the gap formed between the downhole tool and the casing, wherein a ratio of the cross-sectional thickness of the gap to the pre-set cross-sectional thickness of the sealing element is from about 1.05 to about 2.0;
• a first ring member disposed on the mandrel and at a first end of the packing element;
• a second ring member disposed on the mandrel and at a second end of the packing element, wherein the first ring member and the second ring member each comprise a laterally outward surface disposed at an angle between 5 degrees to 20 degrees relative to perpendicular to the mandrel, the laterally outward surface of each of the first ring member and the second ring member extending from the mandrel to a respective radially-outward end of the first ring member and the second ring member;
• a first seal ring disposed laterally outward of the first ring member;
• a second seal ring disposed laterally outward of the second ring member;
• a first inner back-up ring disposed laterally outward of the first seal ring;
• a first outer back-up ring disposed adjacent the first inner back-up ring;
• a second inner back-up ring disposed laterally outward of the second seal ring;
• and
• a second outer back-up ring disposed adjacent the second inner back-up ring.

A method of setting a packer in a wellbore, comprising:

• positioning the packer in the wellbore, the packer including:
• a mandrel;
• a packing element within the wellbore,
• a first ring member disposed on the mandrel and at a first end of the packing element;
• a second ring member disposed on the mandrel and at a second end of the packing element,
• a first seal ring disposed laterally outward of the first ring member;
• a second seal ring disposed laterally outward of the second ring member;
• a first inner back-up ring disposed laterally outward of the first seal ring;
• and
• a first outer back-up ring, disposed adjacent the first inner back-up ring;
• wherein positioning the packer comprises positioning the packing element at a distance from the wellbore bore that is more than a thickness of the packing element, wherein a ratio of the distance to the thickness of the packing element is from about 1.05 to about 2.0, the sealing packing element disposed between the first ring member and the second ring member,
• wherein the first ring member and the second ring member each comprise a laterally outward surface disposed at an angle between 5 degrees to 20 degrees relative to perpendicular to the mandrel, the laterally outward surface of each of the first ring member and the second ring member extending from the mandrel to a respective radially-outward end of the first ring member and the second ring member, and wherein the laterally outward surface of the first ring member is adjacent to the first seal ring and the laterally outward surface of the second ring member is adjacent to the second seal member;
• and
• setting the packing element such that the packing element forms a double hump configuration.