Patent Application
20090101362
1. Field of Invention
The invention is directed to anchor assemblies for slickline setting tools for downhole inflatables such as packers and bridge plugs. In particular, the invention is directed to anchor assemblies capable of providing resistance to slickline pumps so the slickline pumps can be reciprocated and the inflatables can be inflated.
2. Description of Art
Downhole inflatable devices such as bridge plugs and packers are well known in the industry, each having been extensively used over a substantial number of years. While bridge plugs and packers are distinct devices, for purposes of this application, the term “inflatables” refers to bridge plugs and packers, as well as any other downhole well device that is set through inflation.
Inflatables can be set within a wellbore using a slickline that is reciprocated upward and downward to reciprocate a pump that is part of the downhole string connected to the slickline. The pump forces fluid, e.g., wellbore fluid, into the inflatable causing the inflatable to expand and set within the wellbore. In order for the slickline to exert sufficient force to reciprocate the pump, the slickline first must be anchored within the wellbore. By anchoring the slickline, resistive force is provided so that the slickline can pull upward and push downward with the weight of the string to reciprocate the pump and, thus, inflate the inflatable. Because the slickline can inflate the inflatables by mechanical reciprocation, the slickline is not required to be capable of carrying electricity or otherwise carry electrical sources such as batteries to set the anchor assembly.
Broadly, anchor assemblies for use in downhole tool strings for setting an inflatable within a wellbore using a slickline comprise an anchor setting sub-assembly, an inflation sub-assembly disposed below the anchor setting sub-assembly, and an anchor release sub-assembly disposed below the inflation sub-assembly. In one embodiment, the anchor setting sub-assembly is actuated by hydrostatic pressure within the wellbore. The inflation sub-assembly and the anchor release sub-assembly, however, are actuatable by at predetermined fluid pressures, referred to as pump pressures or applied pressures or applied fluid pressures formed within a bore of a mandrel of the anchor assembly. For example, the inflation sub-assembly comprises a valve that is initially closed but is moved to an opened position by an applied pressure, i.e., a pressure that is created by pumping fluid into the bore of the mandrel. Thus, in the embodiment in which hydrostatic pressure actuates the anchor setting sub-assembly, the applied pressure that actuates the valve is greater than the hydrostatic pressure.
Likewise, the anchor release sub-assembly comprises a pump pressure actuatable mandrel release that is also actuated by an applied pressure. The release member is actuated at an applied pressure that is greater than the applied pressure that actuates the valve of the inflation sub-assembly. The mandrel release, when actuated, retracts the anchors that were previously set so that, after the inflatable is set and released by the anchor assembly, the downhole tool string comprising the anchor assembly can be removed from the wellbore.
In one embodiment, the anchor assembly is used to set the inflatable by running a downhole tool string on a slickline into a wellbore. In one particular embodiment, the downhole tool string comprises a pump, a trigger, an anchor assembly, and an inflatable, the pump being disposed above the trigger, the trigger being disposed above the anchor assembly, and the anchor assembly being disposed above the inflatable. The trigger is actuated to allow fluid to enter the anchor assembly and actuate the anchor assembly to radially expand an anchor from an anchor run-in position to an anchor set position in which the anchor engages an inner wall surface of the wellbore. Reciprocation of the slickline activates the pump to pump fluid through the trigger and into the anchor assembly to actuate a valve operatively disposed within the anchor assembly. Actuation of the valve allows fluid to flow into the inflatable where it inflates the inflatable due to additional reciprocation of the slickline to pump fluid through the trigger, through the anchor assembly, and into the inflatable until the inflatable is set within the wellbore. Additional reciprocation of the slickline causes the applied pressure within the anchor assembly to increase until the mandrel release is actuated causing the anchor to retract from the anchor set position to the anchor retracted position.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
Referring now to
Low pressure pump 16 and high pressure pump 18 for use with slickline 12 are known in the art. In general, low pressure pump 16 and high pressure pump 18 are reciprocating pumps having pistons (not shown) disposed within them. The pistons of low pressure pump 16 and high pressure pump 18 are activated by pulling upward on slickline 12 followed by pushing downward on slickline 12. The step of pushing downward on slickline 12 is understood to include releasing the tension on slickline 12 so that the weight of downhole tool string 10 pushes or forces downward the pistons of low pressure pump 16 and high pressure pump 18. One-way check valves 21 are disposed within low pressure pump 16 and high pressure pump 18 so that the fluid being pumped down downhole tool string 10 allows pressure to build up below pumps 16, 18 without allowing the pressure to escape upward.
Trigger 20 can be any type of setting tool known in the art. For purposes of the embodiments described herein, trigger 20 is a valve having an electronic circuit operated by a timer such as those available from Welbor Technology, Inc., located in Houston, Tex. The timer of trigger 20 is set to open fluid flow from high pressure pump 18 through trigger 20 and into anchor assembly 30. After opening, wellbore fluid is permitted to flow through trigger 20 and into anchor assembly 30. Accordingly, the timer can be customized to actuate at a predetermined time calculated based upon when the requisite pressure will be reached for initially actuating the anchors 60 (
In an alternative embodiment, trigger 20 may comprise a rupture disk (not shown) that breaks when hydrostatic pressure acting on the rupture disk reaches a predetermined level, generally equal to or greater than the predetermined level need to actuate anchor assembly 30 to initially set anchors 60 as discussed in greater detail below. Rupture disks are known in the art. Upon breaking of the rupture disk, wellbore fluid is permitted to flow into bore 19.
As illustrated by the arrows in
Referring now to
Anchor setting sub-assembly 32 comprises upper mandrel 44, piston housing 46, spacing adapter 48, inner mandrel 50, upper anchor connector 52, adjustable spacer nut 54, shear screw ring 56 with shear screw 58 dispose therein and releasably connected to inner mandrel 50, anchors 60 having slip surfaces 62 for engaging the inner wall surface of the wellbore (not shown), and lower anchor connector 64. Although many different types of slips 62 are known in the art and can be used with anchor assembly 30, in one specific embodiment, slips 62 include wickers for “biting” into the inner wall surface of the wellbore. Seals 45 are disposed throughout anchor setting sub-assembly 32 to reduce leakage between components. Anchors 60 are connected to upper anchor connector 52, to each other, and to lower anchor connector 64 by anchor pins 61 that, as discussed in greater detail below, provide a pivot point to facilitate extension and retraction of anchors 60 during operation of anchor assembly 30.
Piston housing 46 includes chamber 47 formed between an outer wall surface of upper mandrel 44 and an inner wall surface of piston housing 46. Chamber 47 is at atmospheric pressure. Piston housing 46 is in sliding engagement along the outer wall surface of upper mandrel 44 and engages a shoulder on spacing adapter 48. Spacing adapter 48 is fitted within a bore of adjustable spacer nut 54. Inner mandrel 50 engages a lower end of upper mandrel 44 and is disposed within a bore of spacing adapter 48, adjustable spacer nut 54, upper anchor connector 52, anchors 60, lower anchor connector 64, and the bores of certain components of anchor release sub-assembly 34. Inner mandrel 50 includes shear screw ring 56 along its outer wall surface and held in place by shear screw 58. Shear screw ring 56 is disposed below spacing adapter 48 in a cavity formed by the bore of adjustable spacer nut 54.
Anchor setting sub-assembly 32 is operatively connected to anchor release sub-assembly 34 by shear ring retainer 70 held in place by shear screws 72 and set screws 73. Anchor release sub-assembly 34 comprises mandrel release member 66, pull release ring 68, shear ring retainer 70 having shear screw 72 disposed therein and connected to lower anchor connector 64, release sleeve adapter 74, release sleeve 76, release piston 78, and release mandrel 80. As shown in
Release sleeve adapter 74 forms chamber 75 between the outer wall surface of inner mandrel 50 and an inner wall surface of release sleeve adapter 74. Chamber 75 is in fluid communication with the wellbore environment, i.e., outside of anchor assembly 30, by vent port 77 so that chamber 75 is at hydrostatic pressure. Release sleeve 76 forms chamber 79 between the outer wall surface of inner mandrel 50 and an inner wall Surface of release sleeve 76.
Release sleeve adapter 74 is in sliding engagement with an inner wall surface of release sleeve 76 so that anchors 60 can be retracted, i.e., disengaged from the inner wall surface of the wellbore to the position shown in
Release piston 78 is in sliding engagement with an outer wall surface of release mandrel 80 and release mandrel 80 is in sliding engagement with the outer wall surface of inner mandrel 50. Release mandrel 80 also includes port 81 in fluid communication with chamber 71 formed by an inner wall surface of release piston 78 and an outer wall surface of release mandrel 80. Release piston 78 includes a shoulder for engaging release sleeve 76. Release mandrel 80 includes a shoulder for engaging release piston 78. Seals 45 are disposed throughout anchor release sub-assembly 34 to reduce leakage between components.
Referring now to
Inflation valve sleeve 86 is shown in the embodiment of
Inflation valve mandrel 88 includes upper port 85, middle port 87, and lower port 89. Initially, inflation sub-assembly 36 is in its closed position (
Inflation valve housing 84 engages a shoulder disposed on lower mandrel 90 and the lower end of inflation valve mandrel 88 engages an inner shoulder disposed on lower mandrel 90. Lower mandrel 90 includes force compensator 110 comprising compensator housing 94 in sliding engagement along the outer wall surface of lower mandrel 90. Chamber 93 is formed between the inner wall surface of compensator housing 94 and the outer wall surface of lower mandrel 90. Disposed within chamber 93 is a compensation member. The compensation member is designed to compress as the inflatable inflates. In this manner, force compensator 110 allows bottom sub 99 to move downward as inflatable inflates and, thus, decreases its axially length along downhole tool string 10. In one embodiment, the compensation member comprises beveled bearing ring 92 and crush tube 96. Beveled bearing ring 92 facilitates crushing crush tube 96 as inflatable 24 (
To facilitate compression of crush tube 96, lower mandrel 90 engages an inner shoulder disposed on compensator nut 98. Compensator nut 98 is connected to lower mandrel 90 by set screw 95 and is releasably connected to compensator housing 94 by shear screw 97. Compensator housing 94 engages a shoulder on bottom sub 99 and set screw 95 secures compensator housing 94 to bottom sub 99. Seals 45 are disposed throughout inflation sub-assembly 36 to prevent leakage between components.
Suitable other compensation members include Belleville washers, also known as Belleville springs, coiled springs, and one or more shear screw without a crush tube.
In operation, downhole tool string 10 is assembled and run-in a wellbore to a desired depth. In so doing, hydrostatic pressure enters vent port 77 and vent port 91 so that the pressure within chamber 75 and chamber 83, respectively, as well as lower bore 41 through vent port 91 and port 89, is equalized with the wellbore, i.e., hydrostatic, pressure. Thus, all anchor assembly 30 components below inflation valve sleeve 86 are balanced with the wellbore pressure.
After disposing downhole tool string 10, trigger 20 is actuated or activated to permit fluid flow from the wellbore through trigger 20 and into anchor assembly 30. Actuation or activation of trigger 20 can use any mechanism or method to open fluid flow from the wellbore, through trigger, and into upper bore 39. The fluid, and its accompanying hydrostatic pressure, flows down upper bore 39, e.g., through the bore of upper mandrel 44, through the bore of inner mandrel 50, into the bore of release mandrel 80, through port 81, into chamber 71 of release piston 78, into the bore of inflation valve mandrel 88, and through upper port 85 into chamber 83 above inflation valve sleeve 86. As mentioned above, prior to fluid flowing into bore 39, e.g., into the bore of upper mandrel 44, through the bore of inner mandrel 50, into the bore of release mandrel 80, through port 81, into chamber 71 of release piston 78, into the bore of inflation valve mandrel 88, through upper port 85, and into chamber 83 above inflation valve sleeve 86, all of these areas were at atmospheric pressure so that piston housing 46 is forced to remain in the run-in position (
As illustrated in
Upon reaching a sufficiently strong force against shear screw ring 56, shear screw 58 breaks so that spacing adapter 48 can continue to be forced downward relative to inner mandrel 50 by piston housing 46 which also forces adjustable spacer nut 54 and upper anchor connector 52 downward relative to inner mandrel 60 causing anchors 60 to extend or “buckle” radially outward, i.e., pivot at anchor pins 61, causing slips 62 to be set by engaging the inner wall surface of the wellbore. Thus, anchors 60 are moved from their run-in position (
After anchors 60 are engaged with the inner wall surfaces, sufficient resistive force is provided by anchor assembly 30 so that slickline 12 can be pulled up and “pushed” downward, i.e., reciprocated, so that wellbore fluid is pumped through low pressure pump 16 and high pressure pump 18. It is to be understood that the act of “pushing” generally involves providing slack in slickline 12, i.e., decreasing tension in slickline 12, so that the weight of downhole tool string 10 above anchor assembly 30 will provide the “push” portion of reciprocation of low pressure pump 16 and high pressure pump 18.
As fluid is pumped down through upper bore 39 by low pressure pump 16 and, subsequently, high pressure pump 18, the fluid flows down the bore of upper mandrel 44, through the bore of inner mandrel 50, into the bore of release mandrel 80, into the bore of inflation valve mandrel 88, and through upper port 85 into chamber 83 above inflation valve sleeve 86. The pressure of the fluid being pumped down upper bore 39 is increased above hydrostatic pressure that is present below inflation valve sleeve 86. The pressure of this fluid is, therefore, referred to herein as “pump pressure” or “applied pressure.”
As pump pressure builds up within the areas in fluid communication with upper bore 39, inflation valve sleeve 86 is actuated by the pump pressure, such as by forcing the collet fingers away from flange 100 on the outer wall surface of inflation valve mandrel 88 so that inflation valve sleeve 86 is forced downward relative to inflation valve mandrel 88 to force wellbore fluid out of chamber 83 through vent port 91 and to ultimately block vent port 91 (
After upper bore 39 is placed in fluid communication with lower bore 41, wellbore fluid can be pumped through lower mandrel 90 and into an inflatable (not shown in
Wellbore fluid continues to be pumped through anchor assembly 30 by reciprocating lower pressure pump 16 and/or high pressure pump 18 as the case may be, to inflate the inflatable. As the inflatable inflates, the inflatable exerts a downward force on the entire downhole tool string 10. To reduce this force so inflatable 24 is not prematurely released or deflated, compensator housing 94 is pulled downward. As result, in one specific embodiment, compensator housing 94 compresses or crushes crush tube 96 between beveled bearing ring 92 and compensator nut 98 and pushes bottom sub 99 downward. Accordingly, large forces are prevented from developing between the anchor assembly 30 and the inflatable 24 during inflation which otherwise could pull release the inflatable, i.e., operate a deflation mechanism, or possibly part a connection between anchor assembly 30 and the inflatable.
After inflatable is sufficiently inflated so that the fluid pressure within anchor assembly 30 releases a certain threshold, more fluid begins to be pumped through port 81 of release mandrel 80 and into chamber 71 to act on release piston 78. Fluid flowing into chamber 71 causes release piston 78 to slide downward along the outer wall surface of release mandrel 80. Thus, chamber 71 enlarges in volume as more fluid is pumped down upper bore 39 of anchor assembly 30 until sufficient force acts downwardly on release piston 78 such that shear screw 72 breaks.
When shear screw 72 breaks, release piston 78 and, thus, shear ring retainer 70 and pull release ring 68 are forced downward along the outer wall surface of release mandrel 80 until pull release ring 68 no longer restricts movement of mandrel release member 66. Mandrel release member 66, therefore, disengages from the outer wall surface of inner mandrel 50 so that lower anchor connector 64 can slide downward along the outer wall surface of inner mandrel 50 and, thus, retract anchors 60 away from the inner wall surface of the wellbore. Inflatable can then be released by anchor assembly 30. Thus, because anchor assembly 30 is no longer secured to the wellbore or inflatable 24, downhole tool string 10 can be removed from the wellbore.
Alternatively, inflatable 24 could be deflated, e.g., after subsequent operation of another downhole tool, by additional application of tension, such as over-riding the stroke of force compensator 110. Downhole tool string 10 and, thus, anchor assembly 30 could then be retrieved with inflatable 24 still secured to downhole tool string 10.
In embodiments in which a hydraulic disconnect 22 is disposed between anchor assembly 30 and inflatable 24, the hydraulic disconnect 22 is designed to release the inflatable 24 when a slightly higher pressure is reached within upper bore 39 and lower bore 41 than the pressure within bore 39 required to activate mandrel release member 66. Therefore, anchor assembly 30 is released from the wellbore and, upon a slight increase in pressure within lower bore 41 by continued reciprocation of low pressure pump 16 and/or high pressure pump 18, hydraulic disconnect 22 is released from inflatable 24 so that downhole tool string 10 can be retrieved from the wellbore.
Referring now to
As mentioned above, in the embodiment shown in
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described as modifications and equivalents will be apparent to one skilled in the art. For example, crush tube 96 can be replaced by a series of Belleville washers (also know as a Belleville spring), a coiled spring, or any other similarly functioning compensator member. Additionally, compensator nut 98 is not required to provide resistive force for crush tube 96, the Belleville washers, or the coiled spring. Instead an inner shoulder disposed at the bottom end of compensator housing 94 can provide the resistive force. Moreover, low pressure pump and a high pressure pump can be replaced with a single pump capable of setting the inflatable, retracting the anchors and releasing the inflatable. Further, the release sleeve and the release piston and/or the inflation valve ring and the inflation valve housing can be a single component shaped to provide the structures described herein. In addition, connection of a component to another component is to be understood as including components being connected directly to and indirectly to other components so that one or more intervening components may be disposed between the two components, yet the two components are still deemed “connected to” one another. Moreover, wellbore fluid is not required to be used to create the pump pressure. Instead, fluid can be carried on the downhole tool string, such as in a reservoir so that the fluid is pumped from the reservoir down upper bore 39 and, subsequently, lower bore 41. Thus, the term “fluid” as used herein is to be understood as including fluid from the wellbore, as well as fluid from any other source. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
