Not applicable.
The present invention relates generally to a method and apparatus of attaching a downhole member to a cased wellbore and more particularly, to attaching a tool downhole within a cased wellbore.
As a hydrocarbon well is drilled, the bore hole is lined with a steel pipe known as casing. This casing is cemented to an outer casing or the surrounding earth formation and provides a strong, continuous lining of the sides of the borehole. A wide variety of downhole tools may be affixed to the inside of the casing for conducting a well operation as for example well reference members, pipe hangers, anchors, and packers. The connection of the tool to the inside of the casing is used to support pipe or other member within the casing, to pack off the flow bore of the casing, to anchor a well tool for conducting a well operation, or to resist forces produced by wellbore pressure, drilling operations, milling and sidetracking operations, or other downhole well operations and processes.
Typically downhole members are affixed to the inside of the casing by slips. Slips are normally made from a hardened material and are reciprocably supported in windows in a downhole member. The slips engage the casing through teeth on the outside of the slip. The inside of the slip normally has a tapered surface which interfaces with another tapered surface located on a cone member. When run into the wellbore, the slip is positioned outside of the cone with little or no engagement between the tapered surfaces. When the downhole member is set in place, the cone moves toward the slip forcing the tapered surfaces together. The interfacing tapered surfaces cam the slip outwardly into engagement with the wall of the casing. The cone remains in place behind the slip to maintain the engagement between the slip and the casing wall.
The cone and the slip are normally located on the outside of a central tubular body that often includes an open bore extending through the downhole member. The stacked location of the slip, cone, and body decrease and restrict the diameter of the flowbore through the casing. It is often advantageous to maximize the through bore in the downhole member in order to facilitate operations in the casing below the set downhole member. Many designs have been developed to maximize the through bore using the traditional cone and slip system. These designs often involved making the slips, cones, and body as thin as possible. These designs reach a limit in maximizing the through bore due to the pressures and loads which must be withstood by the downhole member.
The present invention overcomes these and other limitations of the prior art.
The present invention provides a method and apparatus to affix a tool to a cased wellbore. The apparatus includes a body with an engaging surface for an attaching engagement to the interior surface of an existing casing in a borehole. The engaging surface on the body has a first non-engaged position where the engaging surface does not engage the casing and an engaged position where the engaging surface does engage the casing. The engaging surface may be any surface which causes adequate engagement between the body and the casing to dispose the apparatus within the casing. The apparatus further includes an actuation member for actuating the engaging surface from the non-engaged position to the engaged position. The actuation member may be an expansion member which expands the engaging surface into engagement with the casing or which expands engaging surfaces, mounted on the body, into engagement with the casing.
A setting member extends through the body of the apparatus and is attached to one end of the body thus mounting the apparatus onto the setting member. That portion of the setting member extending through the body includes a piston member attached to the actuation member on the apparatus for actuating the movement of the apparatus to the engaging position. The apparatus is actuated to engage with the casing either by expanding the body of the apparatus into the engaging position or expanding the engaging surfaces mounted on the body into the engaging position.
A release member may be used to release the engagement of the apparatus from the casing. The release member is attached to one end of the apparatus body thus mounting the apparatus onto the release member. A portion of the release member extends through the apparatus body and that portion has a lower end which extends below the lower end of the apparatus. The release member portion also includes a piston member engaging the top of the actuation member on the apparatus for driving the actuation member out of the engagement with the apparatus body to release the apparatus from engagement with the casing. The release member is removed with the release member engaging the lower end of the apparatus to also remove the apparatus.
One embodiment of the present invention comprises a tubular body with a longitudinal slot extending along at least a portion of the longitudinal length of the body and a wedge member disposed within the slot. A portion of the slot is V-shaped to accommodate the wedge member with a corresponding V-shape. The outside of the tubular body has an engaging surface such as integral teeth. To set the apparatus, the wedge member is driven into the V-shaped slot. This movement widens the slot and expands the diameter of the tubular body until the engaging surface engages the interior surface of the wall of the casing. The teeth on the outside of the body bite into the casing wall to affix the apparatus in place within the casing.
The flow bore through the casing is only decreased by the thickness of the wall of the tubular body. The forces to be applied to the body determine the thickness of the wall of the tubular body. Therefore the thickness of the wall of the tubular body is minimized so as to be very thin and consequently provide a very large through bore. In a preferred embodiment, the diameter of the through bore of the apparatus in the engaged position is at least 70% of the diameter of the casing. The apparatus of the present invention is well suited for adaptation for use on any number of downhole tools including but not limited to well reference members, liner hangers, casing hangers, anchors, packers, and seal bores.
Thus, the present invention comprises a combination of features and advantages which enable it to overcome various problems of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.
For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:
Referring initially to
In using the terms “above”, “up”, “upward”, or “upper” with respect to a member in the well bore, such member is considered to be at a shorter distance from the surface through the bore hole 14 than another member which is described as being “below”, “down”, “downward”, or “lower”. “Orientation” as used herein means an angular position or radial direction with respect to the axis 16 of the borehole 14. In a vertical borehole, the orientation is the azimuth. The depth is defined as that distance between the surface of the cased borehole 14 and the location of the apparatus 10 within the cased borehole 14. “Drift diameter” is a diameter, which is smaller than the diameter Dc of the casing 12, taking into account the tolerance of the manufactured casing, through which a typical well tool will pass. Typically the drift diameter is approximately ⅛ inch smaller than the nominal diameter of the casing 12.
It is intended that the apparatus 10 be permanently installed within the borehole 14. Permanent is defined as the apparatus 10 being maintained in the cased borehole 14 at least throughout drilling operations. It should be appreciated that the apparatus 10 may be retrievable.
As shown in
The apparatus 10 further includes an actuation member 24 for actuating the engaging surface 20 from the non-engaged position to the engaged position. The actuation member 24 is an expansion member which is disposed in a V-shaped slot 26 in body 18. As actuation member 24 is driven into V-shaped slot 26, body 18 expands with engaging surface 20 into engagement with inner surface 22 of casing 12 or expands engaging surfaces mounted on body 18 into engagement with casing 12. In the engaged position, Dw approximates Dc. Preferably, the inner dimension Di of body 18 in the engaged position is greater than the outer dimension Dw in the non-engaged position such that an apparatus 10 in the non-engaged position will pass through an apparatus 10 in the engaged position.
It should be appreciated that only one or the other of the slot 26 and actuation member 24 need have tapered edges. For example, the slot 26 may only have parallel edges 34 and no tapered edges with the actuation member having tapered edges to spread the parallel edges 34 apart to expand body 18 as actuation member 24 is forced between parallel edges 34. Likewise, the actuation member 24 may have only parallel edges and slot 26 have tapered edges 35 whereby as actuation member 24 is driven between tapered edges 35, body 18 expands. Alternatively, it should be appreciated that the body 18 may be moved relative to a stationary actuation member 24 to expand body 18.
The preferred embodiment of the apparatus 10 has simplicity in that it is thin walled member comprised of only two pieces, i.e., a body and an actuation member.
It should also be appreciated multiple wedges may be disposed on the body 18 of apparatus 10. For example, there may be multiple wedges disposed around body 18, such as four wedges each approximately 90° from each other or three wedges each approximately 120° from each other.
Referring now to
It should be appreciated that slips 32 have teeth which bitingly engage the inside surface 22 of casing 12. This engagement may be varied by varying the number of teeth 33 on slips 32 or by varying the number of slips 32. The slips 32 place less stress into casing 12 than typical liner hangers. Because individual slips are not being used in the preferred embodiment, as in a typical liner hanger, there is a uniform stress distribution around the body 31 which is lower than that of the prior art. Although individual groupings of teeth 33 are shown, it should be appreciated that slips 32 may be evenly spaced around the surface of body 31 while achieving the same load carrying capacity of a hanger. Thus, the present invention has a more uniform load distribution of engagement between body 31 and casing 12. This causes less damage to the casing. Although teeth 33 have been shown on slips 32, it should be appreciated that any frictional surface around body 31 may be used, such as buttons or other frictional material, instead of individual pads with teeth.
As shown in
It should be appreciated that the wedge 38 may be of any size and edges 35, 40 may have any taper preferably less than 45° from the axis 16. The smaller the angle of the taper, the longer the stroke that is required by wedge 38 to achieve a predetermined radial expansion of body 31. A smaller taper angle better maintains wedge 38 within mule shoe V-shaped slot 36 since a smaller taper provides more hoop stress for the mechanical force provided by wedge 38. If the angle is made larger, less hoop stress is achieved. The preferred range of angles of edges 35, 40 for wedge 38 is 5-15° and most preferably 10° from the axis 16. This provides a stroke of approximately six inches by wedge 38 to achieve adequate expansion of well reference member 30 for a 9⅝ inch casing 12. This increases the diameter Dw of well reference member 30 by between ⅜ and ½ inches.
The upper end of body 31 includes an upwardly facing orienting surface 44 forming orientation member 45. The orienting surface 44 of orientation member 45 includes an inclined surface 46 extending from an upper apex to a lower opening 47 of slot 33. Orientation member 45 is sometimes referred to as a mule shoe. The orientation surface 44 is adapted to engage a complimentary mule shoe on a well tool. The complimentary mule shoe surfaces are radial helixes.
Best shown in
The reference member 30 has a diameter Di forming a central bore 15 therethrough with diameter Dw, in the engaged position, preferably approximating the drift diameter of casing 12. Diameter Di of reference member 30 preferably has a minimum diameter of at least 4 inches. It can be appreciated that the inside diameter Di in its contracted position may be adjustable by sizing the V-shaped slot 36.
After being expanded to the engaged position, the inside diameter Di of the well reference member 30 is also large enough to allow the passage of another well reference member 30 in the collapsed and nonengaged position. By allowing the same sized well reference member in its contracted position to pass through the expanded bore of another well reference member, multiple well reference members can be disposed anywhere in the well and may be stacked within the well.
The wall thickness T of body 31 is only as thick as is required to withstand the forces that will be applied to well reference member 30. Thus, the body 31 has a minimum wall thickness providing a maximum central bore 15 through body 31. Because there are no overlapping components, wall 39 of body 31 can be as thick as needed to engage and orient a subsequent well tool. In one preferred embodiment, the wall thickness T of body 31 is ⅜ of an inch thick. Thus, the inside diameter Di of body 31 is less than one inch, preferably ¾ of an inch, smaller than the diameter Dc of the casing 12. In a preferred embodiment, the diameter Di of the through bore of the apparatus 10 in the engaged position is less than 30% smaller than the diameter Dw of the casing 12 and at least 70% of the diameter Dw of the casing 12.
The inside diameter Di of reference member 30 in the engaged position is maximized with respect to the inside diameter Dc of casing 12. For example, it is typical to have a 7 inch casing as the innermost casing string in the well bore. A 7 inch casing has an inside diameter of approximately 6 inches and in a 7 inch casing, the diameter Di of reference member 30 has an inside diameter of at least 5 inches which is only one inch smaller than the diameter of casing 12. More preferably diameter Di has a diameter of 5½ inches which is only ½ inch smaller than the diameter Dc of casing 12. It is preferred that the diameter Di be no less than ¾ inch smaller than the diameter Dc of casing 12. This will allow a 4½ liner with 5 inch couplings to pass through reference member 30.
Diameter Dw of reference member 30 in the engaged position is sufficiently large to allow the next standard sized liner or casing string to pass therethrough. For example, if casing 12 were a 7 inch casing, the next standard size pipe would be 4½ inch pipe, such as a liner. In comparison, a 7 inch big bore packer has a throughbore of less than 4 inches and will not allow the passage of 5 inch couplings or a 4½ inch liner. If a big bore packer were used, a reduced size liner would be required such as a 3½ inch liner so as to pass through the bore of the big bore packer. If casing 12 were 9⅝ inch casing, reference member 30 would have a nominal diameter Dw in the engaged position of 8½ inches and would then accommodate a 7⅝ inch pipe. The diameter Di through reference member 30 would then preferably be between 7¾ and 8 inches. With the well reference member 30 in the expanded position, its outside diameter Dw is approximately 8⅜ inches.
The embodiment shown does not include a latch for attaching other tools or any sealing apparatus for sealing against the wellbore. This embodiment and its uses are further disclosed in U.S. patent application Ser. No. 09/860,870, filed on May 18, 2001, entitled “Well Reference Apparatus and Method”, now U.S. Pat. No. 6,543,536, hereby incorporated herein by reference. It should be appreciated that well reference member 30 may be adapted to latch onto adjacent tools and assemblies as hereinafter described.
Referring now to
Referring now to
Mandrel 62 and outer tubular member 66 form a cylinder 69 housing a piston 70. Piston 70 includes seals 71 which sealingly engage the inner surface of outer tubular member 66 and the outer surface of mandrel 62 and is held in place on mandrel 62 by shear screws 72 or similar releasable attachment means. A collet 74 is releasably attached to mandrel 62 by shear screws 75 or a similar releasable attachment means. Collet 74 includes an upper collar 76 having a plurality of downwardly extending collet fingers 78 with enlarged heads 80 on the end thereof. Collet heads 80 form an upwardly facing shoulder 81 which engages the lower end 48 of well reference member 30. As best shown in
Collet heads 80 project radially outward of the outer surface of well reference member 30 to protect the lower end 48 of well reference member 30. The outside diameter of heads 80 are slightly greater than the outside diameter of body 31 and are chamfered at 85. Heads 80 prevent lower terminal end 48 from hitting anything in the borehole 14 as it passes therethrough. In particular, it is important that nothing engage the lower terminal end 86 of wedge 38 which would tend to drive wedge 38 prematurely up into slot 36.
In the unactuated position shown in
Referring now to
The upward movement of wedge 38 is constrained by edges 35, 40 of V-shaped slot 36, wedge 38 and the interior surface 22 of casing 12. As piston 70 continues to move upwardly, wedge 38 is forced up into V-shaped slot 36 forcing the well reference member 30 to expand into its engaged position. Ultimately the force required to move wedge 38 further into slot 36 reaches the predetermined shear value of shear screws 52. Once the shear value is reached, the shear screws 52 shear, therefore releasing wedge 38 from setting tool 50. The hydraulic actuation of setting tool 50 moves wedge 38 upwardly and into V-shaped slot 36 expanding the outside diameter Dw of body 31 causing slips 32 to bitingly engage the interior surface 22 of casing 12. Now all of the collet fingers 78 move up underneath inside of body 31 and setting tool 50 is completely released from reference member 30. Setting tool 50 is then retrieved through the inside diameter Di of body 31.
It should be appreciated that the wedge 38 may be actuated other than by hydraulic means. For example, wedge 38 may be actuated mechanically or pyrotechnically.
Referring still to
Although apparatus 10 has been described with respect to
Apparatus 10 is not limited to its use as a well reference member or anchor and may be used in other applications. For example, apparatus 10 can also be used as a casing hanger, liner hanger, packer, or any other tool that is to be fixed within the wellbore 14. Another example is use with the system described in U.S. patent application Ser. No. 60/247,295, filed Nov. 10, 2000 and entitled Method and Apparatus for Multilateral Completion, hereby incorporated herein by reference.
Referring now to
Referring now to
Referring again to
The edges 105, 107 of slot 104 and wedge 106, respectively, are radial cuts along the radius of body 102 and along a helical surface so that the inside chordal length of the cut is less than the outside chordal length. This causes the opening between inside edges 107 of wedge 106 to be smaller than that of the outside edges 107. As wedge 106 moves upwardly into V-shaped slot 104, edges 105, 107 interengage, because of the chordal lengths, thereby preventing wedge 106 from moving interiorally of the opening formed by the inside chord of body 102. The outside surface of wedge 102 is maintained by casing 12.
It should be appreciated that wedge 106 may be of any size and edges 105, 107 may have a predetermined taper. The smaller the angle of the taper, the longer the stroke that is required by wedge 106 to achieve a predetermined expansion of body 102. Further, the taper on edges 105, 107 may be sized to provide a predetermined press fit between the engaging surfaces 108 of body 102 and the interior surface 22 of casing 12.
The wall thickness of body 102 is only as thick as is required to support the liner string in the borehole 14. Thus, the body 102 has a minimum wall thickness providing a maximum central bore 103 through body 102. Because there are no overlapping components, the wall of body 102 can be as thick as needed to hang the liner.
The liner hanger 100 of
The inside diameter Di of body 102 in the engaged position is maximized with respect to the inside diameter Dc of casing 12. After being expanded to the engaged position, the bore 103 of the liner hanger 100 is large enough to allow the passage of other well tools and pipe strings.
Referring now to
The upper body 202 is a tubular body 210 having a bore 224 therethrough and a plurality of V-shaped slots 212 that accommodate an equal number of wedge members 214. V-shaped slots 212 are disposed in the mid-portion 213 of upper body 202 between upper annular end 211 and lower end 222. Each V-shaped slot 212 has tapered sides or edges 230 for receiving a wedge member 214 having complimentary tapered sides or edges 232. The upper body 202 has cut away portions 216 allowing one end of the wedges 214 to extend below slots 212. The upper body 202 is equipped with teeth 218 around the outside diameter to grip the inside of the casing. The wedges 214 may also have teeth 220 on the outside surfaces to enhance attachment to the casing 12. Although teeth 218 and 220 have been shown as the engaging surface, it should be appreciated that any frictional surface may be disposed on body 202, such as buttons or an abrasive material.
The edges 230, 232 of slot 212 and wedge members 214, respectively, are radial cuts along the radius of body 202 and along a helical surface so that the inside chordal length of the cut is less than the outside chordal length. This causes the opening between the inside edges 232 of wedge member 214 to be smaller than that of the outside edges 232. As wedge member 214 moves upwardly into V-shaped slot 212, edges 230, 232 interengage, because of the chordal lengths, thereby preventing wedge member 214 from moving interiorally of the opening formed by inside chord of body 202. The outside surface of wedge member 214 is maintained by casing 12.
It should be appreciated that sealing element 208 may be located at various locations on body 202. For example, the sealing element 208 may cover and/or be bonded to teeth 218, 220. Further anti-extrusion rings may be placed on each side of the sealing element 208 to prevent extrusion. The sealing element 208 may be upset to ensure that the sealing element 208 spans any clearance or gap between the packer body and casing 12.
It should be appreciated that wedge member 214 may be of any size and edges 230, 232 may have a predetermined taper. The smaller the angle of the taper, the longer the stroke that is required by wedge member 214 to achieve a predetermined expansion of body 202. Further, the taper on edges 230, 232 may be sized to provide a predetermined press fit between the engaging surfaces 218, 220 on the mid-portion 213 of upper body 202 and the interior surface 22 of casing 12.
The wall thickness of upper and lower body 202, 204 is only as thick as is required for the packer 200 to serve its functions in the borehole 14. Thus, upper and lower body 202, 204 has a minimum wall thickness providing maximum central bores 224, 226 through upper and lower body 202, 204. Because there are no overlapping components, the wall of upper and lower body 202, 204 can be as thick as needed.
The packer 200 of
The inside diameter Di of upper and lower body 202, 204 in the engaged position is maximized with respect to the inside diameter Dc of casing 12. After being expanded to the engaged position, the bores 224, 226 of packer 200 are large enough to allow the passage of other well tools and pipe strings.
In each of the embodiments described above, the apparatus 10 may be released from the casing 12. A release member may be used to release the engagement of the apparatus from the casing. The release member is attached to one end of the apparatus body thus mounting the apparatus onto the release member. A portion of the release member extends through the apparatus body and that portion has a lower end which extends below the lower end of the apparatus. The release member portion also includes a piston member engaging the top of the actuation member on the apparatus for driving the actuation member out of the engagement with the apparatus body to release the apparatus from engagement with the casing. The release member is removed with the release member engaging the lower end of the apparatus to also remove the apparatus.
All of the above-described embodiments feature the benefit of the wedge means for actuating the apparatus 10 into engagement with the casing 12. Further, the apparatus 10 provides a large through bore after setting of the apparatus 10. This expands the range of tools that can then be run through the apparatus 10 after it has been set. The bores of any of the embodiments of the present invention may contain other features to allow the tools to interface with other downhole tools. These types of features include latches and grooves for locking or anchoring other tools to the apparatus 10 such as an insert, liner hanger, anchor, packer, or seal bores for sealing a smaller diameter tubular against the inside diameter of the apparatus 10, and orientation surfaces or muleshoes for orienting other tools, such as whipstocks or mills, within the wellbore 14.
While preferred embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims.
The present application claims the benefit of 35 U.S.C. 119(e) of U.S. provisional application Ser. No. 60/291,833 filed May 18, 2001, and entitled “Casing Attachment Method and Apparatus”, and further, this application is related to U.S. patent application Ser. No. 09/860,870, filed on May 18, 2001 and entitled “Well Reference Apparatus and Method,” now U.S. Pat. No. 6,543,536, both hereby incorporated herein by reference.
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4711326 | Baugh et al. | Dec 1987 | A |
4750563 | Baugh | Jun 1988 | A |
5014782 | Daspit | May 1991 | A |
5168933 | Pritchard, Jr. et al. | Dec 1992 | A |
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Number | Date | Country |
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WO 0188336 | Nov 2001 | WO |
Number | Date | Country | |
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20020174992 A1 | Nov 2002 | US |
Number | Date | Country | |
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60291833 | May 2001 | US |