Patent Application
20240133273
Typically, expandable liner hangers (ELH) rely on multiple metal ribs contacting an inner diameter (ID) of casing to set the ELH. This creates a void between the ELH body, the adjacent ELH ribs, and the casing ID that the ribs have contacted upon expansion. This void may be filled with non-compressible fluid which limits the engagement of the ribs to the casing ID during the expansion process.
Alternatively, the void may be filled with a compressible fluid which allows unrestrained engagement of the ribs with the casing ID, but during subsequent thermal cycles, the fluid may expand and reduce rib engagement with the casing ID. One existing design of ELH incorporates an elastomer in the void so that no fluid is trapped, however, the elastomer fills the void which may restrict full engagement of the ribs to the casing ID.
These drawings illustrate certain aspects of some examples of the present disclosure and should not be used to limit or define the disclosure.
The present disclosure relates to an ELH mechanism for increasing the effective volume in the void space once the ribs engage the casing ID allowing for full engagement during expansion, as well as mitigating a reduction of engagement forces for the ribs during thermal cycles (e.g., urges engagement of the ribs against the casing). The void space may be defined by a body of the ELH, the ribs, and the casing ID. The ELH mechanism incorporates a closed cell foam member within the void space between adjacent ribs. The foam has a solid mass (at least partially solid) of known total volume including a percentage (e.g., 5%-80%) for air composition via air pockets that are not connected to the surrounding void. This closed cell structure has porosity but no permeability.
The available fluid volume between the ribs is the rib-to-rib volume less the volume of the closed cell foam member in its run-in-hole (RIH) state. The foam member when exposed to either increased pressure from adjacent fluid or to mechanical load from the expansion process, collapses, and crushes the air pockets thereby reducing the volume of the foam member in addition to connecting some or all of the air pockets to the outside void.
With the reduction of the total volume of the foam and inclusion of some of the foam air pocket volumes to the available fluid volume, the available fluid volume between the ribs increases upon failing of the foam. This increased fluid volume then allows for unrestricted rib expansion with non-compressible fluids or mitigates rib engagement reduction from compressible fluid expansion due to thermal cycles. The mechanism also provides a minimal increase in buoyancy, thereby reducing the effective weight of the hanger which facilitates deployment in extended reach wells. The mechanism also mitigates any pressure increase in the fluid volume through thermal expansion.
The foam member may be manufactured from any number of materials for example, polymers such as polyurethane, elastomers, metals, ceramics, resins, and/or composites. The foam may fill the entire void between the ribs or at least a portion of the void. The foam may be shaped in any geometry within the spacing between the adjacent ribs and may include a single member or multiple members spaced around the body of the hanger. The percentage of air pockets may be modified to engineer the collapse pressure/load to the specific scenario. The air pockets may incorporate or be generated by hollow beads/spheres to further enhance collapse capacity. These spheres can be made from glass, composite, ceramic, polymer, metal and/or other materials. The foam member may be attached to the ELH member in a variety of ways including bonded directly, mechanically connected, a combination of both or other means.
The foam member 300 may be manufactured from any number of materials for example, polymers such as polyurethane, elastomers, metals, ceramics, resins, and/or composites. The foam may fill the entire void 302 between the ribs 202a and 202b or at least a portion of the void 302. The foam may be shaped in any geometry within the spacing between the adjacent ribs and may include a single member or multiple members spaced around the body 200 (e.g., along circumference) of the tool 100 (e.g., ELH). The foam member 300 may be attached to the body 200 in a variety of ways including bonded directly, mechanically connected, a combination of both or other means.
The available fluid volume between the rib 202a and the rib 202b is the rib-to-rib volume less the volume of the closed cell foam member 300 in its run-in-hole (RIH) state. Thicknesses of the foam member and other dimensions such as length and width may vary depending on particular applications. In some non-limiting examples, a thickness may range from 0.1 inch to 6 inches; a length around a tubular body may vary depending on diameter of tubular body (e.g., 2-20 inches or more); and a width from rib to rib may vary (e.g., 1-20 inches or more).
With the reduction of the total volume of the foam and inclusion of some of the foam air pocket volumes (shown on
The air pockets 502 (e.g., closed cells) may incorporate or be generated by hollow beads/spheres/particles 503 to further enhance collapse capacity. These spheres can be made from glass, composite, ceramic, polymer, metal and/or other materials. The foam member 300 when exposed to either increased pressure from adjacent wellbore fluid 500 or to mechanical load from the expansion/setting process, collapses, and crushes the air pockets 502 thereby reducing the volume of the foam member 300 in addition to connecting some or all of the air pockets to the outside the void 302.
With the reduction of the total volume of the foam and inclusion of some of the foam air pocket volumes to the available fluid volume, the available fluid volume between the ribs increases upon failing of the foam. This increased fluid volume then allows for unrestricted rib expansion with non-compressible fluids or mitigates rib engagement reduction from compressible fluid expansion due to thermal cycles. The mechanism also provides a minimal increase in buoyancy, thereby reducing the effective weight of the hanger which facilitates deployment in extended reach wells.
The foam may fill the entire void between the ribs or at least a portion of the void (see
The air pockets may incorporate or be generated by hollow beads/spheres to further enhance collapse capacity. These spheres can be made from glass, composite, ceramic, polymer, metal and/or other materials. Thicknesses of the foam member and other dimensions such as length and width may vary depending on particular applications. In some examples, a thickness may range from 0.1 inch to 6 inches. A length/distance around a tubular body may vary depending on diameter of tubular body (e.g., 2-20 inches or more). The width/distance from rib to rib may vary (e.g., 1-20 inches or more). The foam member may be attached to the ELH member in a variety of ways including direct bonding, mechanical connections, a combination of both or other means.
At step 702, the foam member is compressed (see
At step 704, the available fluid volume between the ribs increases due to compression of the foam member. This increase in fluid volume urges full engagement of the ribs against the casing ID upon expansion/setting of the ELH. This allows for a more secure hold/grip within the casing/conduit during mechanical loading (setting/expanding ribs) and pressure fluctuations due to temperature changes in the well. Increasing available fluid volume between the ribs upon compression of the foam member reduces effective pressure between the ribs and urges full engagement of the ribs against the casing ID during expansion of the ELH.
Accordingly, the systems and methods of the present disclosure increase fluid volume during mechanical loading and thermal cycling via a foam member disposed in a void defined by the ELH and casing engaged by the ELH. The systems and methods may include any of the various features disclosed herein, including one or more of the following statements.
Statement 1. A downhole tool comprising: a tubular body; ribs extending along a circumference of the tubular body; and at least one foam member disposed on the tubular body and between the ribs.
Statement 2. The downhole tool of the statement 1, wherein the at least one foam member includes closed cells.
Statement 3. The downhole tool of the statement 1 or the statement 2, wherein the at least one foam member includes air pockets.
Statement 4. The downhole tool of any one of the statements 1-3, wherein the at least one foam member includes hollow particles.
Statement 5. The downhole tool of any one of the statements 1-4, wherein the ribs are expandable.
Statement 6. The downhole tool of any one of the statements 1-5, wherein the at least one foam member is attached to the tubular body.
Statement 7. A system comprising: a downhole tool comprising: a tubular body; ribs extending along a circumference of the tubular body; and at least one foam member disposed on the tubular body and between the ribs; and a conduit, the downhole tool disposed in the conduit, wherein a void is defined by the tubular body, the ribs, and the conduit, wherein the at least one foam member is disposed in the void.
Statement 8. The system of the statements 7, wherein fluid is disposed in the void.
Statement 9. The system of any one of the statements 7-8, wherein the ribs are expandable.
Statement 10. The system of any one of the statements 7-9, wherein the at least one foam member includes air pockets.
Statement 11. The system of any one of the statements 7-10, wherein the at least one foam member includes hollow particles.
Statement 12. The system of the statement 11, wherein the at least one foam member is attached to the tubular body.
Statement 13. A method comprising: disposing a downhole tool in a conduit, the downhole tool comprising: a tubular body; ribs extending along a circumference of the tubular body; and at least one foam member disposed on the tubular body and between the ribs; and contacting an inner surface of the conduit with the ribs, wherein a void is defined by the tubular body, the ribs, and the conduit, wherein the at least one foam member is disposed in the void.
Statement 14. The method of the statement 13, further comprising compressing the at least one foam member to increase fluid volume within the void.
Statement 15. The method of any one of the statements 13-14, wherein contact between the ribs and the inner surface of the conduit occurs during expansion of the downhole tool.
Statement 16. The method of any one of the statements 13-15, wherein fluid is disposed in the void.
Statement 17. The method of any one of the statements 13-16, wherein the at least one foam member includes closed cells.
Statement 18. The method of any one of the statements 13-17, wherein the at least one foam member includes air pockets.
Statement 19. The method of any one of the statements 13-18, wherein the at least one foam member includes hollow particles.
Statement 20. The method of any one of the statements 13-19, wherein the conduit comprises casing.
Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations may be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. The preceding description provides various examples of the systems and methods of use disclosed herein which may contain different method steps and alternative combinations of components. It should be understood that, although individual examples may be discussed herein, the present disclosure covers all combinations of the disclosed examples, including, without limitation, the different component combinations, method step combinations, and properties of the system. It should be understood that the compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces.
For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.
Therefore, the present examples are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular examples disclosed above are illustrative only and may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual examples are discussed, the disclosure covers all combinations of all of the examples. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative examples disclosed above may be altered or modified and all such variations are considered within the scope and spirit of those examples. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
