Patent Application
20060102361
1. Field of the Invention
The invention relates generally to improved methods and devices for setting a packer assembly within a wellbore.
2. Description of the Related Art
Packer assemblies are used to secure production tubing within a wellbore. These assemblies typically include an elastomeric seal that is radially expandable to engage the wellbore surface and may also include a set of slips that have serrated or toothed portions that, when set, bitingly engage the wellbore surface. Packer assemblies of this type are often used when it is desired to “tie back” from a section of casing that has been previously set by cementing into the wellbore. There are potential problems in locating and setting the packer assembly in this instance. Typically, the upper end of the previously set casing has a liner hanger with a seal bore. It is desired to land the packer assembly into this seal bore and then set it to secure it within the wellbore. One potential solution would be to use a mechanically set packer. Unfortunately, mechanical setting of this type typically requires that the packer assembly be landed onto a structure (i.e., the liner hanger) in the wellbore. Thus, the packer assembly will be located immediately atop the liner hanger when it may be desired to locate the packer assembly at a distance above the liner hanger.
Additionally, it is desired to have an improved manner and arrangement for setting of a packer assembly within the wellbore to ensure that the slips are well set to structurally anchor the packer assembly in place and that proper fluid seals are established within the annulus of the wellbore.
The present invention addresses the problems of the prior art.
In aspects, the present invention provides a robust packer assembly having features that provide long-term protection against fluid leaks in a wellbore tubular such as a casing or liner. In one embodiment, the packer includes a body, two axially spaced apart seal elements that form a hydraulic chamber or cavity upon being set, and an anchor that secure the packer in the wellbore. The packer includes a hydraulic actuator that sets the seal elements and the anchor. Advantageously, the hydraulic chamber formed by the seal elements substantially isolates any fluid that potentially leaks out of the hydraulic actuator. In one mode of deployment, the seal elements are sequentially set. For example, frangible elements such as shear pins having appropriately selected shear strengths can be use to retain the seal and anchor elements. To set the seals and anchor elements, fluid pressure in the wellbore can be progressively increased to sequentially break the shear pins and set the seal and anchor elements. In one embodiment, the slip anchor includes two sets of slips located axially between the first and second seal elements. In certain embodiments, the first seal element, the and second seal element, and the anchor are adapted to be retracted or otherwise disengaged from the adjacent wellbore tubular. After these elements are unset, the packer can be retrieved using a suitable work string.
The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
In this instance, it is desired to tie back the lower production tubing string to provide a flowline to the surface 26. To accomplish this, a production tubing string 28 is lowered into the wellbore 10 from the wellhead 14. At the lower end of the production tubing string 28 includes a packer assembly 30, in accordance with the present invention. An annulus 32 is defined between the production tubing string 28 and the wall of the wellbore 10.
Beginning at the upper end, the packer assembly 30 includes an upper inner mandrel 42. A central axial flowbore 44 is defined within packer assembly 30 by the inner mandrel 42 and those components axially secured thereto, which make up the packer assembly body. The upper end (not shown) of the mandrel 42 is secured to the production tubing string 28 by threaded connection, as is known in the art. The outer surface of the mandrel 42 features a ramped surface 46. At its lower end (
Returning to the upper portions of the packer assembly 30, it is noted that the upper seal assembly 34 is preferably of the type known as a “ZX seal,” which is available commercially from Baker Oil Tools of Houston, Tex. Other seals or seal types, however, may also be utilized. The seal assembly 34 includes a conical sleeve portion 54 that surrounds the mandrel 42 and an engagement element 56 that is typically fashioned of elastomer for creating a sealing engagement with the wall of the wellbore 10. The lower end of the sleeve portion 54 is secured by set screw 57 and threads to a setting sleeve 58 that is releasably secured to the inner mandrel 42 by a set of shear pins 60. The hydraulic actuator 41 includes a cylinder 62 that radially surrounds the inner mandrel 42 and that is releasably secured to the setting sleeve 58 by a second set of shear pins 64. A hydraulic fluid chamber 66 is defined between the cylinder 62 and the inner mandrel 42. A fluid communication port 68 in the inner mandrel 42 allows fluid from the flowbore 44 to enter the fluid chamber 66. Fluid chamber 66 is sealed by annular fluid seals 70, 72, and 74. An annular piston member 76 and a body lock ring 78 are retained within the fluid chamber 66. The body lock ring 78 is a known component having a radially interior toothed surface that engages a ratchet-like outer surface on the inner mandrel 42.
The lower end of the cylinder 62 is secured by set screws 80 to a second body lock ring 82. The second body lock ring 82 is threadedly connected to a slip setting sleeve 84. The slip setting sleeve 84 features a plurality of ramped surfaces 86 that underlie the upper slip elements 36. An annular ring 88 interconnects the upper slip elements 36 to lower slip elements 38. The ring 88 is secured to upper slips 36 by a set of shear screws 89. It is noted that the slip elements 36 and 38 both have toothed outer surfaces for engaging the wall of the wellbore 10 and that both sets of slip elements 36, 38 can be moved radially outwardly independently of the other set. Slip setting sleeve 90 is located at the lower end of the lower slip elements 38 and presents a number of ramped surfaces 92 that underlie the slip elements 38. The slip setting sleeve 90 is retained in place by lower collar 94 and set screws 96. It should be understood that the use of two sets of slips is only one exemplary embodiment of an anchor. The use of two slip can facilitate design since each set of slips can be configured to engage and secure the packer in opposing axial direction. Other suitable arrangements could include one set of slips that secure the packer in both axial directions. In still other embodiments, an anchor may be omitted from the packer arrangement if, for example, the packer can be suitable suspended in the wellbore by other means.
Lower down on the packer assembly 30, is the lower assembly 40 (see
It is noted that the different sets of shear pins 60, 64, 89, and 104 are provided with different shear values so that they require different amounts of axial force to shear. In one embodiment, shear pins 64 require the lowest amount of force to shear and will, therefore, shear first. Shear pins 89 require the next lowest amount of force to shear and will shear in response to a second, higher amount of force. Shear pins 104 require a higher level of force to shear than the shear pins 89, while shear pins 60 require the highest amount of force to shear and will, therefore, shear last. It should be understood that shear pins are merely representative of any number of frangible elements that are formed to fracture or disintegrate upon application of a predetermined amount of force.
In operation, the production tubing string 28 and affixed packer assembly 30 are lowered into the wellbore 10 to a location where it is desired to set the packer assembly 30. The sub portion 126 of the packer assembly 30 is disposed, at least partially, into the seal bore 24 of the liner hanger 18. Actuation of the packer assembly 30 is accomplished by flowing pressurized hydraulic fluid through the production tubing 28 and into the flowbore 44 within the packer assembly 30. The pressurized fluid actuates the hydraulic actuator 41 upon entering the two fluid chambers 66 and 108 via ports 68, 120, respectively. As fluid pressure is increased within the flowbore 44 and the two fluid chambers 66, 108, the shear pins 64, 89,104, 60 will shear in order, thereby causing the slips 36, 38 and the seal assemblies 34, 40 to become set in a predetermined order. This process is best understood with further reference to
When pressure within the flowbore 44 is further increased to a second predetermined level, the shear screws 89 will be sheared, thereby allowing the upper slips 36 to be urged outwardly by the ramped surfaces 86 of the upper slip setting sleeve 84. The upper slips 36 will be brought into contact with the wall of the wellbore 10, and at this point, the packer assembly 30 will be in the position illustrated in
Fluid pressure within the flowbore 44 is now increased to a further level that is sufficient to shear the third set of shear screws 104. This frees the lower setting sleeve 102 from connection to the cylinder 106. Fluid pressure within the lower fluid chamber 108 will urge the setting sleeve 102 downwardly along with the affixed sleeve portion 98 and seal element 100. Ramped surface 52 will urge the seal element 100 radially outwardly and into contact with the wall of the wellbore 10 in order to establish a fluid seal. At this point, the packer assembly 30 is in the configuration depicted in
Finally, fluid pressure within the flowbore 44 is then increased still further to a level that is sufficient to shear the final set of shear screws 60. When this occurs, the upper setting sleeve 58, sleeve portion 54 and seal element 56 are freed to move axially upwardly upon the inner mandrel 42. The ramped surface 46 causes the seal element 56 to be urged radially outwardly and brought into contact with the wellbore 10 wall. Now, the packer assembly 30 is in the position shown in
The staged or sequential setting process for the packer assembly 30 can be advantageous. Setting of the slips 36, 38 first, allows the packer assembly 30 to be mechanically anchored within the wellbore 10 before the seal assemblies 34, 40 are set, thereby assuring that the seal assemblies 34, 40 will be set where intended and without axial slippage. Also, when seal assemblies 34, 40 are set, it is known that they physically displace fluid in the annulus 32. If both seal assemblies were to be set at the same time, mutual displacement of fluid within the annulus 32 might result in incomplete setting of both assemblies 34, 40. Once this upward movement of fluid has equalized, the upper slip assembly 34 can be set thereafter.
As noted previously, fluid seal redundancy is provided by the use of two seal assemblies 34, 40. Both seals provide barriers that prevent fluid migration across the packer assembly 30. The packer assembly 30 adds a premium seal barrier beyond what conventional assemblies are believed to provide. Additionally, wellbore fluids trapped in the annulus 32 between the two seal assemblies 34, 40 will actually improve the fluid sealing capability of the packer assembly 30. As the fluid heats up during subsequent production, it expands and enhances the seal created by the two seal assemblies 34, 40 by the exertion of fluid pressure against them.
The dual seal assembly also serves to hydraulically isolate the hydraulic actuation portions of the packer assembly 30 from wellbore fluids in the annulus 32. In the event that one or more of the O-ring seals 70, 72, 74, or 110, 112, 114 fails, tubing fluid in the fluid chambers 66, 108 might leak into the annulus 32. The seal assemblies 34, 40 will contain this fluid with the hydraulic cavity or chamber 35.
It is noted that in this embodiment the setting of the packer assembly 30 is a permanent set due to the action of the body lock rings 78, 82, 118, which maintain the assembly 30 in the set position. However, it should be understood that the packer assembly 30 can also be retrievable. For example, elements such as the slips and seals can be adapted to retract or otherwise disengage from the wall to which they are engaged. Once disengaged, the packer assembly 30 can be retrieved utilizing a suitable work string.
The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope of the invention.
This application takes priority from U.S. Provisional Application Ser. No. 60/603,900 filed on Aug. 24, 2004.
| Number | Date | Country | |
|---|---|---|---|
| 60603900 | Aug 2004 | US |
