Patent Application
20100012330
This invention relates, in general, to packer setting mechanisms used in a wellbore that traverses a subterranean hydrocarbon bearing formation and, in particular, to an interventionless set packer and method for setting same.
Without limiting the scope of the present invention, its background will be described in relation to setting packers, as an example.
In the course of treating and preparing a subterranean well for production, well packers are commonly run into the well on a conveyance such as a work string or production tubing. The purpose of the packer is to support production tubing and other completion equipment, such as sand control assemblies adjacent to a producing formation, and to seal the annulus between the outside of the production tubing and the inside of the well casing to block movement of fluids through the annulus past the packer location.
Production packers and other types of downhole tools may be run down on production tubing to a desired depth in the wellbore before they are set. Certain conventional production packers are set hydraulically, requiring that a pressure differential be created across a setting piston. Typically, this is accomplished by running a tubing plug on wireline, slick line, electric line, coiled tubing or another conveyance means through the production tubing down into the downhole tool. Then the fluid pressure within the production tubing is increased, thereby creating a pressure differential between the fluid within the production tubing and the fluid within the wellbore annulus. This pressure differential actuates the setting piston to expand the production packer into sealing engagement with the production liner or casing. Before resuming normal operations through the production tubing, the tubing plug must be removed, typically by retrieving the plug back to the surface of the well.
As operators increasingly pursue production completions in deeper water offshore wells, highly deviated wells and extended reach wells, the rig time required to set a tubing plug and thereafter retrieve the plug can negatively impact the economics of the project, as well as add unacceptable complications and risks. To address the issues associated with hydraulically-set downhole tools, an interventionless setting technique was developed. In particular, a hydrostatically-actuated setting module was designed to be incorporated into the bottom end of a downhole tool, and this module exerts an upward setting force on the downhole tool. The hydrostatic setting module may be actuated by applying pressure to the production tubing and the wellbore at the surface, with the setting force being generated by a combination of the applied surface pressure and the hydrostatic pressure associated with the fluid column in the wellbore. In particular, a piston of the hydrostatic setting module is exposed on one side to a vacuum evacuated initiation chamber that is initially closed off to wellbore annulus fluid by a port isolation device, and the piston is exposed on the other side to an enclosed evacuated chamber generated by pulling a vacuum.
In operation, once the downhole tool is positioned at the required setting depth, surface pressure is applied to the production tubing and the wellbore annulus until the port isolation device actuates, thereby allowing wellbore fluid to enter the initiation chamber on the one side of the piston while the chamber engaging the other side of the piston remains at the evacuated pressure. This creates a differential pressure across the piston that causes the piston to move, beginning the setting process. Once the setting process begins, O-rings in the initiation chamber move off seat to open a larger flow area, and the fluid entering the initiation chamber continues actuating the piston to complete the setting process. Therefore, the bottom-up hydrostatic setting module provides an interventionless method for setting downhole tools since the setting force is provided by available hydrostatic pressure and applied surface pressure without plugs or other well intervention devices.
However, the bottom-up hydrostatic setting module may not be ideal for applications where the wellbore annulus and production tubing cannot be pressured up simultaneously. Such applications include, for example, when a packer is used to provide liner top isolation or when a packer is landed inside an adjacent packer in a stacked packer completion. The production tubing can not be pressured up in either of these applications because the tubing extends as one continuous conduit out to the pay zone where no pressure, or limited pressure, can be applied.
In such circumstances, if a bottom-up hydrostatic setting module is used to set a packer above another sealing device, such as a liner hanger or another packer, for example, there is only a limited annular area between the unset packer and the set sealing device below. Therefore, when the operator pressures up on the wellbore annulus, the hydrostatic pressure begins actuating the bottom-up hydrostatic setting module to exert an upward setting force on the packer. However, when the packer sealing elements start to engage the casing, the limited annular area between the packer and the lower sealing device becomes closed off and can no longer communicate with the upper annular area that is being pressurized from the surface. Thus, the trapped pressure in the limited annular area between the packer and the lower sealing device is soon dissipated and may or may not fully set the packer.
Therefore, a need has arisen for an interventionless operable to fully set a downhole tool, such as a packer, within a wellbore that is not dependent upon surface pressure being applied to the wellbore annulus to set the packer.
The present invention disclosed herein comprises an interventionless set packer that does not require the use of surface pressure being applied to the wellbore annulus for setting.
In one aspect, the present invention is directed to a packer for establishing a sealing engagement with a surface disposed in a wellbore. The packer includes a packer mandrel and a seal assembly that is slidably disposed about the packer mandrel. The seal assembly has a running position and a radially expanded sealing position. A piston is slidably disposed about the packer mandrel and is operably associated with the seal assembly. A collet assembly is disposed about the packer mandrel and is releasably coupled to the piston such that radially inwardly shifting at least portion of the collet assembly decouples the collet assembly from the piston allowing the piston to shift longitudinally relative to the packer mandrel which operates the seal assembly from the running position to the radially expanded sealing position, thereby setting the packer.
In one embodiment of the packer, the piston and packer mandrel define a chamber that is at a pressure lower than the pressure of the wellbore such as atmospheric pressure, a vacuum or the like. In another embodiment, the collet assembly includes a plurality of collet fingers. In this embodiment, the collet fingers may include radially outwardly extending protrusions that extend radially outwardly beyond an outer diameter of the piston. Also in this embodiment, the piston may include a detent formed in its inner surface for releasably engaging a tab of each of the collet fingers.
In another aspect, the present invention is directed to a packer for establishing a sealing and gripping engagement with a surface disposed in a wellbore. The packer includes a packer mandrel and a seal assembly that is slidably disposed about the packer mandrel. The seal assembly has a running position and a radially expanded sealing position. A slip assembly is slidably disposed about the packer mandrel. The slip assembly has a running position and a radially expanded gripping position A piston is slidably disposed about the packer mandrel and is operably associated with the seal assembly and the slip assembly. A collet assembly is disposed about the packer mandrel and is releasably coupled to the piston such that radially inwardly shifting at least portion of the collet assembly decouples the collet assembly from the piston allowing the piston to shift longitudinally relative to the packer mandrel which operates the seal assembly from the running position to the radially expanded sealing position and operates the slip assembly from the running position to the radially expanded gripping position, thereby setting the packer.
In one embodiment, a pair of wedges radially outwardly directs the slip assembly when the piston shifts longitudinally relative to the packer mandrel. In another embodiment, a pair of backup shoes is slidably disposed about the packer mandrel and is operably associated with the seal assembly. The backup shoes have a running position and a sealing position, wherein when the piston shifts longitudinally relative to the packer mandrel, the backup shoes are operated from the running position to the sealing position.
In a further aspect, the present invention is directed to a packer for establishing a sealing engagement with a surface disposed in a wellbore. The packer includes a packer mandrel and a seal assembly that is slidably disposed about the packer mandrel. The seal assembly has a running position and a radially expanded sealing position. A piston is slidably disposed about the packer mandrel and defines a chamber therewith. The chamber is at a pressure lower than a pressure in the wellbore. The piston is operably associated with the seal assembly. A collet assembly is disposed about the packer mandrel and is releasably coupled to the piston such that radially inwardly shifting at least portion of the collet assembly decouples the collet assembly from the piston allowing the pressure in the wellbore to shift the piston longitudinally relative to the packer mandrel which operates the seal assembly from the running position to the radially expanded sealing position, thereby setting the packer.
In yet another aspect, the present invention is directed to a method for setting a packer to establish a sealing engagement with a surface located in a wellbore. The method includes providing a profile disposed within the wellbore that is located relative to the surface, lowering the packer into the wellbore, engaging a collet assembly of the packer with the profile of the wellbore and responsive to the engaging, radially outwardly extending a seal assembly of the packer into sealing engagement with the surface.
The method may also include longitudinally sliding a piston relative to a packer mandrel, disengaging the collet assembly from the piston, engaging protrusions on collet fingers of the collet assembly with the profile of the wellbore and radially inwardly shifting at least a portion of the collet assembly with the profile of the wellbore.
In an additional aspect, the present invention is directed to a method for setting a packer to establish a sealing and gripping engagement with a surface located in a wellbore. The method involves providing a profile disposed within the wellbore that is located relative to the surface, lowering the packer into the wellbore, engaging a collet assembly of the packer with the profile of the wellbore and responsive to the engaging, radially outwardly extending a seal assembly of the packer into sealing engagement with the surface and radially outwardly extending a slip assembly of the packer into gripping engagement with the surface.
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
while the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.
In the following description of the representative embodiments of the invention, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used for convenience in referring to the accompanying drawings. In general, “above”, “upper”, “upward” and similar terms refer to a direction toward the earth's surface along a wellbore, and “below”, “lower”, “downward” and similar terms refer to a direction away from the earth's surface along the wellbore.
Referring initially to
Importantly, even though
Continuing with
Note that, in this specification, the terms “liner” and “casing” are used interchangeably to describe tubular materials, which are used to form protective linings in wellbores. Liners and casings may be made from any material such as metals, plastics, composites, or the like, may be expanded or unexpanded as part of an installation procedure, and may be segmented or continuous. Additionally, it is not necessary for a liner or casing to be cemented in a wellbore. Any type of liner or casing may be used in keeping with the principles of the present invention.
Liner 56 may include one or more packers 44, 46, 48, 50, 60 that may be located proximal to the top of liner 56 or at lower portion of liner 56 that provide zonal isolation to the production of hydrocarbons to certain zones of liner 56. Packers 44, 46, 48, 50, 60 include and are actuated by the interventionless set packer setting mechanism of the present invention. When set, packers 44, 46, 48, 50, 60 isolate zones of the annulus between wellbore 32 and liner 56. In this manner, formation fluids from formation 14 may enter the annulus between wellbore 32 and casing 34 in between packers 44, 46, between packers 46, 48, and between packers 48, 50.
In addition, liner 56 includes sand control screen assemblies 38, 40, 42 that are located near the lower end of liner 56 and substantially proximal to formation 14. As shown, packers 44, 46, 48, 50 may be located above and below each set of sand control screen assemblies 38, 40, 42.
Referring now to
A wedge 88 is disposed about a packer mandrel 90 and mandrel 82 and is coupled to mandrel 82 at upper threaded connection 86. Wedge 88 has a camming outer surface that will engage an inner surface of a slip assembly 92. As should be apparent to those skilled in the art, wedge 88 may have a variety of configurations including configurations having other numbers of wedge sections, such configurations being considered within the scope of the present invention.
Slip assembly 92 is located between wedge 88 and a wedge 94. In one embodiment, slip assembly 92 may have teeth 93 located along its outer surface for providing a gripping arrangement with the interior of the well casing. As explained in greater detail below, when a compressive force is generated between wedge 88, slip assembly 92, and wedge 94, slip assembly 92 is radially expanded into contact with the well casing.
Initially, relative movement between wedge 94 and slip assembly 92 is opposed by shear screw 96 attached to packer mandrel 90. As discussed further below, shearing of shear screw 96 enables wedge 94 to move relative to slip assembly 92.
Substantially adjacent to wedge 94 is an upper element backup shoe 98 that is slidably positioned around packer mandrel 90. Additionally, a seal assembly, depicted as expandable seal elements 100, 102, 104, is slidably positioned around packer mandrel 90 between upper element backup shoe 98 and a lower element backup shoe 106. In the illustrated embodiment, three expandable seal elements 100, 102, 104 are shown; however, a seal assembly of the packer of the present invention may include any number of expandable seal elements.
Upper element backup shoe 98 and lower element backup shoe 106 may be made from a deformable or malleable material, such as mild steel, soft steel, brass, and the like and may be thin cut at their distal ends. The ends of upper element backup shoe 98 and lower element backup shoe 106 will deform and flare outwardly toward the inner surface of the casing or formation during the setting sequence as further described below. In one embodiment, upper element backup shoe 98 and lower element backup shoe 106 form a metal-to-metal barrier between packer 80 and the inner surface of the casing.
Another wedge 110 is disposed about packer mandrel 90. Wedge 110 has a camming outer surface that will engage an inner surface of a slip assembly 112. As should be apparent to those skilled in the art, wedge 110 may have a variety of configurations including configurations having other numbers of wedge sections, such configurations being considered within the scope of the present invention.
Initially, relative movement between wedge 110 and lower element backup shoe 106 is opposed by shear screw 108 attached packer mandrel 90. As discussed further below, shearing of shear screw 108 enables wedge 110 to move lower element backup shoe 106 in an upwardly direction.
Slip assembly 112 is located between wedge 110 and a wedge 116. In one embodiment, slip assembly 112 may have teeth 113 located along its outer surface for providing a gripping arrangement with the interior of the well casing. As explained in greater detail below, when a compressive force is generated between wedge 110, slip assembly 112, and wedge 116, slip assembly 112 is radially expanded into contact with the well casing.
Initially, relative movement between wedge 116 and slip assembly 112 is opposed by shear screw 114 attached to packer mandrel 90. As discussed further below, shearing of shear screw 114 enables wedge 116 to move relative to wedge 110.
Packer mandrel 90, wedge 116, and a piston 122 form a cavity 118 for a hydraulically-actuated, top-down contingency access located internally of packer mandrel 90. The inner surface of packer mandrel 90 may be configured to receive a punch-to-set tool (not shown) operable to punch a hole through the wall of the packer mandrel 90 in the vicinity of cavity 118 in the event additional or contingency pressure is required to operate packer mandrel 90. The term “punch-to-set tool” may identify any device operable to perforate the packer mandrel 90, including but not limited to chemical, mechanical and pyrotechnic perforating devices. The punch-to-set tool also acts as a tubing plug within the packer mandrel 90 as will be more fully described below. In another embodiment, the packer mandrel 90 includes a pre-punched port through the mandrel wall in the vicinity of cavity 118, but this embodiment provides somewhat less control over the possible inadvertent setting expandable seal elements 100, 102, 104.
A piston 122 is slidably disposed about packer mandrel 90 and coupled to wedge 116 through a threaded connection 120. Piston 122 extends between wedge 116 and a collet assembly including one or more collet fingers 144. One or more seals 124, 128 and centralizer ring 126 are located between packer mandrel 90 and the upper portion of piston 122 to provide a sealing relationship between packer mandrel 90 and piston 122. Additionally, one or more seals 134, 138 and centralizer ring 136 are located between packer mandrel 90 and the lower portion of piston 122 to provide a sealing relationship between packer mandrel 90 and piston 122. Centralizer rings 126, 136 are operable to properly position piston 122 about the packer mandrel 90 and form a uniformly shaped atmospheric chamber 130.
Seals 124, 128, 134, 138 may consist of any suitable sealing element or elements, such as a single O-ring, a plurality of O-rings, as illustrated, and/or a combination of backup rings, O-rings, and the like. In various embodiments, Seals 124, 128, 134, 138 and/or centralizer rings 126, 136 comprise AFLAS® O-rings with PEEK back-ups for severe downhole environments, Viton O-rings for low temperature service, Nitrile or Hydrogenated Nitrile O-rings for high pressure and temperature service, or a combination thereof.
Atmospheric chamber 130 comprises an elongate cavity formed between packer mandrel 90 and piston 122, and it is initially evacuated by pulling a vacuum. The vacuum in atmospheric chamber 130 acts against hydrostatic piston 122. Seals 124, 128, 134, 138 are provided between packer mandrel 90 and piston 122 to seal off atmospheric chamber 130.
In addition, piston 122, packer mandrel 90, and collet fingers 144 define a chamber 140 that facilitates the operation between collet fingers 144 and piston 122. A detent 142 is formed on the inner surface of piston 122 near the lower end of cavity chamber 140 for releasably accepting a tab 164 of collet fingers 144, as best seen in
Referring now to
Detent 142 may be formed in the inner surface or wall of piston 122 such that it provides a unique profile or shape for engaging a particular tab 164 of collet finger 144. Detent 142 has a depth that provides releasable engagement with tab 164 of collet finger 144 such that when protrusion 166 engages liner top 146, collet finger 144 will move inwardly toward packer mandrel 90 thereby moving or collapsing tab 164 inwardly and disengaging with detent 142, thus enabling piston 122 to slide upward as described further below, and as best seen in
Referring now to
Referring to
Referring back to
Referring to
Referring collectively to
Surface profiles may be manufactured or created in wellbore 32, casing 34, liner 56, liner top 146, or other downhole surfaces that are sized to activate a particular packer 80. These surface profiles are positioned or created at locations desirable to set packer 80 prior to running packer 80 into wellbore 32. These surface profiles are slightly different than their surrounding surface profiles to enable specific engagement with protrusions 166, 172, 178.
In one instance, a surface profile may exist between liner top 146 and casing 34 as best seen in
In operation, packer 80 of
As packer 80 approaches liner top 146 of liner 56, collet fingers 144 engage liner top 146 that causes them to contract inwardly towards packer mandrel 90, as best seen in
Once the shear force between piston 122 and packer mandrel 90 exceeds a predetermined amount, shear screw 114 shears allowing the upward force of piston 122 to act upon wedge 116 to move wedge 116 upward towards slip assembly 112. As wedge 116 contacts slip assembly 112, slip assembly 112 moves upwardly over wedge 110, which starts to set slip assembly 112 against the inner surface of a setting surface, such as casing 34.
As slip assembly 112 is extending outwardly toward the inner surface of casing 34, it further moves upward causing an upward force on wedge 110. Once the shear force between slip assembly 112, wedge 110 and packer mandrel 90 exceeds a predetermined amount, shear screw 108 shears allowing wedge 110 to force lower element backup shoe 106 to begin to move upward relative to packer mandrel 90. As piston 122, wedge 116, slip assembly 112, wedge 110, and lower element backup shoe 106 begin to move upward, expandable seal elements 100, 102, 104 begin to move upward and also to extend outwardly toward casing 34.
The upward movement of expandable seal elements 100, 102, 104 forces upper element backup shoe 98 and lower element backup shoe 106 to flare outward toward casing 34 to provide a metal-to-metal seal in addition to the seal of expandable seal elements 100, 102, 104 between casing 34 and packer mandrel 90, as best seen in
Upon the upward and sealingly movement of lower element backup shoe 106, expandable seal elements 100, 102, 104, and upper element backup shoe 98, an upward force is transmitted to wedge 94. Once the shear force between wedge 94 and packer mandrel 90 exceeds a predetermined amount, shear screw 96 shears allowing the upward force of wedge 94 to act upon slip assembly 92. As wedge 94 contacts slip assembly 92, slip assembly 92 moves upwardly over wedge 88 and wedge 94, which moves slip assembly 92 outwardly against the inner surface of casing 34. As shown in
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
