The present application is a U.S. National Stage patent application of International Patent Application No. PCT/US2016/021200, filed on Mar. 7, 2016, the benefit of which is claimed and the disclosure of which is incorporated herein by reference in its entirety.
The present disclosure relates generally to subterranean wellbore operations and, more specifically, to reclosable multi-zone isolation tools utilizing a pull-force lock mechanism.
It is common to encounter hydrocarbon wells that traverse more than one separate subterranean hydrocarbon bearing zone. In such wells, the separate zones may have similar or different characteristics. For example, the separate zones may have significantly different formation pressures. Even with the different pressures regimes, it may nonetheless be desirable to complete each of the zones prior to producing the well. In such cases, it may be desirable to isolate certain of the zones from other zones after completion.
For example, when multiple productive zones that have significantly different formation pressures are completed in a single well, hydrocarbons from a high pressure zone may migrate to a lower pressure zone during production. It has been found, however, that this migration of hydrocarbons from one zone to another may decrease the ultimate recovery from the well. One way to overcome this fluid loss from a high pressure zone into a lower pressure zone during production and to maximize the ultimate recovery from the well is to initially produce only the high pressure zone and delay production from the lower pressure zone. Once the formation pressure of the high pressure zone has decreased to that of the lower pressure zone, the two zones can be produced together without any loss of reserves. It has been found, however, that from an economic perspective, delaying production from the lower pressure zone while only producing from the high pressure zone may be undesirable.
Illustrative embodiments and related methods of the present disclosure are described below as they might be employed in reclosable multi-zone isolation apparatuses that employ a pull-force lock mechanism. In the interest of clarity, not all features of an actual implementation or method are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. Further aspects and advantages of the various embodiments and related methods of the disclosure will become apparent from consideration of the following description and drawings.
As described herein, illustrative embodiments and methods of the present disclosure are directed to reclosable multi-zone isolation tools having a mandrel assembly with a pull-force lock feature. In general, the tool includes an outer and inner tubular having an annular flow path defined there between, and a central flow path defined by the inner tubular. The annular flow path is in fluid communication with an upper zone, while the central flow path is in fluid communication with a lower zone. A sleeve is positioned in the annular flow path and axially moveable between an open and closed position. A mandrel assembly is slidingly positioned within the inner tubular and coupled to the sleeve to thereby actuate the sleeve between an open and closed position only when a push force is applied. The mandrel assembly includes an upper mandrel component and a lower mandrel component. If a push force is applied to either the upper or lower mandrel components, the sleeve may be actuated. A “push force” is defined herein as any force that urges one component to move toward another component. However, if a pull force is applied to either the upper or lower mandrel component, the mandrel assembly “locks out,” thereby preventing movement of the sleeve. A “pull force” is defined herein as any force acting on the upper or lower mandrel components which urges one component away from the other.
Using the pull force lockout feature of the present disclosure, any differential pressure between the upper annulus and the inner string will only function the sleeve in one direction (for example, the open position). Therefore, during the well life, if the annulus pressure (upper zone) exceeds the inner string pressure (lower zone), the tool will not close itself. Rather, it requires mechanical intervention to close. Accordingly, by preventing unintentional reclosing of the sleeve, a more reliable isolation tool is provided.
Referring initially to
A completion string disposed within wellbore 10 includes upper and lower sand screen assemblies 16, 18 that are located proximate to zones 12, 14, respectively. Wellbore 10 includes a casing string 20 that has been perforated at locations 22, 24 to provide fluid flow paths into casing 20 from zones 12, 14, respectively. The completion string includes production tubing 26, packers 28, 30 and a crossover sub 32 to enable fluid flow between the interior of the completion string and annulus 34.
The completion string also includes multi zone isolation tool 36, according to certain illustrative embodiments of the present disclosure. As explained in greater detail below, tool 36 functions to connect lower sand screen assembly 18 and production tubing 26 via a first flow path. Tool 36 also functions to selectively isolate and connect upper sand screen assembly 16 to annulus 34 via a second flow path. Thus, tool 36 selectively isolates zone 12 and zone 14 and allows zones 12, 14 to be independently produced.
Referring next to
Disposed within housing assembly 102 is an inner tubular assembly 124 that is formed from a plurality of tubular members that are securably and sealingly coupled together by threading, set screws or similar technique. In the illustrated embodiment, tubular assembly 124 includes an upper tubular member 126 having a polished bore receptacle 128, a first upper intermediate tubular member 130 having a radially expanded region 132, a second upper intermediate tubular member 134 having a lower shoulder 136, a first intermediate tubular member 138, a second intermediate tubular member 140, a first lower intermediate tubular member 142 having a profile 144, a second lower intermediate tubular member 146, a third lower tubular member 148, and a fourth lower tubular member 149. An intermediate lower mandrel 152 engages the lower end of mandrel component 153 as shown in
Slidably disposed within tubular assembly 124 is a mandrel assembly 150 that is formed by an upper mandrel component 151 and a lower mandrel component 153. As will be described in more detail below, mandrel assembly 150 is coupled to sleeve 176 via pin 182 to thereby shift sleeve 176 between the open and closed positions. Upper mandrel component 151 slidingly engages lower mandrel component 153. In the illustrated embodiment, mandrel assembly 150 includes profiles 154a,b which may be utilized to mechanically shift mandrel assembly 150 using an intervention tool. Together, tubular assembly 124 and mandrel 150 define a central flow path 172 that extends between the upper and lower ends of tool 100. As previously described with reference to
Together, housing assembly 102 and tubular assembly 124 define a substantially annular flow path 174. As previously described with reference to
As previously described, mandrel assembly 150 includes upper mandrel component 151 and lower mandrel component 153. Mandrel assembly 150 is operable to move if a push force is applied to upper mandrel component 151 or lower mandrel component 153. However, once sleeve 176 is in the open position, if a pull force is applied to lower mandrel component 153, a pull force mechanism will lock out mandrel assembly 150 from further movement. The pull force on lower mandrel component 153 may often be caused by high annulus pressure (in annular flow path 174) relative to the pressure in central flow path 172. In such cases, the pressure differential may apply a pulling force to lower mandrel component 153; however, the lock out feature of the present disclosure prevents such unwanted movement.
The operation of tool 100 will now be described with reference to
After treatment or other operations to the lower zone or zones are complete, the lower zones may be plugged off and a tubing string may be stabbed into polished bore receptacle 128 of inner tubular assembly 124. Here, for example, the lower zones may be plugged off by a ball valve installed in the tubing string below the tool; however, any kind of valve or plug installed below the tool that prevents fluid and pressure communication to the lower zones can be used. Nevertheless, in this configuration, annular flow path 174 and central flow path 172 are no longer in fluid communication with one another above tool 100. Now, increased pressure within central flow path 172 is communicated to the lower end of lower mandrel component 153, thus resulting in a push force being applied that forces lower mandrel component 153 up against upper mandrel component 151. As can be seen in
Therefore, as the push force is applied to the lower end of lower mandrel component 153, lower mandrel component 153 is urged up against upper mandrel component 151 at a push force transfer point 163. Push force transfer point 163 is the intersecting point of the upper and lower mandrel components 151,153. Push force transfer point 163 includes a shoulder 165 on lower mandrel component 153, and the end surface 167 of upper mandrel component 151. At push force transfer point 163, a push force may be transferred from lower mandrel component 153 to upper mandrel component 151 and vice versa.
As the push force continues to be applied to upper mandrel component 151, a predetermined force value is reached whereby the collet fingers of collet assembly 180 are radially retracted to pass through a downwardly facing shoulder 186 of housing assembly 102, and sleeve 176 and mandrel assembly 150 shift in the uphole direction to the positions depicted in
When it is desired to return tool 100 from the open position to the closed position in certain illustrative methods, a shifting tool (e.g., lock mandrel and plug) may be run downhole on a conveyance (e.g., wireline) and positioned within tool 100. The lock mandrel and plug is operable to engage either profile 154a of the upper mandrel component 151 or profile 154b of lower mandrel component 153. Once engaged, the shifting tool may be moved axially to apply the push force, also moving mandrel assembly 150, to reclose and/or reopen sleeve 176.
When a pull force is applied to lower mandrel components 151,153, lug 302 is forced out of groove 159 (
The foregoing disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the apparatus in use or operation in addition to the orientation depicted in the figures. For example, if the apparatus in the figures is turned over, elements described as being “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the illustrative term “below” can encompass both an orientation of above and below. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.
Embodiments of the present disclosure described herein further relate to any one or more of the following paragraphs:
1. An apparatus for isolating a first zone from a second zone in a subterranean wellbore, the apparatus comprising an outer tubular; an inner tubular positioned within the outer tubular, thereby forming an annular flow path there between that is in fluid communication with the first zone, wherein the inner tubular defines a central flow path therein that is in fluid communication with the second zone; a sleeve positioned in the annular flow path to control fluid flow there through, the sleeve being axially moveable relative to the outer and inner tubular between a closed position and an open position; and a mandrel assembly slidingly positioned within the inner tubular and coupled to the sleeve, the mandrel being operable to shift the sleeve between the open and closed position, the mandrel assembly comprising an upper mandrel component and a lower mandrel component slidingly engaging the upper mandrel component, wherein the lower mandrel component is operable to move the sleeve if a push force is applied to the lower mandrel component, but the mandrel assembly becomes locked out if a pull force is applied to the lower mandrel component.
2. An apparatus as defined in paragraph 1, wherein the upper mandrel component slidingly engages an inner surface of the lower mandrel component.
3. An apparatus as defined in paragraphs 1 or 2, wherein the upper mandrel component slidingly engages an inner surface of the lower mandrel component; the upper mandrel component comprises a groove on an outer surface of the upper mandrel component; and the lower mandrel component comprises a collet finger positioned between the inner tubular and the upper mandrel component, the collet finger having a collet head which mates within the groove.
4. An apparatus as defined in any of paragraphs 1-3, wherein the upper mandrel component slidingly engages an inner surface of the lower mandrel component; the upper mandrel component comprises a groove on an outer surface of the upper mandrel component; and the lower mandrel component comprises an extended portion positioned between the inner tubular and the upper mandrel component, the extended portion having a lug which mates within the groove.
5. An apparatus as defined in any of paragraphs 1-4, wherein the mandrel assembly further comprises a push force transfer point, the push force transfer point comprising a lower mandrel component shoulder; and an upper mandrel component end surface which mates with the shoulder.
6. An apparatus as defined in any of paragraphs 1-5, wherein the lower mandrel component comprises a collet assembly surrounding the upper mandrel component, the collet assembly being operable to lock the mandrel assembly in response to the pull force applied to the lower mandrel component.
7. An apparatus as defined in any of paragraphs 1-6, wherein the lower mandrel component comprises an extended portion having a lug thereon, the extended portion surrounding the upper mandrel component and operable to lock the mandrel assembly in response to the pull force applied to the lower mandrel component.
8. An apparatus as defined in any of paragraphs 1-7, further comprising a pull force lock mechanism forming part of the lower mandrel component.
9. An apparatus as defined in any of paragraphs 1-8, wherein the outer tubular comprises an extension that forms an annular pocket; and the sleeve comprises at least one seal on an inner surface thereof such that, in the closed position, the seal engages an outer surface of the inner tubular and, in the open position, the seal engages an outer surface of the extension of the outer tubular.
10. An apparatus as defined in any of paragraphs 1-9, further comprising a collet assembly coupled to the sleeve, the collect assembly selectively preventing shifting of the sleeve relative to the outer tubular when the sleeve is in the open and closed position.
11. An apparatus as defined in any of paragraphs 1-10, further comprising an equalization pathway positioned within the annular flow path to selectively prevent actuation of the sleeve between the open and closed positions.
12. A method for isolating a first zone from a second zone in a subterranean wellbore, the method comprising disposing a multi-zone isolation tool within the wellbore in a closed position, the tool having an inner tubular defining a central flow path and an outer tubular defining an annular flow path with the inner tubular, the annular flow path in fluid communication with the first zone, the central flow path in fluid communication with the second zone, wherein a mandrel assembly includes an upper mandrel component that slidingly engages a lower mandrel component; applying a push force to the upper or lower mandrel components; in response to the push force, shifting a sleeve coupled to the mandrel assembly between the closed position, whereby the annular flow path is blocked, to an open position whereby the annular flow path is opened; and locking out the mandrel assembly if a pull force is applied to the lower mandrel component.
13. A method as defined in paragraph 12, wherein locking out the mandrel assembly comprises applying the pull force to the lower mandrel component; and causing a collet finger of the lower mandrel component to wedge between the upper mandrel component and the inner tubular.
14. A method as defined in paragraphs 12 or 13, wherein locking out the mandrel assembly comprises applying the pull force to the lower mandrel component; and causing a lug extension of the lower mandrel component to wedge between the upper mandrel component and the inner tubular.
15. A method as defined in any of paragraphs 12-14, wherein locking out the mandrel assembly comprises applying the pull force to the lower mandrel component; and causing a pull force lock mechanism to activate.
16. A method as defined in any of paragraphs 12-15, wherein the activation comprises causing the pull force lock mechanism to wedge between the upper mandrel component and the inner tubular.
17. A method for isolating a first zone from a second zone in a subterranean wellbore, the method comprising disposing an apparatus into the wellbore and performing a downhole multi-zonal operation using the apparatus, wherein the apparatus is defined as in any of paragraphs 1-11.
Although various embodiments and methods have been shown and described, the present disclosure is not limited to such embodiments and methods and will be understood to include all modifications and variations as would be apparent to one skilled in the art. Therefore, it should be understood that this disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2016/021200 | 3/7/2016 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2017/155504 | 9/14/2017 | WO | A |
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