Patent Application
20240392642
The invention relates to what is generally known as a completion, workover, stimulation, or intervention of subterranean wells. Specifically, this invention relates to flow control devices, plugs and packers, and installing/removing flow control devices, plugs and packers from a subterranean wellbore.
Packers, plugs, and flow control devices such as landing nipples are used to support well stimulation, well completion, well workover, and well intervention operations. In many horizontal or near horizontal downhole applications (e.g., shale fracking) a plug or other device must be placed in the horizontal wellbore section. In these exemplary applications, a plug performs two actions: (1) grip, and (2) seal. One way of performing these actions is with a system using slips and elastomers that are pushed towards the wellbore using a cone and compression system. These systems may not be reliable or are limited because of the possibility of the elastomers extruding during use and losing their ability to seal or even swabbing off the device during the installation.
Another way of performing one or both of these actions is stretching a solid metal tube with a cone or other device. In this context, stretching means the expanding of a solid tube (i.e., a tube that is not slotted) such that both the outer perimeter and inner perimeter of the solid tube are enlarged. These systems may not be reliable or are limited because a solid metal tube can only be stretched a certain amount before it no longer has the mechanical integrity to perform its function. This technology is generally known to the industry as solid expandable.
Accordingly, there is a need for an apparatus that seals and/or grips against the wellbore wall without requiring any materials to be stretched or losing its ability to seal.
Embodiments of the invention allow for an apparatus, referred to as a roll-out apparatus, to be installed into a well tubular or open hole at a setting location. In one embodiment the roll-out apparatus includes a load ring that is rolled-out via an energizing ring. In the rolled-out position, the load ring may grip, seal, or both grip and seal to an inner surface of a well tubular or open hole creating a ledge in the wellbore. The ledge created by the roll-out apparatus may be used as seat for a ball or dart to create a diversion device, or to be used as a ledge to support the installation of downhole tools such as a pressure gauge.
Embodiments of the roll-out apparatus include a load ring having a generally tubular shape with at least one slot extending from the front face of the ring to the back face of the ring. The slot enables the load ring to roll-out or enlarge by bending, when energized on an inner surface of the load ring. The slot in the load ring follows a circuitous path and includes a first inner surface and a second inner surface that are configured to contact one another when the load ring is energized or enlarged. The load ring is further configured to contact an inner surface of the subterranean well at the setting location. This contact will result in a either a grip, a seal, or both a grip and seal. This interaction secures the roll-out apparatus in the subterranean well at the setting location.
To allow installation, the roll-out apparatus is typically run on a setting tool system, where the load ring and energizing ring is connected to the setting tool via a core, deployment device or system. The roll-out apparatus is first positioned on the deployment device. The system is then deployed into a wellbore and after the setting location is reached, the setting tool is activated causing the outer surface of the energizing ring to contact the inner surface of the load ring to enlarge the outer circumference of the load ring in a radial direction. This causes the load ring to contact an inside surface of the subterranean well at the setting location.
Those skilled in the art will appreciate that seal or sealing means that if a ball, dart, or plug is attached to the roll-out apparatus, and pressure is applied on top of the roll-out apparatus with the ball, plug, or dart, the leak rate is sufficiently low to allow fluids to be diverted into the formation above the roll-out apparatus. In other words, a 100% seal may be accomplished, but is not required to provide full functionality.
An advantage of the proposed method and apparatus is that it is a tubular ring that is enlarged by bending, to provide gripping and/or sealing to the inner surface of the subterranean well. The tubular ring includes a slot that enables the outer circumference of the load ring to enlarge in a radial direction thereby causing the outer surface of the load ring to contact an inner surface of the subterranean well at the setting location. The slot follows a circuitous path and includes a first inner surface and a second inner surface that are configured to contact one another when the load ring is energized or enlarged. Although the roll-out apparatus does not require additional parts to achieve its functionality, items such as a core, dart, plug, or ball may be incorporated with or after the installation, thereby interacting with the roll-out apparatus, creating additional functionality and possibly enhancing its grip and/or seal with the tubular wall. Thus, the roll-out apparatus may have profiles, shoulders or contours to interact with another device such as but not limited to: a ball, a dart, or a seal assembly.
The roll-out apparatus includes a load ring that may have a textured outer surface modified to enhance gripping and/or sealing to the wellbore walls. Such enhancements include, but are not limited to, particles such as silicon carbide (SiC) attached to the outer surface, which are harder than the material of the wellbore wall and/or the roll-out apparatus. Attachment of these particles may increase the friction force between the load ring and the subterranean well and can be accomplished using an epoxy or resin or other methods including, but not limited to: (1) sintering; (2) profiles machined or attached to the outer surface (the profiles may be treated to increase their hardness); and (3) sealing systems such as elastomers or thermo plastics bonded to the roll-out apparatus. The outer surface of the load ring may include at least one shoulder extending to or above the textured surface configured to engage the inner surface of the subterranean well. Those skilled in the art will appreciate that many different gripping and sealing systems or components exist and that these can be used on their own or in combination with each other. Even though the load ring's main purpose is to seal and grip, those skilled in the art will appreciate that the load ring may also be used for either gripping or sealing.
The roll-out apparatus and its other components can be made from a variety of materials, including but not limited to: alloy steel, stainless steel, duplex steel, elastomers, thermo plastics, composites, degradable materials, dissolvable material, aluminum, or combinations thereof. As discussed, another device or system such as a ball or dart can be installed to interact with the roll-out apparatus to collectively form a plug and/or to further enhance conformance of the roll-out with the inner circumference of the wellbore and/or enhance the gripping/sealing capabilities or other properties, performance, or features. These other devices or systems may be installed during, with, or after the installation of the roll-out apparatus. Some of these devices or systems can be used to enhance the case of installation of the roll-out apparatus.
Other enhancements to the roll-out apparatus may include but are not limited to a load ring assembly that includes two or more rings interlocked together. Each ring includes a slot extending from the front face of the ring to the back face of the ring. The circuitous path of the load ring assembly is formed by orienting the slot of one ring at a different angular orientation to the adjacent ring so that the slots of each ring do not overlap when the load ring is enlarged by the energizing ring.
The specification provides one embodiment of an apparatus configured to be deployed in a subterranean well at a setting location having a load ring and an energizing ring. The load ring includes an outer surface having an outer circumference, an inner surface, a central axis, and a wall having a wall thickness. The wall includes at least one slot extending through the entire wall thickness, and the slot follows a circuitous path from a front face of the load ring to a back face of the load ring. The slot has a first inner surface and a second inner surface, and a portion of the first inner surface and a portion of the second inner surface are configured to contact one another when the outer circumference of the load ring is enlarged;
The energizing ring in this embodiment includes an outer surface, an inner surface, and a central axis. The outer surface of the energizing ring is configured to contact the inner surface of the load ring and to enlarge the outer circumference of the load ring in a radial direction. This causes the outer surface of the load ring to seal to an inner surface of the subterranean well at the setting location. Those skilled in the art will appreciate that in some cases and due to the high loads that the roll-out apparatus is subjected to, the apparatus may move or slip relative to the setting location. This movement or slipping is expected and normally not more than a few inches.
In this embodiment, the circuitous path of the slot may include a first portion that runs parallel to the central axis at the front face, a second portion that runs parallel to the central axis at the back face, and a third portion that runs perpendicular to the central axis at one or more locations between the front face and the back face. The circuitous path may also include at least one portion that is oriented at an angle to the central axis. In addition, the outer surface of the load ring may include a textured surface configured to engage and grip the inner surface of the subterranean well. The textured surface may also include a particulate configured to increase the friction force between the load ring and the subterranean well. In another embodiment, the outer surface of the load ring may include at least one shoulder extending to or above the textured surface to engage and grip the inner surface of the subterranean well.
In this embodiment, the inner surface of the load ring may include a convex surface relative to the central axis of the load ring, and the outer surface of the energizing ring may include a tapered surface relative to the central axis of the energizing ring. In another embodiment, the inner surface of the load ring may include a tapered surface relative to the central axis of the load ring, and the outer surface of the energizing ring may include a convex surface relative to the central axis of the energizing ring. In addition, the load ring, the energizing ring, or both the load ring and energizing ring may be made of a material that galvanically corrodes in a subterranean well. Similarly, the load ring, the energizing ring, or both the load ring and energizing ring may be made of a material that disintegrates or dissolves as a result of an interaction with a fluid in a subterranean well. The load ring, the energizing ring, or both the load ring and energizing ring may also include a composite material.
The load ring may be an assembly of two or more rings interlocked together. Each load ring may have a slot extending through the entire wall thickness from the front face of the ring to the back face of the ring. The circuitous path of the load ring may be formed by orienting the slot of at least one ring at a different angular orientation to the adjacent ring so that the slots of each ring do not overlap when the load ring is enlarged by the energizing ring.
According to another embodiment, the specification provides a method of installing an apparatus in a subterranean well. The method includes positioning a load ring and an energizing ring on a deployment device. The load ring includes an outer surface having an outer circumference, an inner surface, a central axis, and a wall having a wall thickness. The wall of the load ring includes at least one slot extending through the entire wall thickness, and the slot follows a circuitous path from the front face of the load ring to the back face of the load ring. The energizing ring includes an outer surface, an inner surface, and a central axis. The deployment device may include a pivot point configured to reduce the friction force between the deployment device and the inner surface of the subterranean well.
The method further includes inserting the deployment device and the ring into the subterranean well. The ring may be positioned on the deployment device in a first orientation that allows the ring and the deployment device to traverse the subterranean well. The method further includes delivering the deployment device, the load ring, and the energizing ring to a setting location in the subterranean well. Once at the setting location, the method includes activating the deployment device to move the outer surface of the energizing ring to contact the inner surface of the load ring to enlarge the outer circumference of the load ring in a radial direction. This causes the outer surface of the load ring to seal to an inner surface of the subterranean well at the setting location.
In this method, the circuitous path of the slot may include a first portion that runs parallel to the central axis at the front face, a second portion that runs parallel to the central axis at the back face, and a third portion that runs perpendicular to the central axis at one or more locations between the front face and the back face. The circuitous path may also include at least one portion that is oriented at an angle to the central axis. In addition, the outer surface of the load ring may include a textured surface configured to engage and grip the inner surface of the subterranean well. The textured surface may also include a particulate configured to increase the friction force between the load ring and the subterranean well. Alternatively, the outer surface of the load ring may include at least one shoulder extending to or above the textured surface to engage and grip the inner surface of the subterranean well.
In this method, the inner surface of the load ring may include a convex surface relative to the central axis of the load ring, and the outer surface of the energizing ring may include a tapered surface relative to the central axis of the energizing ring. Alternatively, the inner surface of the load ring may include a tapered surface relative to the central axis of the load ring, and the outer surface of the energizing ring may include a convex surface relative to the central axis of the energizing ring. In addition, the load ring, the energizing ring, or both the load ring and energizing ring may be made of a material that galvanically corrodes in a subterranean well. Similarly, the load ring, the energizing ring, or both the load ring and energizing ring may be made of a material that disintegrates or dissolves as a result of an interaction with a fluid in a subterranean well. The load ring, the energizing ring, or both the load ring and energizing ring may also include a composite material.
The load ring in this method may be an assembly of two or more rings interlocked together. Each load ring may have a slot extending through the entire wall thickness from the front face of the ring to the back face of the ring. The circuitous path of the load ring may be formed by orienting the slot of at least one ring at a different angular orientation to the adjacent ring so that the slots of each ring do not overlap when the load ring is enlarged by the energizing ring.
According to another embodiment, the specification provides a subterranean well assembly. The subterranean well has an inner surface at a setting location, which may be defined by casing. The subterranean well also includes a load ring and an energizing ring. The load ring includes an outer surface having an outer circumference, an inner surface, a central axis, and a wall having a wall thickness. The wall includes at least one slot extending through the entire wall thickness, and the slot follows a circuitous path from the front face of the load ring to the back face of the load ring. The slot has a first inner surface and a second inner surface, and a portion of the first inner surface and a portion of the second inner surface are configured to contact one another when the outer circumference of the load ring is enlarged.
The energizing ring includes an outer surface, an inner surface, and a central axis. The outer surface of the energizing ring is configured to contact the inner surface of the load ring and to enlarge the outer circumference of the load ring in a radial direction. This causes the outer surface of the load ring to seal to an inner surface of the subterranean well at the setting location.
In this embodiment, the circuitous path of the slot may include a first portion that runs parallel to the central axis at the front face, a second portion that runs parallel to the central axis at the back face, and a third portion that runs perpendicular to the central axis at one or more locations between the front face and the back face. The circuitous path may also include at least one portion that is oriented at an angle to the central axis. In addition, the outer surface of the load ring may include a textured surface configured to engage and grip the inner surface of the subterranean well. The textured surface may also include a particulate configured to increase the friction force between the load ring and the subterranean well. In another embodiment, the outer surface of the load ring may include at least one shoulder extending to or above the textured surface to engage and grip the inner surface of the subterranean well.
In this embodiment, the inner surface of the load ring may include a convex surface relative to the central axis of the load ring, and the outer surface of the energizing ring may include a tapered surface relative to the central axis of the energizing ring. In another embodiment, the inner surface of the load ring may include a tapered surface relative to the central axis of the load ring, and the outer surface of the energizing ring may include a convex surface relative to the central axis of the energizing ring. In addition, the load ring, the energizing ring, or both the load ring and energizing ring may be made of a material that galvanically corrodes in a subterranean well. Similarly, the load ring, the energizing ring, or both the load ring and energizing ring may be made of a material that disintegrates or dissolves as a result of an interaction with a fluid in a subterranean well. The load ring, the energizing ring, or both the load ring and energizing ring may also include a composite material.
The load ring may be an assembly of two or more rings interlocked together. Each load ring may have a slot extending through the entire wall thickness from a front face of the ring to a back face of the ring. The circuitous path of the load ring may be formed by orienting the slot of at least one ring at a different angular orientation to the adjacent ring so that the slots of each ring do not overlap when the load ring is enlarged by the energizing ring.
This patent application claims priority to U.S. patent application Ser. No. 17/848,996 filed Jun. 24, 2022, which claims priority to U.S. patent application Ser. No. 17/207,528, filed Mar. 19, 2021, which claims priority to U.S. Provisional App. No. 62/994,005 filed 2020 Mar. 24 and to U.S. Provisional App. No. 63/110,989 filed 2020 Nov. 7, all of which are hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63110989 | Nov 2020 | US | |
| 62994005 | Mar 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17848996 | Jun 2022 | US |
| Child | 18793222 | US | |
| Parent | 17207528 | Mar 2021 | US |
| Child | 18793222 | US |
