This invention relates in general to wellhead assemblies and in particular to a seal nose ring that improves tolerance to hanger movement.
Seals are used between inner and outer wellhead tubular members to contain internal well pressure. The inner wellhead member may be a casing hanger located in a wellhead housing and that supports a string of casing extending into the well. A seal or packoff seals between the casing hanger and the wellhead housing. Alternatively, the inner wellhead member could be a tubing hanger that supports a string of tubing extending into the well for the flow of production fluid. The tubing hanger lands in an outer wellhead member, which may be a wellhead housing, a Christmas tree, or a tubing head. A packoff or seal seals between the tubing hanger and the outer wellhead member.
A variety of seals located between the inner and outer wellhead members have been employed in the prior art. Prior art seals include elastomeric and partially metal and elastomeric rings. Prior art seal rings made entirely of metal for forming metal-to-metal seals (“MS”) are also employed. The seals may be set by a running tool, or they may be set in response to the weight of the string of casing or tubing. One type of prior art metal-to-metal seal has seal body with inner and outer walls separated by a cylindrical slot, forming a “U” shape. An energizing ring is pushed into the slot in the seal to deform the inner and outer walls apart into sealing engagement with the inner and outer wellhead members, which may have wickers formed thereon. The energizing ring is typically a solid wedge-shaped member. The deformation of the seal's inner and outer walls exceeds the yield strength of the material of the seal ring, making the deformation permanent.
During setting of the seal, the imparted forces may cause a seal leg to deflect downwards relative to the other seal leg. This can introduce plastic strain into the seal, making it susceptible to tear or shear when the casing hanger moves. To address this problem, a threaded connection has been utilized below the seal that connects a nose ring to the seal. The nose ring has a thin, annular tab, that protrudes upward and contacts the inner seal leg. This tab is supposed to resist the setting forces imparted to it when the energizing ring is driven into the seal to thereby prevent the inducement of plastic strain due to inner seal leg deflection.
This same tab is also designed to buckle during pressure testing of the seal and/or BOP stack with a plug-type or isolation tool. During pressure testing a large force, up to several million pounds, is transferred to the top of the casing hanger. This force causes the casing hanger to deflect downwards, carrying with it the inner seal leg, which is engaged to it. At this point the tab is supposed to buckle, allowing independent movement of the inner and outer seal legs. If the legs were rigidly coupled to each other, the seal body would be torn in half from the large load and deflections created by the pressure test. Even with a buckling tab, eventually the relative displacements between the inner and outer seal legs may become so great that the seal will shear itself apart. To limit this relative displacement, test pressures may be lowered, complex load mechanisms on each hanger position may be added instead of a simple stacking arrangement, or wickers may be entirely abandoned on the casing hanger side of the seal in a “slick neck” arrangement. These approaches compromise the robustness of the system.
The annular tab, however, may buckle prematurely due to Poisson effect, which is the tendency of a material to expand in directions perpendicular to the applied compression. In practical applications, the large radial interference between the energizing ring and each of the seal legs causes the seal legs to grow downwards due to the Poisson effect. Because a large radial force is required to effect a gas-tight seal to high pressures, the resulting axial force due to the growth of the seal legs is also high and sufficient to cause the tab to buckle. This premature buckling of the tab may result in a crooked or twisted installation of the seal body and increased plastic strains in the area that MS-type seals typically fail due to excessive hanger movement during pressure testing. To deal with this type of problem, an active hanger with complex mechanisms in the third position could be used. This option however is costly and complex.
A need exists for a technique that addresses the seal problems described above. In particular, a need exists for a technique to make seals more tolerant to increased hanger movement by accounting for Poisson effect in the seal legs. The following technique may solve these problems.
A seal assembly is located between a wellhead housing having a bore and a casing hanger. Housing is typically located at an upper end of a well and serves as an outer wellhead member. The casing hanger has an upward facing shoulder for supporting a lower portion of the seal assembly. A metal-to-metal seal assembly has an inner seal leg with and inner wall sealing against the cylindrical wall of casing hanger and an outer seal leg with an outer wall surface that seals against wellhead housing bore. The seal legs form a U-shaped pocket or slot. An extension extends downward from the outer seal leg and is connected to a nose ring having a downward facing shoulder that rests on the casing hanger shoulder to provide a reaction point for setting operations.
A lock ring retained within a recess formed in an upper interior portion of the nose ring holds the seal to the nose ring and allows for retrieval. An upward facing shoulder formed on an upper portion of the nose ring contacts the lower surface of the inner seal leg. The upward facing shoulder is contacted by the lower surface during setting operations and resists the forces exerted during setting operations to prevent the downward deflection of the inner leg. Although high, this axial force is not sufficient to buckle the shoulder during setting.
The shoulder also eliminates any buckling due to Poisson effect from the resulting axial force due to the growth of the seal legs during setting operations. The shoulder creates a solid platform that prevents crooked or twisted setting of the seal and thereby prevents plastic strain in the seal. Further, the shoulder does not buckle during pressure testing and a gap is provided between a lower surface of the seal extension and an upward facing mating surface of the nose ring that may range between 0.020 to 0.050 inches depending on the application and materials. The gap closes up during setting operations.
The invention advantageously reduces plastic strains induced during installation when compared to the prior art.
Referring to
Continuing to refer to the prior art seal assembly in
Referring to
In this example, the inner wellhead member comprises a casing hanger 18, which is shown partially in
The invention departs from the prior art with respect to features located below the seal. In this example, an extension extends downward from the outer seal leg 26 and is connected to a nose ring 51 having a downward facing shoulder 53 that rests on shoulder 19 of the casing hanger 18 to provide a reaction point for setting operations. A lock ring 52 that is retained within a recess 54 formed in an upper interior portion of the nose ring 51, holds the seal to the nose ring 51 and allows for retrieval. The lock ring 52 replaces the threaded connection 34 (
Continuing to refer to
In this embodiment, the lock ring 52 retained within the recess 54 formed in the nose ring 51 also provides a set amount of float or space 66 (
The end result of this arrangement is that plastic strains are greatly reduced at installation when compared to the prior art. Due to the enhancements in the nose ring 51, the annulus seal can now advantageously tolerate an increased range of hanger 18 deflections, simplifying the system architecture, and allow for higher test pressures.
Further, this invention removes the need for an expensive Inconel® hanger in the third position, which would require its own specific MS-type seal as well as MS-emergency type seals. Instead, a single part maybe used for all three hanger positions. In addition, this invention permits the use of MS-type seals where only wickerless-type seals could be supplied. The wicker type seals are greatly preferred due to their ability to minimize axial movement of the seal legs with respect to the outer and inner wellhead members.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. These embodiments are not intended to limit the scope of the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
This application claims priority to provisional application 61/391,477, filed Oct. 8, 2010.
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61391477 | Oct 2010 | US |