Aspects of the present disclosure relate to a control line protector for use with a stage tool assembly for cementing a wellbore.
Control lines are often lowered into a wellbore along an outer surface of a drill or cementing string assembly. The control lines are used to supply power to one or more downhole devices. The control lines can potentially be damaged when pinched between the outer surface of the string assembly and the inner surface of the wellbore. In addition, control lines can be damaged when pumping cement into the wellbore through the string assembly.
Therefore, there is a need for new and/or improved tools and methods for protecting such control lines.
In one embodiment, a stage tool assembly comprises a stage tool, comprising a body having a bore; a plurality of port holes disposed through an outer surface of the body; and a plurality of securing pin holes disposed on the outer surface of the body; a control line protector, comprising a first collar and a second collar; and a rib coupled to the first collar and the second collar; a plurality of control lines are configured to supply power to one or more sensors and are disposed between the rib and the outer surface of the body the one or more sensors disposed on an outer surface of the body; and a plurality of securing pin members disposed in the plurality of securing pin holes to prevent the control line protector from moving relative to the body.
In one embodiment, a method of cementing a wellbore comprises lowering a stage tool assembly into the wellbore, wherein the stage tool assembly comprises a stage tool, a control line protector coupled to the stage tool, a plurality of control lines disposed between the control line protector and the stage tool, one or more sensors coupled to the plurality of control lines, and one or more securing pin members disposed in an outer surface of the stage tool that prevent rotation of the control line protector relative to the stage tool; opening a plurality of port holes of the stage tool to allow fluid flow through the plurality of port holes; pumping cement through the stage tool assembly and out of the plurality of port holes and into the wellbore; and closing the plurality of port holes of the stage tool to prevent fluid flow through the plurality of port holes.
So that the manner in which the above-recited features of the disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.
The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to welding, interference fitting, and/or fastening such as by using bolts, threaded connections, pins, clips, and/or screws. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to integrally forming. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to direct coupling and/or indirect coupling, such as indirect coupling through components such as links.
Referring to
The body 103 may comprise a first body portion 111, a second body portion 112, and a third body portion 113. The first, second, and/or third body portions 111, 112, 113 may be coupled together and/or integrally formed together at a unitary body. The second body portion 112 is disposed between the first body portion 111 and the third body portion 113. The second body portion 112 may have a larger outer diameter than the first body portion 111 and the third body portion 113. The second body portion 112 may have multiple outer diameters portions. The body 103 further comprises a bore 114 disposed therethrough with an inner surface 115. The body 103 further comprises an outer surface 116.
The body 103 may also comprise a plurality of port holes 117. The plurality of port holes 117 extend through the body 103. The plurality of port holes 117 extend from the inner surface 115 to the outer surface 116. The plurality of port holes 117 may be located on the second body portion 112. In one or more embodiments, the plurality of port holes 117 may be located on the first body portion 111 or on the third body portion 113. The plurality of port holes 117 may be located on the body 103 such that fluid is permitted to flow through the bore 114 and out of the plurality of port holes 117 without interfering with other functions of the stage tool assembly 100.
The body 103 may also comprise a plurality of securing pin holes 139. The plurality of securing pin holes 139 may be configured to receive a plurality of securing pin members 138. The plurality of securing pin members 138 may comprise at least one axial securing pin member 109 and a plurality of rotational securing pin members 110. The securing pin members 138 may be disposed in the securing pin holes 139 and coupled to the securing pin holes 139 by methods including, but not limited to, threading, welding, brazing, cementing, fastening, or press fitting.
The plurality of securing pin holes 139 may further comprise a plurality of rotational securing pin holes 118 disposed on the outer surface 116 of the body 103. The plurality of rotational securing pin holes 118 may be one or more blind holes that do not extend all the way through the wall thickness of the body 103. The plurality of rotational securing pin holes 118 may be through holes that do extend all the way through the wall thickness of the body 103 but are sealed so that the plurality of rotational securing pin holes 118 do not create a leak path from the bore 114 to the outer surface 116 of the body 103. The plurality of rotational securing pin holes 118 may be located on the outer surface 116 of the body 103 in any location so long as they do not create a leak path from the bore 114 to the outer surface 116. The plurality of rotational securing pin holes 118, in combination with the plurality of rotational securing pin members 110, rotationally secure the control line protector 106 and the plurality of control lines 107 to the body 103 (e.g. prevent the control line protector 106 and the plurality of control lines 107 from rotating about the body 103). In one or more embodiments, the plurality of rotational securing pin holes 118 may be located at the same axial position with respect to the body 103 as the plurality of port holes 117. In one or more embodiments, each of the plurality of rotational securing pin holes 118 may be in different axial positions with respect to one another. In one or more embodiments, each of the plurality of securing pin holes 139 maybe in different axial locations with respect to the body 103 and the plurality of port holes 117. In one or more embodiments, the plurality of rotational securing pin holes 118 are located on both sides of a rib 124 of the control line protector 106. In one or more embodiments, the plurality of rotational securing pin holes 118 may be located in a place such that the plurality of rotational securing pin members 110 are disposed through, or integrated with, the rib 124.
The plurality of securing pin holes 139 comprises at least one axial securing pin hole 119 disposed on the outer surface 116 of the body 103. The at least one axial securing pin hole 119 may be one or more blind holes that do not extend all the way through the wall thickness of the body 103. The at least one axial securing pin hole 119 may be a through hole that does extend all the way through the wall thickness of the body 103 but is sealed so that the axial securing pin hole 119 does not create a leak path from the bore 114 to the outer surface 116 of the body 103. The at least one axial securing pin hole 119 may be located on the outer surface 116 of the body 103 in any location so long as it does not create a leak path from the bore 114 to the outer surface 116. The at least one securing pin hole 119, in combination with the at least one axial securing member 109, axially secures the control line protector 106 and the plurality of control lines 107 to the body 103 and prevents axial movement of the control line protector 106 with respect to the body 103. In one or more embodiments, the axial securing pin hole 119, in combination with the at least one axial securing member 109, may also rotationally secure the control line protector 106 and the plurality of control lines 107 preventing rotation with respect to the body 103. In one or more embodiments, the at least one axial securing pin hole 119 may be in the same axial position with respect to the body 103 as the plurality of port holes 117. In one or more embodiments, the at least one axial securing pin hole 119 may be in the same axial position with respect to the body 103 as the plurality of rotational securing pin holes 118. In one or more embodiments, the at least one axial securing pin hole 119 may be in a different axial position with respect to the body 103 as the plurality of port holes 117 and the plurality of rotational securing pin holes 119.
The control line protector 106 may comprise a first collar 120 coupled to a second collar 121 by a rib 124. The first collar 120 and second collar 121 may each comprise a first clamp 122 and a second clamp 123. The first clamp 122 and the second clamp 123 of the first collar 120 may be coupled to each other at one end of the rib 124, and the first clamp 122 and the second clamp 123 of the second collar 121 may be coupled to each other at the opposite end of the rib 124. The first collar 120 and the second collar 121 may clamp against the outer surface 116 of the body 103. The clamping force may be sufficient to prevent the first collar 120 and the second collar 121 from moving axially and rotationally with respect to the body 103.
The rib 124 comprises a channel 125 and an outer surface 136. The shape of the channel 125 may include, but is not limited to, a U-shape, a C-shape, and a square-shape. The channel 125 and the outer surface 116 of the body 103 create a cavity 126, through and within which the plurality of control lines 107 are located. The cavity 126 prevents the plurality of control lines 107 from moving outside of the cavity 126. The rib 124 prevents the control lines 107 from being pinched, cut, eroded, or otherwise be damaged while being lowered into a wellbore. The rib 124 also secures the control lines 107 in the desired rotational position with respect to the body 103. It may be desired to keep the control lines 107 away from the plurality of port holes 117, or protrusions or other portions of the body 103 that may also damage the control lines 107.
The rib 124 may have a first end 127 and a second end 128. The first end 127 may be coupled to the first collar 120 by one or more hinge pins 131, and the second end 128 may be coupled to the second collar 121 by one or more hinge pins 131. The rib 124 may also comprise at least one rib axial securing pin hole 129, which, in combination with the at least one axial securing pin hole 119 and the at least one axial securing pin member 109, prevent axial movement of the rib 124, the control line protector 106, and the plurality of control lines 107 with respect to the body 103. The at least one rib axial securing pin hole 129, in combination with the at least one axial securing pin hole 119 and the at least one axial securing pin member 109, may also prevent rotational movement of the rib 124, the control line protector 106, and the plurality of control lines 107 with respect to the body 103. The rib 124 may be made of a metallic or composite material.
The rib 124 may be rotationally fixed by the plurality of rotational securing pin members 110. In one or more embodiments, the rib 124 is rotationally fixed by the plurality of rotational securing pin members 110, which contact opposing edges of the rib 124. In some embodiments, the rib 124 is rotationally fixed by the plurality of rotational securing pin members 110 by a hole and fastener connection. In some embodiments, the rib 124 is rotationally fixed by the plurality of rotational securing pin members 110 by threaded connection. In some embodiments, the rib 124 is rotationally fixed by the plurality of rotational securing pin members 110 by clamp force. In one or more embodiments, the rotational securing pin members 110 may be integral to the control line protector 106 or the body 103. The plurality of rotational securing pin members 110 may be, but are not limited to, clamp, a body, a fastener, a pin, a bolt, a set screw, or a screw.
The at least one axial securing member 109 may be disposed in the at least one rib axial securing pin hole 129 and the at least one axial securing pin hole 119. The at least one axial securing member 119 may be configured to prevent the control line protector 106 and the plurality of control lines 107 from moving axially with respect to the body 103. The at least one axial securing pin member 109 may be, but is not limited to, a clamp, a body a fastener, a pin, a bolt, a set screw, or a screw. In one or more embodiments, the at least one axial securing member 109 is integral to the body 103 or the control line protector 106. The at least one axial securing member 109 may be made of a metallic or a composite material.
The plurality of control lines 107 may be communicatively coupled the stage tool assembly 100 and/or one or more external devices. The plurality of control lines 107 may also supply power to the one or more sensors 108. The plurality of control lines 107 are disposed between the outer surface 116 of the body 103 and the rib 124. The plurality of control lines 107 may also be disposed in the cavity 126 formed by the channel 125 of the rib 124 and the outer surface 116 of the body 103. The plurality of control lines 107 may include, without limitation, instrumentation lines, power supply lines, or other lines used as necessary to communicatively couple the stage tool assembly 100 to and/or from one or more external devices.
The one or more sensors 108 may be communicatively coupled to at least one of the plurality of control lines 107. At least one of the plurality of control lines 107 may supply power to the one or more sensors 108. The one or more sensors 108 may be disposed on and/or coupled to the body 103. The one or more sensors 108 may be disposed on the outer surface 116. The one or more sensors 108 may be drilled into the body 103. The one or more sensors 108 may be rigidly coupled to the body 103 through methods including, but not limited to welding, brazing, cementing, or fastening. The one or more sensors 108 may be configured to detect conditions of the stage tool assembly 100 including but not limited to leaks or cracks in the stage tool assembly 100. The one or more sensors 108 may be configured to detect conditions of a wellbore (such as wellbore 133 as shown in
For example, the stage tool assembly 100 may be used to cement a wellbore that contains hazardous gases, such as CO2. The one or more sensors 108 may detect hazardous gases that flow up through the wellbore, such as CO2 that may leak through leak paths in the cemented portions of the wellbore (such as cement 135 shown in
Referring to
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The outer surface 136 of the rib 124 may extend a distance D1 from a central axis 132 of the stage tool assembly 100. The distance D1 may be the largest distance that any component of stage tool assembly 100 extends from the central axis 132 of stage tool assembly 100 such that the rib outer surface 136 is the furthest point from the central axis 132 of the stage tool assembly 100. The rib outer surface 136 may then be configured to be a contact portion if the stage tool assembly 100 were to contact the sidewalls of a wellbore. The outer surface 116 of the body 103 may extend a distance D2 from the central axis 132 of the stage tool assembly 100. The plurality of rotational securing pins 110 may protrude from the outer surface 116 of body 103 such that the end of the plurality of rotational securing pins 110 extend a distance D3 from the central axis 132 of the stage tool assembly 100. The distance D3 may be larger than distance D2 but less than distance D1. The plurality of rotational securing pins 110 extending the distance D3, between the distance D2 and the distance D1, prevents rotation of rib 124, the control line protector 106, and the control lines 107 without the plurality of securing pin members 110 becoming the outermost contact point of the stage tool assembly 100.
Referring to
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When the stage tool assembly 100 is moved into the unblocked configuration, cement 135 is pumped through the bore 114 of the stage tool assembly 100 and is flowed out of the plurality of port holes 117 and into the annulus created between the stage tool assembly 100 and the wellbore 133. The control line protector 106 and the plurality of securing pin members 138 are configured to prevent the control lines 107 from crossing or moving into the flow of cement 135 out from the plurality of port holes 117, which can potentially erode or damage the control lines 107. The cement 135 may harden in the annulus created between the stage tool assembly 100 and the wellbore 133, thereby fixing the stage tool assembly 100 in place relative to the wellbore 133 and sealing the wellbore 133. The control line protector 106, the plurality of control lines 107, the plurality of securing pin members 138, and the one or more sensors 108 are similarly cemented in the wellbore 133 but otherwise remain operational.
Referring to
During lowering and/or when the stage tool 137 is cemented with the wellbore 133, power can be supplied through the one or more control lines 107 to the one or more sensors 108. The sensors 108 are configured to monitor one or more fluids within the wellbore 133. The sensors 108 are also configured to send a signal through the one or more control lines 107 indicating that a hazardous gas, such as CO2, has been detected. The presence of hazardous gas detected by the one or more sensors 108 may provide an indication that there is a leak within the cement of the wellbore 133 and/or the stage tool 137, and that remedial action may be taken by an operator of the wellbore 133 if needed.
The steps of the method of cementing the wellbore 133 as illustrated in
It will be appreciated by those skilled in the art that the preceding embodiments are exemplary and not limiting. It is intended that all modifications, permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the scope of the disclosure. It is therefore intended that the following appended claims may include all such modifications, permutations, enhancements, equivalents, and improvements. The disclosure also contemplates that one or more aspects of the embodiments described herein may be substituted in for one or more of the other aspects described. The scope of the disclosure is determined by the claims that follow.
This application claims benefit of U.S. provisional patent application Ser. No. 63/598,828, filed Nov. 14, 2023, which is herein incorporated by reference in its entirety.
Number | Date | Country | |
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63598828 | Nov 2023 | US |