Completion assemblies are used in a variety of well related applications. For example, completion assemblies can be utilized in well treatment and well production applications in oil wells and gas wells. The completion assemblies are deployed downhole into a wellbore and secured at a desired location within the wellbore. In many applications, a given well is completed with two or more completion assemblies.
Various control lines are routed downhole along or through the completion assemblies to enable communication with many types of well tools. If completion assemblies are deployed separately or subsequently disconnected, accommodation must be made for connecting and/or disconnecting the control lines. However, the process of engaging and/or disengaging the mechanical structure of the completion assemblies and the control lines can be difficult. For example, difficulties have arisen in orienting the completion assemblies with respect to each other to enable coupling of control lines. Difficulties also have arisen in providing a system that can be engaged and disengaged in a relatively easy, dependable and repeatable manner.
In general, the present invention provides a system and method for moving a downhole equipment assembly into engagement or out of engagement with a lower completion positioned in a wellbore. An upper communication line extends through or past the downhole equipment assembly, and a lower communication line is located with the lower completion. During engagement, the downhole equipment assembly is connected with the lower completion and the communication lines are coupled via a wet mate system.
Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
The present invention generally relates to a well system that facilitates the engagement and disengagement of a downhole equipment assembly with a lower completion in a wellbore. The downhole equipment assembly may be part of an upper completion. The well system also enables communication lines to be engaged and/or disengaged in a simple, repeatable manner while in a wellbore. The communication line or lines routed along the downhole equipment assembly and lower completion are automatically engaged or disengaged as the downhole equipment assembly and the lower completion are mechanically engaged or disengaged, respectively, via a wet mate system.
In oil and gas wells, the wells can be completed with two or more completion assemblies in which an upper completion comprises the downhole equipment assembly. Communication lines, such as a hydraulic communication lines, pneumatic communication lines, electrical communication lines, and optical communication lines, are connected between completions. The connections allow an upper completion to be disconnected from a lower completion and pulled out of the well without removing the lower completion. Subsequently, the upper completion can be reconnected to the lower completion and communications can resume along the communication lines.
The system and methodology described herein are useful in, for example, both one-trip and two-trip approaches to deployment of downhole equipment assemblies and lower completions. By way of example, the downhole equipment assembly may comprise an electric submersible pumping system, a packer, a flow control valve, or other equipment below which hydraulic, pneumatic, electrical, optical or other communication is required. In the one-trip approach, an upper completion (including a downhole equipment assembly) and a lower completion may be assembled together on the surface and installed into the well during the same trip downhole. When desired, the upper completion can be disconnected from the lower completion and pulled. For the one-trip approach, the connection between the upper completion and the tower completion is designed to handle the tensile load applied by the lower completion during deployment into the wellbore. In the two-trip approach, the upper completion is installed into the well after installation of the lower completion. This allows a well treatment or well treatments, e.g. a gravel pack, to be carried out after installation of the lower completion but prior to installation of the upper completion. The two-trip approach enables use of a connection between completions that does not have as high a load bearing requirement.
Referring generally to
Upper completion 34 can be selectively moved out of engagement with lower completion 32 and back into engagement with lower completion 32 repeatedly via wet mate system 37. In the embodiment illustrated, upper completion 34 may comprise a variety of downhole equipment assemblies 33. The equipment assembly 33 often comprises many additional components, although only a top sub 46 of the assembly is illustrated as connected to an upper completion mandrel 48 to facilitate explanation. Top sub 46 is representative of, for example, an electric submersible pumping system, a packer, a flow control valve, or another suitable assembly 33. Furthermore, wet mate system 37 comprises a latch mechanism 50 that may be in the form of a collet used to mechanically engage upper completion 34 with lower completion 32. By way of example, collet 50 comprises a snap latch collet.
The wet mate system 37 may further comprise a shiftable power sleeve 52 that is shiftable between a locked position in which collet 50 is locked in engagement with lower completion 32 and a release position that enables mechanical release of upper completion 34/downhole equipment assembly 33 from lower completion 32. The actuation of shiftable power sleeve 52 is explained in greater detail below. Wet mate system 37 also may comprise a secondary collet 54 positioned below collet 50. Secondary collet 54 can be used to perform specific actions upon the engagement and/or disengagement of upper completion 34 and lower completion 32. For example, secondary collet 54 can be utilized in shifting components to block access to lower communication line 38 when upper completion 34 is disengaged and moved away from lower completion 32.
For example, lower completion 32 may comprise a lower completion housing 56 having a lower protection sleeve 58 movable to block access to lower communication line 38. In the embodiment illustrated, lower protection sleeve 58 is slidably mounted along an interior of lower completion housing 56. The lower protection sleeve 58 comprises engagement features 60 designed to releasably engage corresponding engagement features 62 of secondary collet 54. Thus, when upper completion 34 is disengaged and pulled upwardly from lower completion 32, secondary collet 54 moves lower protection sleeve 58 upwardly until the sleeve blocks access to lower communication line 38.
When upper completion 34 is engaged with lower completion 32 within wellbore 36, a primary fluid flow, e.g. a production fluid flow, can be established through the completion assemblies. For example, lower completion 32 may comprise a central flow passage 64 that is aligned with a corresponding central flow passage 66 of upper completion 34. Flow passages 64, 66 enable the production of fluid up through well system 30 and wet mate system 37 to a desired collection location and/or down through well system 32 and wet mate system 37 to the surrounding formation. The components and configuration of the wet mate system 37 can be selected to allow the wet mate system to be separate from or integrated into the upper and lower completions depending on the overall design of well system 30. In the present example, components of wet mate system 37 are positioned on the lower end of upper completion 34 and on the upper end of lower completion 32.
An enlarged view of the wet mate system 37 comprising a portion of upper completion 34 and lower completion 32 is provided in
The shiftable power sleeve 52 can be shifted to a release position by applying an appropriate input downhole, such as a hydraulic pressure input. For example, if one or more of the upper communication lines 40 comprises a hydraulic communication line, the hydraulic communication line can be pressurized to move the shiftable power sleeve. In the example illustrated in
In the event there are no hydraulic communication lines or the hydraulic communication line providing flow to chamber 78 is blocked, a redundant hydraulic actuation system can be used to move shiftable power sleeve 52. In this example, upper completion 34 comprises a second rupture disk 82 deployed in a passage 84 extending between the internal passage 66 of upper completion 34 and chamber 78. Application of sufficient pressure along the completion interior, e.g. along internal passage 66, of upper completion 34 causes rupture disk 82 to break. The pressurized fluid is then able to flow through passage 84 to chamber 78 and move shiftable power sleeve 52 to the release position, thereby disengaging the upper completion 34 from the lower completion 32.
If the interior of upper completion 34 is hydraulically connected with the surrounding annulus, the ability to create a pressure differential for moving shiftable power sleeve 52 by applying pressure along passage 66 is not possible. Accordingly, upper completion 34 may further comprise an atmospheric chamber 86 that enables shifting of the shiftable power sleeve 52 to its release position by applying sufficient pressure along upper completion 34. The pressure can be applied along the interior of upper completion 34, along the exterior, e.g. surrounding annulus, of upper completion 34, or along both the interior and exterior of upper completion 34. This application of internal and external pressure creates a pressure differential with atmospheric chamber 86 and shifts power sleeve 52 to the release position. Further redundancy can be provided by constructing shiftable power sleeve 52, or at least a lower portion of shiftable power sleeve 52, from a material that is dissolvable over time when exposed to a specific well fluid.
Another frangible member, e.g. rupture disk, 87 can be employed in passage 44. Member 87 is used to selectively block the passage 44/communication line 40 to prevent inadvertent formation of a high speed jet exiting the communication line due to hydrostatic pressure. Without member 87, the jet can occur while the upper completion 34 is separated from the lower completion 32. Following engagement of the upper completion 34/downhole equipment assembly 33 with lower completion 32, the frangible member 87 can be broken via pressure applied from the surface to establish communication with the lower completion 32.
When upper completion 34 is moved upwardly, the secondary or lower collet 54 pulls lower protection sleeve 58 upwardly. As illustrated in
During disengagement and/or engagement of upper completion 34 with lower completion 32 via wet mate system 37, a communication line union 94 operatively connects the upper communication line or lines 40 with the lower communication line or lines 38 regardless of the rotational orientation of the upper completion 34 relative to the lower completion 32. The union 94 may be designed to provide communication between upper communication line 40 and lower communication line 38 at a plurality of relative angles between the upper and lower completions. In the embodiment illustrated, the communication lines are operatively connected throughout 360° of angular displacement of the upper completion 34 relative to the lower completion 32. The union 94 may be an annular ring member in the form of a hydraulic channel or other physical signal conductor able to transmit signals between upper and lower communication lines. By way of example, union 94 may comprise a concentric union deployed circumferentially around upper completion mandrel 48 at a location that positions union 94 proximate side port 92 when the upper and lower completions are fully engaged.
By way of further example, union 94 may comprise an annular hydraulic channel for use with hydraulic communication lines. In addition or alternatively, the union 94 may comprise an annular conductive member for connecting electrical lines. The conductive member comprises, for example, a pair of contact rings, a ring and a brush, an inductive coupler, or other suitable conductive elements that extend around the circumference of the upper completion mandrel. Similarly, an optical signal connector also can be constructed to provide an annular connection for transmitting optical signals. In
One embodiment of collet 50 is illustrated in
When a two-trip approach is used, the wet mate system forming the connection between upper completion 34 and lower completion 32 need not be as robust because the connection need not take the load of the lower completion during deployment. One embodiment of a well system 30 designed for deployment of a completion and a downhole equipment assembly in a two-step approach is illustrated in
The connection between upper completion 34 and lower completion 32 can once again be formed with a collet, e.g. collet 50 illustrated in
As in the one-trip embodiment, the upper portion of wet mate system 37 used in a two-trip approach also may comprise secondary collet 54 used to lift lower protection sleeve 58, as illustrated in
In an alternate embodiment, an upper protection sleeve 106 is slidably mounted along the exterior of upper mandrel 48, as illustrated in
Referring generally to
As illustrated, downhole equipment assembly 33 is selectively joined with lower completion 32 via wet mate system 37. Wet mate system 37 may comprise an upper section 126 and a lower section 128 that may be selectively connected and disconnected to enable corresponding engagement and disengagement of the downhole equipment assembly 33 and upper communication lines 40 with lower completion 32 and lower communication lines 38. By way of example, the wet mate system 37 may comprise the components described above in which one or more latch mechanisms and non-directional unions are used to facilitate repeated engagement and disengagement.
As described above, downhole equipment assembly 33 may comprise a variety of assemblies including electric submersible pumping systems, packers, flow control valves, and other assemblies. In the example illustrated, the assembly 33 comprises an electric submersible pumping system 129 having a submersible motor 130 coupled to a submersible pump 132 through a motor protector 134. Production fluid may be delivered from lower completion 32 up through wet mate system 37 and discharged into an annulus via a discharge head 136. The discharged fluid flows past submersible motor 130 and motor protector 134 until being drawn into submersible pump 132 via an intake 138. The fluid can then be produced uphole through a tubing 140. The components and arrangement of components in electric submersible pumping system 129 can vary, and those components can be incorporated into a variety of upper completions.
In the event the electric submersible pumping system 129 requires maintenance or other service, the wet mate system 37 is disengaged and the upper completion 34, with electric submersible pumping system 129, is pulled to the surface. After maintenance, replacement and/or other servicing is completed, the upper completion 34 is run downhole and installed onto the lower completion 32 by engaging wet mate system 37. Upon engagement of the wet mate system, communication along the hydraulic lines, electric lines or other communication lines 40, 38 can be resumed.
The embodiments described above provide examples of well systems that utilize the wet mate system 37 to facilitate engagement and disengagement of a variety of downhole equipment assemblies and the completions used in a well environment. However, the size, shape, and configuration of the various components can be adjusted according to the specific application and the number of downhole trips used for a given job. Various components can be arranged differently, and additional components can be incorporated into the design. For example, the connection between the upper and lower completions can be formed by a collet or other suitable mechanisms. Additionally, the collet can be mounted on the upper completion or the lower completion. If a threaded collet is utilized, the threaded region can be positioned to engage a threaded region on either the lower completion or the upper completion. Additionally, the number, type and arrangement of communication lines can be selected according to the specific well applications for which the system is designed.
Accordingly, although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Such modifications are intended to be included within the scope of this invention as defined in the claims.
The following is a continuation-in-part of prior patent application Ser. No. 11/850,243, filed Sep. 5, 2007.
Number | Date | Country | |
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Parent | 11850243 | Sep 2007 | US |
Child | 12056643 | US |