The present disclosure relates to wellbore operations. Specifically, the present disclosure relates to systems and methods for engagement of wellbore components, such as metal-to-metal annulus packoffs and hangers.
Oil and gas operations may be conducted in a variety of operations, such as subsea or surface environments, where components are installed on a rig or sea floor. Systems used in oil and gas operations may be heavy, experience extreme temperature or pressure scenarios, and be challenging to move between locations. As a result, reducing the number of components utilized or reducing the number of “runs” or “trips” within a wellbore is desirable. Certain operations may use a series of tubulars that are positioned coaxially within a wellbore, where inner tubulars are “hung” or otherwise suspended from outer tubulars. Normally, these tubulars are separately installed and secured into position, which may increase a number of runs, and thereby, increase costs associated with the wellbore. Similar drawbacks are also present during removal of the components.
Applicants recognized the problems noted above herein and conceived and developed embodiments of systems and methods, according to the present disclosure, for wellbore operations.
In an embodiment, a wellbore system includes a hanger lock energizing ring, a hanger lock ring, and a shoulder ring, wherein the shoulder ring supports at least a portion of the hanger lock ring on a shoulder. The wellbore system further includes a seal energizing ring coupled to the shoulder ring, the seal energizing ring being positioned axially lower than the shoulder. The wellbore system also includes a seal element associated with the seal energizing ring, the seal element being driven into an energized position by the seal energizing ring. The wellbore system further includes a seal lock energizing ring arranged axially lower than the shoulder ring, the seal lock energizing ring being driven to move via one or more extensions coupled to the seal lock energizing ring. The wellbore system includes a seal lock ring positioned axially lower than the shoulder ring, the seal lock ring being supported, at least in part, by the seal energizing ring. Both the hanger lock ring and the seal lock ring are set, substantially simultaneously, responsive to movement of the one or more extensions.
In another embodiment, a method includes landing at least a portion of a seal assembly on a hanger. The method also includes applying a first uphole force to a shoulder ring, the shoulder ring transferring at least a portion of the first uphole force to an upper seal energizing ring to drive the upper seal energizing ring in a downhole direction. The method further includes energizing an upper seal of a seal element via the upper seal energizing ring. The method includes energizing a lower seal of the seal element via a lower seal energizing ring. The method also includes applying a second uphole force to set a hanger lock energizing ring and a seal lock energizing ring.
In an embodiment, a seal assembly includes a seal element having an upper seal and a lower seal, the seal element being driven into an energized position via engagement of the upper seal and the lower seal by an upper seal energizing ring and a lower seal energizing ring. The seal assembly further includes a shoulder ring coupled to the upper seal energizing ring, the shoulder ring to transmit a downward force to at least the upper seal energizing ring to drive the upper seal energizing ring in a downward direction after at least a portion of the seal assembly is landed on a hanger. The seal assembly also includes a hanger lock ring positioned on a shoulder of the shoulder ring, the hanger lock ring being driven in a radially outward direction and into a wellhead housing responsive to movement in the downward direction by a hanger lock energizing ring. The seal assembly further includes a seal lock energizing ring coupled to the hanger lock energizing ring, the seal lock energizing ring being set simultaneously with the hanger lock ring.
In an embodiment, a wellbore system includes a hanger lock energizing ring, a hanger lock ring, and a shoulder ring, wherein the shoulder ring supports at least a portion of the hanger lock ring on a secondary shoulder and the hanger lock energizing ring coupled to one or more extensions. The wellbore system also includes a seal energizing ring coupled to the shoulder ring, the seal energizing ring being positioned axially lower than the secondary shoulder. The wellbore system further includes a seal element associated with the seal energizing ring, the seal element being driven into an energized position by the seal energizing ring. The wellbore system also includes a seal lock energizing ring arranged axially lower than the shoulder ring, the seal lock energizing ring being driven to move via the one or more extensions coupled to the seal lock energizing ring and the hanger lock energizing ring. The wellbore system further includes a seal lock ring positioned axially lower than the shoulder ring, the seal lock ring being supported, at least in part, by the seal energizing ring. Both the hanger lock ring and the seal lock ring are set, substantially simultaneously, responsive to movement of the one or more extensions.
The foregoing aspects, features, and advantages of the present disclosure will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
The foregoing aspects, features, and advantages of the present disclosure will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
When introducing elements of various embodiments of the present disclosure, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment”, “an embodiment”, “certain embodiments”, or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as “above”, “below”, “upper”, “lower”, “side”, “front”, “back”, or other terms regarding orientation or direction are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations or directions. It should be further appreciated that terms such as approximately or substantially may indicate +/−10 percent.
Embodiments of the present disclosure are directed toward systems and method for simultaneous or near-simultaneous actuation for engagement of an inner annulus packoff lock ring with a casing/tubing hanger and an outer hanger lock ring with a wellhead housing. In at least one embodiment, both upper and lower lock rings are actuated into engagement with a corresponding groove using one or more solid actuators, which may be coupled using load members which extend through a lock down carrier. Various embodiments simplify operational tooling and allow one or more seals to be locked down from above (e.g., from an uphole position), which improves debris tolerance and installation reliability.
Various embodiments are directed toward simultaneous or near-simultaneous locking of packoff and hanger lock rings in one stroke via one or more solid actuation rings for actuating and backing up the lock ring. In at least one embodiment, a pair of solid actuation rings are used (e.g., at top and bottom locations). In at least one embodiment, a lock down carrier serves as a primary load transferring body that allows a tool to set a seal. The tool applies a force to this body that sets the seal directly. In various embodiments, the lock down carrier houses one or more load transfer members, which may be an arrangement of bolts or extensions, that are contained in a series of corresponding holes that are formed through the lock down carrier body. These bolts or extensions may be threaded into a seal lock actuation ring (e.g., a solid ring seal lock actuation sleeve) that sets a seal lock down ring. In certain embodiments, the upper section of the shoulder bolts are housed and secured in a series of holes in the hanger lock actuation ring. In at least one embodiment, once the seal is set, a second function of the tool drives the hanger lock actuation sleeve down to drive the hanger lock ring out and into engagement with a wellhead housing. At the same time or substantially the same time, the shoulder bolts are driven down through the lock ring carrier. Because the seal lock actuation sleeve is fastened to the ends of these shoulder bolts, the seal lock ring is driven into engagement with the hanger neck. In at least one embodiment, the lock down carrier has a secondary load shoulder that allows the hanger lock down force to be transferred through the lock down carrier, into the hanger lock ring, and directly into the housing without going through the seal elements. The secondary load shoulder is thereby not the primary hanger neck shoulder and does not take any or a significant portion of the subsequent hanger weight from a hanger landed above or pressure end load from a test plug or other equipment that may land above the hanger. It should be appreciated that a variety of configurations may be utilized for the respective load shoulders in order to distribute forces within the wellbore. By way of example only, the secondary load shoulder may be arranged at an angle sloping downwards and away from a bore axis and, in contrast, the primary load shoulder may be arranged at an angle sloping downwards toward the bore axis.
Various embodiments overcome present challenges of locking a seal to hanger body at the same or substantially the same time as locking the hanger to the wellhead. As a result, embodiments may reduce a number of trips into the wellbore, thereby decreasing costs, among other benefits. In at least one embodiment, embodiments enable the annulus packoff to be set through the lockdown carrier directly, which may enable the lock rings to be energized on a separate tool function. Accordingly, the setting forces to set the seal are applied directly to the seal and not through a selective mechanism, like a shear ring. In this manner, the seal can be set directly through the lock down carrier and the lock rings are set with a separate tool function at substantially the same time.
One efficient way to start drilling a wellbore 106 is through use of a suction pile 134. Such a procedure is accomplished by attaching the wellhead housing 108 to the top of the suction pile 134 and lowering the suction pile 134 to a sea floor 136. As interior chambers in the suction pile 134 are evacuated, the suction pile 134 is driven into the sea floor 136, as shown in
In at least one embodiment, a hanger lock ring 206 is positioned circumferentially with respect to the shoulder ring 204 such that at least a portion of the hanger lock ring 206 is radially outward of at least a portion of the shoulder ring 204, with respect to an assembly axis 208. In operation, the assembly axis 208 is parallel to a wellbore axis, but it should be appreciated that certain components may bend or otherwise be positioned at an angle such that the assembly axis 208 is not always in a straight vertical position as shown in
Various embodiments include a hanger rock ring passage 216 and a shoulder ring passage 218 that enables an extension 220, which is shown here as a shoulder bolt, to extend toward and couple to a seal lock energizing ring (E-ring) 222. For example, in the illustrated configuration the extension 220 is coupled to a lip 224 of the hanger lock r-ring 202 and movement with respect to the lip may be blocked, for example via one or more fasteners 226, such as a set screw. That is, a gap between the fasteners 226 and the extension 220 may enable predetermined movement or sliding of the extension 220, but movement beyond a certain degree would be blocked by the fasteners 226. The extension 220 is then positioned within the respective passages 216, 218 and coupled to the seal lock E-ring 222, for example via one or more mating connections, such as threads. It should be appreciated that various embodiments may include different extension configurations, such as a solid or semi-solid piece, a piece that includes a circumferential span, or the like. Moreover, in at least one embodiment, different configurations may be provided for coupling the illustrated components together, such as one or more overlapping regions between the extension 220 and the hanger lock E-ring 202, among other options. In at least one embodiment, a back face of the lock ring 206 includes one or more relief slots, which may be spaced circumferentially. These relief slots may have varying widths and be positioned to accommodate the extensions 220. Accordingly, as the lock ring 206 expands, the relief slots enable expansion around the extensions 220 without interference.
In this example, the extension 220 extends from the hanger lock E-ring 202 and axially beyond an end of the shoulder ring 204. That is, an end of the extension 220 is axially lower than an end of the shoulder ring 204. It should be appreciated that, in various embodiments, the extension 220 may vary in length. Moreover, there may be multiple extensions where some extend at different lengths than others. As will be described in detail below, movement of the hanger lock E-ring 202 in an axially downward direction along the assembly axis 208 is transmitted to the extension 220, which further drives the seal lock E-ring 222 in an axially downward direction. This movement will facilitate energizing both the lock rings simultaneously.
An upper seal E-ring 228 may be coupled to the shoulder ring 204, for example using one or more fastening mechanisms 230 such as threads, fasteners, or the like. In various embodiments, the upper seal E-ring 228 is arranged below a shoulder 232 of the shoulder ring 204, where the shoulder 232 is an extension that projects radially outward with respect to a body portion of the shoulder ring 204. As illustrated, the shoulder 232 includes an uphole side 234 (e.g., a top side, an axially higher side) and a downhole side 236 (e.g., a bottom side, an axially lower side) where the hanger lock ring 206 is positioned on the uphole side 234 and the upper seal E-ring 228 is positioned to abut the downhole side 236. It should be appreciated that while contact between the upper seal E-ring 228 and shoulder 232 is shown in
In the illustrated embodiment, the seal lock E-ring 222 is arranged circumferentially within the upper seal E-ring 228 in that at least portions of the upper seal E-ring 228 is positioned radially outward of the seal lock E-ring 222, with respect to the assembly axis 208. In at least one embodiment, a seal lock E-ring 222 position within the upper seal E-ring 228 is based, at least in part, on dimensions of one or more of the hanger lock E-ring 202, the shoulder ring 204, and/or the extension 220. By way of example only, a longer (e.g., axially longer) shoulder ring 204 may change a position of the seal lock E-ring 222 with respect to the upper seal E-ring 228.
Further illustrated is a shelf 238 extending radially inward from a body of the upper seal E-ring 228. The illustrated shelf 238 is positioned axially lower than the seal lock E-ring 222 and is further separated from the fastening mechanism 230. In various embodiments, a radial extent of the shelf 238 may be based, at least in part, on one or more additional component within the system, such as one or more tubulars or the illustrated seal lock ring 240. For example, as shown in
Continuing with the upper seal E-ring 228, a groove is illustrated to receive one or more retainer segments 242. The retainer segments 242 are positioned within the groove and extend radially inward, with respect to the assembly axis 208, and may be utilized to position or otherwise retain a seal element 244, which as described below may include both an upper seal and a lower seal. The illustrated retainer segments 242 may include a span (not shown) of a certain circumferential extent. That is, the retainer segments 242 may correspond to a plurality of segments 242, where segments 242 may have equal or different circumferential extends. As will be described, segments 242 may be installed through one or more apertures formed within upper seal E-ring 228. The retainer segments 242 support the seal element 244 along an edge 246 that contacts an overhang 248 of the seal element 244. Accordingly, at least a portion of the retainer segments 242 are radially overlapped by the seal element 244. It should be appreciated that, in at least one embodiment, one or more fasteners may be utilized to secure the seal element 244 to the upper seal E-ring 228 and/or to the retainer segments 242. Furthermore, it should be appreciated that the retainer segments 242 may act as a passive restraint with respect to the seal element 244 such that the retainer segments 242 block movement of the seal element 244 in a downward (e.g., downhole) direction but permit movement in an upward (e.g., uphole) direction. Additionally, it should be appreciated that the movement between the seal element 244 and the retainer segments 242 may be driven by movement of the upper seal E-ring 228, rather than movement of the seal element 244. However, one or both of the components may move axially with respect to one another. In this example, the retainer segments 242 extend into a notch 250 formed, at least in part, by a reduced outer diameter portion axially below the overhang 248.
In at least one embodiment, a space 252 is present between the shelf 238 and the overhang 248. In at least one embodiment, the space 252 is substantially equivalent in length to a gap 254 between the retainer segments 242 and a bottom of the notch 250. In operation, the space 252 and the gap 254 may, at least in part, restrict or otherwise define a movement length of one or more of the upper seal E-ring 228 and/or the seal element 244. By way of example, the upper seal E-ring 228 may be driven in an axially downward direction such that a bottom of the shelf contacts the overhang 248 and/or such that the retainer segments 242 are moved to a bottom of the notch 250. Such movement may serve to activate the seal element 244.
The illustrated seal element 244 includes an upper opening 256 and a lower opening 258, where the upper opening 256 receives an end 260 of the upper seal E-ring 222 and the lower opening 258 receives an end 262 of a lower seal E-ring 264. In this example, the respective ends 260, 262 are shaped to have respective variable diameters such that a first end diameter 266A, 266B is smaller than a second end diameter 268A, 268B. Accordingly, as the respective ends 260, 262 are driven further into their associated openings 256, 258 the seal element 244 undergoes greater expansion to form the seal with the housing (not pictured) on the seal OD side. It should be appreciated that a seal is also formed on the seal ID side. By way of example, the ID side seals are energized by the interference between the seal element 244 and a hanger neck (not pictured). In at least one embodiment, movement of the seal element 244 past the straight hanger seal pocket forms the ID seal.
In a configuration that substantially mirrors at least a portion of the upper seal E-ring 222, the lower seal E-ring 264 is associated with one or more retainer segments 242 that include respective edges 246 that interact with overhangs 248. In contrast to the configuration described above, the position of the respective space 252 and gap 254 associated with the lower seal E-ring 264 may move in an axially upward direction and/or the seal element 244 may move an in axially downward direction, thereby reducing lengths of the spaces 252 and/or gap 254 as the lower seal E-ring 264 is driven into the lower opening 258.
Further illustrated is a retainer ring 270 that is positioned axially lower, at least in part, than the seal element 244 and is positioned against a lower shoulder 272 of the lower seal E-ring 264. In at least one embodiment, the retainer ring 270 is utilized to lock the lower seal E-ring 264 into place, for example by moving into a groove or slot formed within a hanger, among other options. In operation, the retainer ring 270 may further be deenergized to allow removal of the seal system 200, for example retainer ring 270 may maintain a position of the lower seal E-ring 264 to prevent dragging the seal element 244 in an energized position during removal.
Embodiments of the present disclosure may also include a wiper o-ring 274, which in this example is positioned axially below (e.g., downhole) of the retainer ring 270 and is positioned within a groove formed within at least a portion of the lower shoulder 272. The wiper o-ring may be utilized to clean one or more surfaces, such as an outer diameter of a hanger neck, among other options.
As will be described below, various embodiments of the present disclosure may be utilized to set and retrieve the seal system 200 where one or more components are set and/or energized substantially simultaneously. By way of example, in a seal setting sequence, one or more portions of the seal assembly 200 may be landed on a hanger shoulder. For example, a back side of the lower shoulder 272 may be landed on a hanger shoulder, where the hanger is positioned within a wellbore that may, in certain embodiments, include a wellhead housing radially outward from and co-axial with the hanger. A running tool may be utilized to apply a force from an uphole direction (e.g., a downward force), where the force is applied to the shoulder ring 204, either directly or via connections with one or more components, such that the force is transmitted to the upper seal E-ring 228, which drives the end 260 into the upper opening 256. As a portion of the seal element 244 is energized, load may continue to be applied until the lower seal E-ring 264 is driven into the lower opening 258. Such a force will energize the seal element 244 and also engage the retainer ring 270, for example within an opening or groove of the hanger. As force continues to be applied and/or a second force function on the tool is applied, the extensions 220 may be driven in a downward direction against the seal lock E-ring 222, where the downward movement of the attached hanger lock E-ring 202 may drive the hanger lock ring 206 into mating grooves of the housing, while also activating the seal lock E-ring 222 and the seal lock ring 240. In this manner, both the seal and hanger lock rings may be simultaneously or substantially simultaneously be energized. It should be appreciated that the order in which the upper and lower seals are set may be reversed such that the upper seal (e.g., the seal associated with the upper opening 256) is set second and the lower seal (e.g., the seal associated with the lower opening 258) is set first. Furthermore, in embodiments, both seals may be set simultaneously or substantially simultaneously. In at least one embodiments, the seals are set based on a friction balance between different sliding parts, and as a result, the ordering may vary based on one or more operational factors.
Various embodiments may further be drawn toward a seal retrieval sequence. In at least one embodiment, one or more retrieval faces may be utilized, where a tool may couple to at least one of the hanger lock ring E-ring 202 and/or the shoulder ring 204. It should be appreciated that other retrieval interfaces may also be utilized in various embodiments. A force may be applied in an upward direction (e.g., an uphole force, a force toward a surface location, etc.) to disengage both lock rings 206, 240. As the shoulder ring 204 is moved in an upward direction, the upper seal of the seal element 244 (e.g., the seal associated with the upper opening 256) is unenergized due to the movement of the end 260. However, due to the location of the retainer ring 270, the lower seal E-ring 264 associated with the lower seal (e.g., the seal associated with the lower opening 258) may be maintained at the landed elevation. As the upper seal E-ring 228 is moved in an upward direction, the retainer segments 242 may contact the associated overhang 248, which may lead to deenergizing the lower seal and deenergizing the retainer ring 270. As a result, the assembly 200 may then be removed after the seal element 244 is deenergized.
In this example, the extensions 220 are illustrated as individual components that are circumferentially positioned about the assembly axis 208. For example, the extensions 220 may correspond to bolts or shoulder bolts that extend through the lock ring passage 216 and the shoulder ring passage 218 to couple to the seal lock r-ring 222. In various embodiments, there are more or fewer extensions 220 than the number illustrated in
As shown in
In this embodiment, the hanger lock ring 206 is secured to the shoulder ring 204 via a pin 408. The pin 408 extends through respective apertures 410, 412 formed through the hanger lock ring 206 and the shoulder ring 404. In at least one embodiment, the pin 408 is positioned approximately 180-degrees from the lock ring split opening. In at least one embodiment, a plurality of pins 408 are used, which may be in a stacked configuration. In one or more embodiments, more than one pin may be aligned or stacked, but in this configuration, only a single pin is shown. In operation, the pin 408 may prevent rotation or torsion of the hanger lock ring 206. For example, the pin 408 may block twisting during installation or during activation of the hanger lock E-ring 202. As will be described below, a position of one or more of the hanger lock ring 206 and/or the shoulder ring 204 along a length 414 of the pin 408 may change during different phases of installation and removal. That is, as the hanger lock ring 206 is driven radially outward toward the wellhead housing 406, the hanger lock ring 206 may slide along the length 414 of the pin.
In various embodiments, the hanger lock E-ring 202 may include one or more openings 416 positioned to align with the pin 408. For example, the hanger lock E-ring 202 may receive a force from an uphole location and be driven in an axially downward direction, which may, at least in part, facilitate radially outward movement of the hanger lock ring 206. Accordingly, one or more embodiments, a bottom end of the hanger lock E-ring 202 may move downward and toward the pin 408. To prevent the pin 408 from blocking or restricting movement, the one or more openings 416 may enable passage of the pin 408 without restricting the axial movement of the hanger lock E-ring 202. Furthermore, it should be appreciated that, in other embodiments, a length of the hanger lock E-ring 202 is particularly selected such that at full insertion of the hanger lock E-ring 202 the pin 408 is not contacted.
The configuration of
When comparing the position of various components in
Further illustrated in
Furthermore, the upward movement of the hanger lock ring 206 also drives upward movement of the extensions 220, which are coupled to the seal lock E-ring 222. Accordingly, removal of the downward force also disengages the seal lock ring 240 such that the seal lock ring 240 transitions out of the groove 508.
The foregoing disclosure and description of the disclosed embodiments is illustrative and explanatory of the embodiments of the invention. Various changes in the details of the illustrated embodiments can be made within the scope of the appended claims without departing from the true spirit of the disclosure. The embodiments of the present disclosure should only be limited by the following claims and their legal equivalents.
This application is a continuation of U.S. patent application Ser. No. 17/514,270 titled “SYSTEM AND METHOD FOR HANGER AND PACKOFF LOCK RING ACTUATION,” filed Oct. 29, 2021, which is incorporated by reference herein in its entirety for all intents and purposes.
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Number | Date | Country | |
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20240093563 A1 | Mar 2024 | US |
Number | Date | Country | |
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Parent | 17514270 | Oct 2021 | US |
Child | 18519936 | US |