This disclosure relates to well seal systems, and more particularly to seals for a wellbore annulus.
Drilling and production operations of a hydrocarbon well require control of a wellbore environment. In the oil and gas industry, wellheads are installed over open wellbores and on top of one or more surface casing that extend at least partially into the wellbore. Tubing installed in the wellbore prior to the installation of the surface casings are often called conductors. The annulus or annuli between various conductors or between a conductor and a surface casing are often cemented or left open since no flowing formations are expected to flow through these annuli to the surface.
This disclosure describes annulus seal systems, such as seal systems in tubing annuli in a wellbore.
In some aspects, an annulus seal system includes a retention plate that mounts to a first tubing in a wellbore at an uphole longitudinal end of the first tubing. The retention plate includes a first surface. The annulus seal system also includes an annular isolation system to couple to the retention plate. The annular isolation system includes a bottom holding plate positioned in an annulus between the first tubing and a second tubing that is positioned adjacent to the first tubing, a seal element residing on the bottom holding plate, where the seal element can seal the annulus between the first tubing and the second tubing, a torque plate, and a top holding plate. The seal element is positioned between the bottom holding plate and the torque plate, and the torque plate is configured to move in a longitudinal direction toward the bottom holding plate to compress the seal element between the bottom holding plate and the torque plate. The top holding plate can mount to the retention plate, and the top holding plate includes an adjustment mechanism engaged with the torque plate. The adjustment mechanism controls movement of the torque plate in the longitudinal direction.
This, and other aspects, can include one or more of the following features. The top holding plate can include a threaded aperture, and the adjustment mechanism can include a lockdown screw engaged with the threaded aperture. The torque plate can include a wedge surface engaged with the lockdown screw, where the torque plate moves in response to a movement of the lockdown screw. The lockdown screw can be disposed through the top holding plate in a lateral direction that is perpendicular to the longitudinal direction, an end of the lockdown screw can contact the wedge surface of the torque plate, and the movement of the lockdown screw in the lateral direction can control the movement of the torque plate in the longitudinal direction. The top holding plate can include a first aperture, the retention plate can include a second aperture aligned with the first aperture, and the annulus seam system can further include a retention fastener positioned through the first aperture and the second aperture to mount the top holding plate to the retention plate. The retention fastener can include a stud positioned through the first aperture and the second aperture, and retention nuts to secure the stud to the top holding plate and retention plate. The retention fastener can include a bolt positioned through the first aperture and the second aperture, and a retention nut coupled to the bolt. A bottom surface of the top holding plate can mount to the first surface of the retention plate. The annulus seal system can further include a second fastener for securing the top holding plate to the bottom holding plate. The top holding plate can include a second aperture, the bottom holding plate can include a threaded cap, and the second fastener can include a cap screw extending through the second aperture to the threaded cap. The retention plate can be welded to the first tubing. The retention plate can be a flanged end of the first tubing.
Certain aspects encompass a method for sealing a wellbore annulus. The method includes mounting, with a first fastener, a top holding plate of an annular isolation system to a first tubing disposed in a wellbore. The annular isolation system includes a bottom holding plate having an annular shape and comprising a first surface, a seal element having an annular shape and disposed on the first surface of the bottom holding plate, a torque plate disposed on the seal element and positioned opposite to the bottom holding plate, where the torque plate includes an annular shape, and the seal element is positioned between the bottom holding plate and the torque plate, and a top holding plate connected to the bottom holding plate and including an adjustment mechanism engaged with the torque plate. The method also includes moving the torque plate with the adjustment mechanism in a downhole direction, and in response to moving the torque plate in the downhole direction, compressing the seal element between the torque plate and the bottom holding plate, and sealing, with the seal element, an annulus between the first tubing and a casing disposed in the wellbore.
This, and other aspects, can include one or more of the following features. The top holding plate can include a threaded aperture, the adjustment mechanism can include a lockdown screw engaged with the threaded aperture, the torque plate can include a wedge surface engaged with the lockdown screw, and moving the torque plate with the adjustment mechanism can include rotating the lockdown screw within the threaded aperture and pushing the torque plate in the downhole direction with the lockdown screw in response to rotating the lockdown screw. Compressing the seal element between the torque plate and the bottom holding plate can include laterally expanding the seal element to sealingly engage with the first tubing and the casing.
In some aspects, an annulus seal system includes an annular isolation system to connect to a tubing disposed in a wellbore. The annular isolation system includes a bottom holding plate having an annular shape and comprising a first surface, a seal element having an annular shape and disposed on the first surface of the bottom holding plate, the seal element to expand in a radial direction, and a torque plate disposed on the seal element and positioned opposite to the bottom holding plate. The torque plate includes an annular shape, wherein the seal element is positioned between the bottom holding plate and the torque plate, and the torque plate moves in a longitudinal direction to compress the seal element between the bottom holding plate and the torque plate. The annular isolation system also includes a top holding plate connected to the bottom holding plate and including an adjustment mechanism engaged with the torque plate, the adjustment mechanism to control movement of the torque plate in the longitudinal direction.
This, and other aspects, can include one or more of the following features. The adjustment mechanism can include a lockdown screw through the top holding plate, the lockdown screw to move the torque plate in response to rotation of the lockdown screw. The torque plate can include a wedge surface configured to match a profile of the lockdown screw, wherein the wedge surface moves in response to rotation of the lockdown screw against the wedge surface of the torque plate. The annulus seal system can further include a fastener for securing the top holding plate to the bottom holding plate. The annulus seal system can further include a retention plate coupled to the tubing at an uphole longitudinal end of the tubing, and a fastener for securing the top holding plate to the retention plate, where the seal element can be disposed in an annulus of the wellbore between the tubing and a casing disposed radially within the tubing.
The details of one or more implementations of the subject matter described in this disclosure are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
Like reference numbers and designations in the various drawings indicate like elements.
This disclosure describes seal systems for annuli in a wellbore. An example annulus seal system can be positioned in an annulus between wellbore tubing, such as between a casing and a conductor, between conductors, between casings, or between other wellbore tubing, after the wellbore tubing is run into and positioned within a wellbore. The annulus seal system attaches to a longitudinally uphole end of a first tubing, and includes a flexible seal element that is disposed in an annulus between the first tubing and an adjacent tubing, such as adjacent and concentric casing tubing, to seal the annulus while also accounting for flexibility due to movement of the tubing and fluctuations in the size of the annulus during the life of the well. The example annulus seal system also includes an adjustment mechanism that acts to control a compression of the seal element, where the compression of the seal element results in a radial expansion of the seal element in the annulus.
In the oil and gas industry, wellheads are installed over open wellbores and on top of one or more surface casing that extend at least partially into the wellbore. Tubing installed in the wellbore prior to the installation of the surface casings are called conductors. A conductor is a pipe or tubing that is set into the ground and provides a foundation for a well to be drilled. A conductor is typically the first string of casing installed in a well, and can be lowered into a wellbore and cemented in place, driven into the ground (such as by a pile driver, or jetted into place such as in offshore wells), or otherwise positioned in a well. The example annulus seal system of the present disclosure can be mounted on a conductor to seal an annulus between the conductor and an adjacent casing, or can be mounted on any other tubing in a wellbore to seal the annulus at an uphole end of the annulus. The annulus or annuli between various conductors or between a conductor and a surface casing are often cemented or left open since no flowing formations are expected to flow through these annuli to the surface. Although production flow is not typically expected in these annuli, these annuli can leak to the environment through these open annuli. The annulus seal systems of the present disclosure can seal these annuli. In some conventional instances, a welded plate is used to isolate these annuli on existing wells, but these welds often crack or fail since a rigid weld does not factor in growth fluctuation of wellbore tubing, such as during start up and shut-in periods. The annulus seal system of the present disclosure includes a flexible seal that seals the annulus while also accounting for flexibility due to movement of the tubing and fluctuations in the size of the annulus during the life of the well.
In some instances, the annulus seal system includes a circular or split seal element, such as a packer element, that is positioned in place in an annulus by top and bottom holding plates. The top and bottom holding plates can be secured to each other with cap screws or other fasteners, and the seal element is energized (for example, radially expanded via compression) by one or more lockdown screws acting on a torque plate that acts to compress the seal element and seal off an open annulus. The top holding plate or the bottom holding plate is mounted on or otherwise coupled to a tubing, such as at an uphole longitudinal end of the tubing. A portion of the annulus seal system is positioned in the annulus, such that upon compression of the seal element, the seal element radially expands (for example, radially inward, radially outward, or both) to engage and seal against walls of the adjacent tubing.
After some or all of the wellbore 102 is drilled, a portion of the wellbore 102 extending from the wellhead 104 to the subterranean zone 108 can be lined with lengths of tubing, called casing. The wellbore 102 can be drilled in stages, and a casing may be installed between stages. In the example well system 100 of
The wellhead 104 is installed over the open wellbore 102 on top of the first surface casing 110 and second surface casing 112. The well system 100 also includes a pipe or tubing installed in the wellbore 102 prior to the installation of the surface casings 110 and 112, called a conductor 116. The example well system 100 includes one conductor 116 positioned radially outward of the first surface casing 110 and second surface casing 112 relative to central wellbore axis A-A. The conductor 116 is positioned adjacent to the first surface casing 110. The conductor 116 and the first surface casing 110 form an annulus between them, which can be cemented or left open, for example, since no flowing formations are expected to flow through this annuli to the surface 106.
The conductor 116 is set into the surface 106 of the Earth and provides a foundation for the wellbore 102 to be drilled. The conductor 116 is typically the first string of casing installed in the wellbore 102, and is lowered into the wellbore 102 and cemented in place, driven into the surface 106 (such as by a pile driver, or jetted into place such as in offshore wells), or otherwise positioned in the wellbore 102. The example well system 100 of
The wellhead 104 defines an attachment point for other equipment of the well system 100 to attach to the well 102. For example, the wellhead 104 can include a Christmas tree structure including valves used to regulate flow into or out of the wellbore 102. In the example well system 100 of
The wellhead 104 of the example well system 100 also includes an annulus seal system 120 positioned at an uphole longitudinal end of the wellbore 102 above the conductor 116, first surface casing, second surface casing 112, or a combination of these. The annulus seal system 120 seals an annulus between two adjacent tubing, such as between the conductor 116 and the first surface casing 110, between the first surface casing 110 and the second surface casing 112, or both. The annulus defines the space between adjacent tubing in the wellbore 102, such as a conductor-casing-annulus between the conductor 116 and the first surface casing 110, or a casing-casing-annulus between the first surface casing 110 and the second surface casing 112. While the annulus seal system 120 of the example well system 100 of
In some implementations, the example annulus seal system 120 is mounted on the conductor 116 to seal an annulus between the conductor 116 and the adjacent first surface casing 110, which resides radially inwardly of the conductor 116. However, the example annulus seal system 120 can be mounted on any other tubing in the wellbore 102 to seal the annulus at an uphole end of the annulus. The conductor-casing-annulus, casing-casing-annulus, or both, are cemented or left open, since no flowing formations are expected to flow through these annuli to the surface 106. However, although production flow is not typically expected in these annuli, these annuli can leak flow to the environment through these open annuli. The annulus seal system 120 acts to seal these annuli. The example annulus seal system 120 includes a flexible seal that radially expands to seal the annulus while also accounting for flexibility due to movement of the tubing and fluctuations in the size of the annulus during the life of the wellbore 102.
The example annulus seal system 200 includes a retention plate 202 mounted to the conductor 116 at an uphole longitudinal end of the conductor 116. In some instances, the retention plate 202 mounts to the first surface casing 110. The retention plate 202 includes a first surface 204 on an uphole side of the plate 202. The plate is oriented horizontally (substantially or exactly) relative to the vertical orientation of the conductor 116. In some implementations, the retention plate 202 is welded to the conductor 116, such as by a weld 206 on an underside of the retention plate 202 opposite of the first surface 204.
The annulus seal system 200 also includes an annular isolation system 210 that selectively couples to the retention plate 202, such as by mounting, fastening, or other type of connection. In some instances, the annular isolation system 210 couples to the conductor 116 or first surface casing 110 without the retention plate 202, and instead mounts (directly or indirectly) to a surface of the conductor 116, first surface casing 110, or other pipe structure. The annular isolation system 210 includes a bottom holding plate 212 positioned in the annulus between the conductor 116 and the first surface casing 110, a seal element 214 residing on the bottom holding plate 212, and a torque plate 216. The seal element is 214 is positioned between the bottom holding plate 212 and the torque plate 216, and is configured to seal the annulus between the conductor 116 and the first surface casing 110. The torque plate 216 can be biased to move in a longitudinal direction toward the bottom holding plate 212 to compress the seal element 214 between the bottom holding plate 212 and the torque plate 216.
The bottom holding plate 212, seal element 214, torque plate 216, or a combination of these, are sized to fit partially or entirely within the annulus between the adjacent tubing. These portions of the annular isolation system 220 can include a lateral dimension (for example, annular width) that is just less than a width of the annulus. Having an annular width that is just less than the width of the annulus itself allows the annular isolation system 220 to be lowered into the annulus, where the seal element 214 can subsequently be radially expanded (as described below) in order to seal the annulus.
The seal element 214 is radially expandable to engage and seal against the radially inner wall of the conductor 116 and the radially outer wall of the first surface casing 110. The seal element 214 can expand from a first, radially retracted position (as depicted in
In some implementations, the seal element 214 includes an elastomeric ring-shaped (or partial ring-shaped) seal that, upon compression in the longitudinal direction, can extend radially (outward and inward). The elastomeric seal can be formed of an elastomeric material, such as rubber, silicone, polyurethane, or other elastomers. In some implementations, the seal element 214 can include an inflatable packer that inflates from the first position to the second position, a swellable packer that swells from the first position to the second position, a hydraulic actuated packer that actuates from the first position to the second position, or another type of expandable packer element.
The bottom holding plate 212, seal element 214, and torque plate 216 are partially or completely disposed within the annulus. The example annular isolation system 210 also includes a top holding plate 218 that connects to the bottom holding plate 212, seal element 214, torque plate 216, a combination of these, or all of these, to support the bottom holding plate 212, seal element 214, and torque plate 216 in the annulus. The top holding plate 218 connects to the retention plate 202, for example, by mounting directly onto the first surface 204 of the retention plate 202 or otherwise coupling to the retention plate 202. In some implementations, the top holding plate 218 can connect directly to the conductor 116, first surface casing 110, or another component to support the bottom holding plate 212, seal element 214, and in some instances the torque plate 216, within the annulus.
The top holding plate 218 includes an adjustment mechanism 220 engaged with the torque plate 216. The adjustment mechanism 220 controls the movement of the torque plate 216 in the longitudinal direction (parallel to axis A-A), for example, to control the compression of the seal element 214. In the example annular isolation system 210 of
In some implementations, the torque plate 216 includes a wedge surface 226 that is engaged with the lockdown screw 222. For example, the wedge surface 226 is a chamfered edge of the torque plate 216 that engages with the angled end of the lockdown screw 222, which acts to transfer the lateral force from the lockdown screw 222 into longitudinal force on the torque plate 216. The torque plate 216 moves in response to movement of the lockdown screw 222. In some examples, the lockdown screw 222 is disposed through the top holding plate 218 in a lateral direction perpendicular to the longitudinal direction, and the distal end of the lockdown screw 222 is configured to contact the wedge surface 226 of the torque plate 216. The movement of the lockdown screw 222 in the lateral direction controls the movement of the torque plate 216 in the longitudinal direction.
The adjustment mechanism 220 of the example annular isolation system 210 is shown as the lockdown screw 222. However, the adjustment mechanism 220 can take other forms. For example, the adjustment mechanism 220 can include a spring-loaded pin that, once activated (or released), applies a force against the torque plate 216 to compress the seal element 214. In certain instances, the adjustment mechanism 220 can include fasteners on the top holding plate 218 that are energized, or torqued, to apply a downhole longitudinal force against the torque plate 216 to compress the seam element 214.
The adjustment mechanism 220 can include a single lockdown screw 222, or multiple lockdown screws 222 distributed along a partial or total length (for example, partial or total circumference) of the top holding plate 218. In some instances, the adjustment mechanism 220 includes four or more lockdown screws 222 spaced (evenly or unevenly) along the top holding plate 218, for example, to apply a more consistent force to the torque plate 216, and therefore an evenly distributed compressive force on the seal element 214.
A bottom surface of the top holding plate 218 mounts to the 204 first surface of the retention plate 202. In the example annulus seal system 200 of
In some implementations, the annular isolation system 210 includes one or more second fasteners 230 for securing the top holding plate 218 to the bottom holding plate 212. The second fastener 230 can include a cap screw that engages a threaded cap in the bottom holding plate 212. For example, the top holding plate 218 can include an aperture, the bottom holding plate 212 includes the threaded cap, and the cap screw extends through the aperture to the threaded cap. Other fastener types can be used to connect the top holding plate 218 to the bottom holding plate 212.
In some instances, the retention plate 202 is a flanged end of the conductor pipe 116. For example, instead of the retention plate 202 being welded to the conductor 116, the retention plate 202 can be integral with the conductor 116 as an outwardly flanged longitudinal end of the conductor 116.
The retention plate 202, top holding plate 218, bottom holding plate 212, torque plate 216, or a combination of these plates are formed of a rigid material that is durable enough to withstand the caustic environment of a wellbore. For example, each of these plates can be formed of a rigid metal.
The seal element 214 is compressed to seal off the annulus. The seal element can be energized to a desired degree using the adjustment mechanism 220. In some implementations, the seal element 214 can be replaced as desired or as needed, for example, by disconnecting and removing the annular isolation system 210 from the retention plate 202, replacing the seal element 214 with a new seal element, and reconnecting the annular isolation system 210 to the retention plate 202.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure.
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