U.S. patent application number 09/903753 was filed with the patent office on 2002-04-11 for expandable lockout apparatus for a subsurface safety valve and method of use.
Invention is credited to Anderson, Robert James, Hill, Thomas G. JR..
Application Number | 20020040788 09/903753 |
Document ID | / |
Family ID | 26932628 |
Filed Date | 2002-04-11 |
United States Patent
Application |
20020040788 |
Kind Code |
A1 |
Hill, Thomas G. JR. ; et
al. |
April 11, 2002 |
Expandable lockout apparatus for a subsurface safety valve and
method of use
Abstract
In one aspect of the invention, a locking assembly for a
wellbore valve is provided comprising a cylindrical sleeve
insertable into an interior of the valve. After insertion into the
valve, the body is expanded into interference with a closing
mechanism of the valve, thereby locking the valve in an open
position.
Inventors: |
Hill, Thomas G. JR.;
(Kingwood, TX) ; Anderson, Robert James;
(Aberdeen, GB) |
Correspondence
Address: |
WILLIAM B. PATTERSON
THOMASON, MOSER & PATTERSON, L.L.P.
3040 Post Oak Boulevard, Suite 1500
Houston
TX
77056
US
|
Family ID: |
26932628 |
Appl. No.: |
09/903753 |
Filed: |
July 12, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60239506 |
Oct 11, 2000 |
|
|
|
Current U.S.
Class: |
166/382 ;
166/321; 166/323 |
Current CPC
Class: |
E21B 2200/04 20200501;
E21B 43/105 20130101; E21B 2200/05 20200501; E21B 34/102
20130101 |
Class at
Publication: |
166/382 ;
166/323; 166/321 |
International
Class: |
E21B 034/10 |
Claims
1. A locking assembly for a wellbore valve, comprising: a
cylindrical sleeve, the sleeve insertable into a valve body when
unexpanded and constructed and arranged to interfere with a closing
mechanism of the valve body when expanded.
2. The locking assembly of claim 1, wherein the sleeve includes
walls with at least one aperture formed therein.
3. The locking assembly of claim 2, wherein the at least one
aperture is slot-shaped prior to expansion and diamond-shaped after
expansion of the sleeve.
4. The locking assembly of claim 3, wherein the at least one
aperture facilitates the expansion of the sleeve.
5. The locking assembly of claim 1, further including means for
expanding the walls of the sleeve with an outward, radial
force.
6. The locking assembly of claim 1, wherein the expanded sleeve
directly interferes with the closing mechanism.
7. The locking assembly of claim 1, wherein the expanded sleeve
indirectly interferes with the closing mechanism.
8. A method of locking a wellbore valve in an open position, the
method comprising: inserting a cylindrical sleeve into an interior
of the valve; and expanding the sleeve within the interior whereby
the expanded sleeve interferes with a closing mechanism of the
valve, thereby locking the valve in an open position.
9. The method of claim 8, further including opening the valve prior
to insertion of the sleeve.
10. The method of claim 8, further including inserting an expander
tool into an interior of the sleeve.
11. The method of claim 10, wherein the expander tool includes
outwardly extending fluid actuated members.
12. The method of claim 11, wherein the sleeve is expanded by
radial pressure of the members on an interior surface of the
sleeve.
13. The method claim 8, wherein the sleeve is expanded into direct
contact with a closing mechanism.
14. The method of claim 8, wherein the sleeve is expanded into
indirect contact with the closing mechanism.
15. The method of claim 8, wherein the valve is a flapper
valve.
16. The method of claim 8, wherein the valve is a ball valve.
17. A lockout sleeve for a safety valve in a wellbore, comprising:
an expandable tubular having an outer diameter substantially equal
to or less than a drift diameter of the wellbore.
18. The apparatus of claim 17, wherein an inner diameter of the
tubular is expandable to a diameter substantially equal to or
greater than the drift diameter of the wellbore.
19. The apparatus of claim 18, wherein the tubular is a ductile
material.
20. The apparatus of claim 17, wherein the tubular has one or more
surface features.
21. The apparatus of claim 20, wherein the one or more surface
features are slots, slits, holes, ovals, diamonds, perforations, or
a combination thereof.
22. A method for locking out a safety valve in a wellbore,
comprising: placing a tubular in the wellbore; placing an expansion
tool in the wellbore; landing the tubular and the expansion tool
adjacent the safety valve; positioning the tubular and the
expansion tool within an inner diameter of the safety valve;
energizing the expansion tool and causing extendable members
therein to extend radially to contact an inner diameter of the
tubular; and expanding the tubular into substantial contact with
the inner diameter of the safety valve.
23. The method of claim 22, wherein the tubular is expanded to a
diameter substantially equal to or greater than the drift diameter
of the wellbore.
24. The method of claim 22, wherein the safety valve is
mechanically opened prior to positing the tubular and the expansion
tool within the inner diameter of the safety valve.
25. The method of claim 22, wherein the tubular and the expansion
tool are placed in the wellbore on a run-in string of tubulars.
26. The method of claim 25, wherein the run-in string of tubulars
is a coiled tubing.
27. A method for locking out a safety valve in a wellbore,
comprising: placing a tubular in the wellbore, the tubular having
an outer diameter substantially equal to or less than a drift
diameter of the wellbore; placing an expansion tool in the
wellbore; landing the tubular and the expansion tool adjacent the
safety valve; locating a flow tube disposed within the valve;
positioning the tubular and the expansion tool within an inner
diameter of the safety valve; energizing the expansion tool and
causing extendable members therein to extend radially to contact an
inner diameter of the tubular; and expanding the tubular into
substantial contact with the inner diameter of the safety valve
adjacent the flow tube.
28. The method of claim 27, wherein the tubular is expanded to a
diameter substantially equal to or greater than the drift diameter
of the wellbore.
29. The method of claim 27, wherein the safety valve is
mechanically opened prior to positing the tubular and the expansion
tool within the inner diameter of the safety valve.
30. The method of claim 27, wherein the tubular and the expansion
tool are placed in the wellbore on a run-in string of tubulars.
31. The method of claim 29, wherein the run-in string of tubulars
is a coiled tubing.
Description
RELATED APPLICATIONS
[0001] This application claims priority to co-pending provisional
U.S. patent application Ser. No. 60/239,506, filed Oct. 11, 2000,
entitled "Expandable Lockout Apparatus For A Subsurface Safety
Valve And Method Of Use", which is hereby incorporated by reference
in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to methods and apparatus for locking a
wellbore valve in an open position. More particularly, the
invention relates to methods and apparatus for permanently locking
a subsurface safety valve in an open position through the use of
expandable tubulars.
[0004] 2. BACKGROUND OF THE RELATED ART
[0005] For oil and gas wells, especially those that operate
offshore, redundant safety devices typically include a valve
located about 500 feet below the ocean mud line sealably connected
to the production tubing string through which production fluids
pass. The valve, typically referred to as a subsurface safety
valve, ensures that if the fluid conduit between the ocean floor
and the platform is disrupted (by a passing vessel for instance)
that the flow of production fluid from the sub-sea well head will
be cut off and the ocean will not be contaminated with production
fluid. If the subsurface safety valve malfunctions during its
operational life, it may become necessary to permanently lock out
the valve in an open position. This is particularly necessary when
the safety valve has malfunctioned and closed, commonly due to a
control line break or hydraulic chamber leak. The most common type
of subsurface safety valve in use in subterranean wells today is
the "surface controlled subsurface safety valve", commonly and
hereinafter referred to as an SCSSV. SCSSVs are required by
regulatory agencies in all offshore wells worldwide. SCSSVs may
also be used in land wells where the risk of wellhead damage and
uncontrolled blowout of the well is high. Examples of subsurface
safety valves include flapper (as shown in FIG. 6), ball (as shown
in FIG. 7), and annulus type valves. Safety valves are typically
actuated by a reciprocating flow tube or choke. In the case of a
flapper type valve, the flapper pivots about a hinge to close and
block the flow of fluid through the valve. In essence, SCSSVs are
"normally closed" downhole valves which are operated by pressurized
hydraulic fluid in a small diameter control line extending from an
actuator integral to the valve to a control panel on the earth's
surface. Pressure in the control line exerted by the control panel
holds the SCSSV in the open position, permitting fluid to pass
through the valve and to the surface of the well for collection.
Disruption of that pressure for any reason causes the valve to
close. For example, if a control line or hydraulic seal failure
occurs, loss of hydraulic pressure causes inadvertent closure of
the flapper.
[0006] Valves, including SCSSVs, may be held in an open position by
placing a spring metal band which expands from a contracted, run-in
position to a radially enlarged locking position adjacent the
flapper thereby holding the valve member open. For example, U.S.
Pat. No. 4,577,694, which is hereby incorporated by reference,
discloses a running tool that holds a metal band spring in the
collapsed position for placement in the well. When released, the
spring expands into contact with the valve member, thereby holding
it in the open position. One disadvantage to a metal band spring is
that hydrocarbons flowing past the metal band spring cause eddies
and low pressure areas that can cause the spring to inadvertently
collapse and flow upward with production. This action can permit
the "permanently locked out" SCSSV to inadvertently shut, thereby
stopping the flow of hydrocarbons from the well. This results in
costly remedial workover operations and lost production.
[0007] Other methods of locking out the SCSSV include incorporation
of a lockout device integrally into a valve actuating mechanism.
However, this solution complicates the design and adds to the total
cost of the valve. An example of this type of lockout mechanism is
described in U.S. Pat. No. 4,624,315, which is hereby incorporated
by reference. Because of the high degree of reliability and
longevity of modern SCSSVs, the need arises very infrequently for
locking most SCSSVs open. Furthermore, the integral lock open
mechanism has an adverse effect on the reliability of the SCSSV by
being continuously subjected to subsurface well conditions during
normal operations. As such, it may be damaged, corroded or stuck in
the retracted position, preventing a necessary lock open operation
when required.
[0008] Insertable locking devices for safety valves are also
hampered by the physical characteristics of wellbores. Wellbores
and inside diameters thereof vary greatly from well to well. Also,
the inside diameter of a wellbore may vary at different depths. The
"drift" diameter of a wellbore refers to a maximum diameter of a
length of bar that will pass unimpeded through the inside diameter
of a wellbore. Any insertable locking device must therefore meet
limitations in space inherent in a particular wellbore.
[0009] One attempt to compensate for variable physical
characteristics of a wellbore has been to utilize expandable
tubular technology. Both slotted and solid tubulars can be expanded
in situ to enlarge a fluid path through the tubular and also to fix
a smaller tubular within the inner diameter of a larger tubular
therearound. Tubulars are expanded by the use of a cone-shaped
mandrel or by an expansion tool with expandable, fluid actuated
members disposed on a body and run into the wellbore on a tubular
string. During expansion of a tubular, the tubular walls are
expanded past their elastic limit. Examples of expandable tubulars
include slotted screen, joints, packers, and liners. FIGS. 1a and
1b are perspective views of an exemplary expansion tool 100 and
FIG. 1c is an exploded view thereof. The expansion tool 100 has a
body 102 which is hollow and generally tubular with connectors 104
and 106 for connection to other components (not shown) of a
downhole assembly. The connectors 104 and 106 are of a reduced
diameter (compared to the outside diameter of the longitudinally
central body part 108 of the tool 100), and together with three
longitudinal flutes 110 on the central body part 108, allow the
passage of fluids between the outside of the tool 100 and the
interior of a tubular therearound (not shown). The central body
part 108 has three lands 112 defined between the three flutes 110,
each land 112 being formed with a respective recess 114 to hold a
respective roller 116. Each of the recesses 114 has parallel sides
and extends radially from the radially perforated tubular core 115
of the tool 100 to the exterior of the respective land 112. Each of
the mutually identical rollers 116 is near-cylindrical and slightly
barreled. Each of the rollers 116 is mounted by means of a bearing
118 at each end of the respective roller for rotation about a
respective rotational axis which is parallel to the longitudinal
axis of the tool 100 and radially offset therefrom at 120-degree
mutual circumferential separations around the central body 108. The
bearings 118 are formed as integral end members of radially
slidable pistons 120, one piston 120 being slidably sealed within
each radially extended recess 114. The inner end of each piston 120
(FIG. 1a) is exposed to the pressure of fluid within the hollow
core of the tool 100 by way of the radial perforations in the
tubular core 115. In this manner, pressurized fluid provided from
the surface of the well, via a tubular, can actuate the pistons 120
and cause them to extend outward and to contact the inner wall of a
tubular to be expanded.
[0010] Therefore, a need exists to provide a method and apparatus
for permanently holding open the SCSSV by a mechanism which is
entirely separate from the SCSSV mechanism, and one which would not
tend to flow out of position during production operations.
Additionally, a need exists to provide a lockout sleeve device
utilizing expandable tubular technology which can be subsequently
inserted in the well conduit only when it becomes necessary to
permanently lock the SCSSV in an open position.
BRIEF SUMMARY OF THE INVENTION
[0011] In one aspect of the invention, a locking assembly for a
wellbore valve is provided comprising a cylindrical sleeve
insertable into an interior of the valve. After insertion into the
valve, the body is expanded into interference with a closing
mechanism of the valve, thereby locking the valve in an open
position.
[0012] In another aspect, a method and apparatus for locking out a
safety valve in a wellbore is provided in which a tubular, or a
lockout sleeve, having an outer diameter substantially equal to or
less than a drift diameter of the wellbore and an expansion tool
are placed in the wellbore. The safety valve is located and the
lockout sleeve and expansion tool are landed adjacent the safety
valve. With the valve in an open position, the lockout sleeve and
the expansion tool are positioned within an inner diameter thereof.
The expansion tool is energized causing extendable members therein
to extend radially to contact an inner diameter of the lockout
sleeve. The lockout sleeve is expanded into substantial contact
with the inner diameter of the safety valve, wherein the inner
diameter of the expanded lockout sleeve is substantially equal to
or greater than the drift diameter of the wellbore.
[0013] In another aspect, a method for locking out a safety valve
in a wellbore is provided in which a tubular, or lockout sleeve,
having an outer diameter substantially equal to or less than a
drift diameter of the wellbore and an expansion tool are placed in
the wellbore. The lockout sleeve and expansion tool are landed
adjacent the safety valve and a flow tube disposed within the
safety valve is located. With the valve in an open position, the
lockout sleeve and the expansion tool are positioned within an
inner diameter thereof. The expansion tool is energized causing
extendable members therein to extend radially to contact an inner
diameter of the lockout sleeve. The lockout sleeve is expanded into
substantial contact with the inner diameter of the safety valve
adjacent the flow tube, wherein the inner diameter of the expanded
lockout sleeve is substantially equal to or greater than the drift
diameter of the wellbore.
[0014] In yet another aspect, an apparatus for locking out a safety
valve in a wellbore is provided having a tubular, or lockout
sleeve, with an outer diameter substantially equal to or less than
a drift diameter of the wellbore. Preferably, the lockout sleeve
has one or more surface features. The lockout sleeve is made of a
ductile material and the surface features may be slots, holes,
ovals, diamonds, perforations, or a combination thereof. Further,
an inner diameter of the lockout sleeve is expandable to a diameter
substantially equal to or greater than the drift diameter of the
wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] So that the manner in which the above recited features,
advantages and objects of the present invention are attained and
can be understood in detail, a more particular description of the
invention, briefly summarized above, may be had by reference to the
embodiments thereof which are illustrated in the appended
drawings.
[0016] It is to be noted, however, that the appended drawings
illustrate only typical embodiments of this invention and are
therefore not to be considered limiting of its scope, for the
invention may admit to other equally effective embodiments.
[0017] FIG. 1a is a perspective view of an expansion tool;
[0018] FIG. 1b is a perspective end view in section thereof;
[0019] FIG. 1c is an exploded view of the expansion tool;.
[0020] FIG. 2 is a perspective view of an embodiment of an
unexpanded lockout sleeve according to the invention;
[0021] FIG. 3 is a perspective view of the embodiment shown in FIG.
2 in an expanded state;
[0022] FIG. 4 is a section view of a flapper section of a
subsurface safety valve having an expansion tool and an unexpanded
tubular disposed therein;
[0023] FIG. 5 is a section view of the embodiment shown in FIG. 4,
wherein the tubular is expanded;
[0024] FIG. 6 is a section view of a flapper type surface
controlled subsurface safety valve, having an expanded tubular
according to an embodiment of the invention disposed therein;
and
[0025] FIG. 7 is a section view of a ball type surface controlled
subsurface safety valve, having an expanded tubular according to an
embodiment of the invention disposed therein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0026] FIG. 2 is a perspective view of an embodiment of an
unexpanded lockout sleeve 10 according to the invention. The
lockout sleeve 10 has a generally tubular body having an outer
diameter (OD), an inner diameter (ID), and a predetermined length
L1. The lockout sleeve 10 is preferably made of a ductile material
having sufficient properties to resist forces designed to yield the
lockout sleeve, yet able to plastically and/or elastically deform
during application of such forces to a larger diameter without
breaking or rupturing. Preferably, the lockout sleeve 10 has a
plurality of slots 16 formed in its wall 18. Alternatively, the
lockout sleeve may be a solid tubular without any surface features
or have a single longitudinal slot extending the length (L1) of the
sleeve. The slots 16 are preferably arranged in a longitudinal
pattern in an overlapping fashion to facilitate expansion. However,
it should be understood that the slots 16 may be any appropriate
shape of configuration to enable the lockout sleeve 10 to expand
with the application of a radial force. Other surface features
include slits, ellipses, ovals, holes, perforations, irregular
shapes, such as dog bone slots, or combinations thereof.
[0027] Prior to expansion of the lockout sleeve, the outside
diameter 12 of the lockout sleeve 10 is substantially equal to or
less than the maximum diameter that will drift to a desired
location in the wellbore. After expansion of the sleeve, the inside
diameter 14 of the lockout sleeve 10 is preferably greater than or
equal to the drift diameter of the wellbore.
[0028] FIG. 3 is a perspective view of an embodiment of an expanded
lockout sleeve 10 according to the present invention. The expanded
slots 16 form a diamond shape as the lockout sleeve 10 is expanded.
In use, the expansion tool 100 is lowered into the wellbore (not
shown) to a predetermined position and thereafter pressurized fluid
is provided in the run-in tubular 130. In the preferred embodiment,
some portion of the fluid is passed through an orifice or some
other pressure increasing device and into the expansion tool 100
where the fluid urges the rollers 116 outwards to contact the wall
of the tubular, or lockout sleeve 10, therearound. The expansion
tool 100 exerts forces against the wall of the lockout sleeve 10
therearound while rotating and, optionally, moving axially within
the wellbore. The result is the lockout sleeve is expanded past its
elastic limits along at least a portion of its outside diameter.
Gravity and the weight of the components urges the expansion tool
100 downward in the wellbore even as the rollers 116 of the
expander tool 100 are actuated. The expansion can also take place
in a "bottom up" fashion by providing an upward force on the run-in
tubular string. A tractor (not shown) may be used in a lateral
wellbore or in some other circumstance when gravity and the weight
of the components are not adequate to cause the actuated expansion
tool 100 to move downward along the wellbore. The run-in string of
tubulars may include coiled tubing and in that instance, a mud
motor may be utilized adjacent the expansion tool to provide
rotational force to the tool. The structure of mud motors is well
known. The mud motor can be a positive displacement Moineau-type
device and includes a lobed rotor that turns within a lobed stator
in response to the flow of fluids under pressure in the coiled
tubing string. The mud motor provides rotational force to rotate
the expansion tool in the wellbore while the rollers are actuated
against an inside surface of a tubular therearound. Additionally,
the run-in string may be replaced by wire (or e-line) line
providing electrical energy to an electrical motor and also having
the strength to hold the weight of the appartus in the wellbore. In
this embodiment, the electrical motor runs a downhole pump
providing a source of pressurized fluid to an expander tool,
tractor and/or a mud motor.
[0029] FIG. 4 is a section view of a flapper section 34 of a
subsurface safety valve 39 having an expansion tool 100 and an
unexpanded lockout sleeve 10 disposed therein. The lockout sleeve
10 and expansion tool 100 are disposed on the end of a run-in
string 130, or coil tubing, which may be used to provide hydraulic
fluid to the expansion tool 100. The lockout sleeve 10 and
expansion tool 100 are shearably connected and are placed in the
wellbore as an assembly. The assembly is lowered to a desired
location within the safety valve 39. The flapper section 34 of the
safety valve 39 rotates about a hinge pin 36 (shown in an open
position). Once the assembly is located at the desired location in
the wellbore, the flapper section 34 is opened by the downward
force of the assembly on the flapper section 34. Fluid pressure to
actuate the rollers 116 of the expansion tool 100 is provided from
the surface of the well through the run-in string 130. The rollers
116 are then actuated and extended radially outward to contact the
inner diameter 14 of the lockout sleeve 10. The lockout sleeve 10
is then expanded into substantial contact with the inner diameter
of the safety valve 39.
[0030] FIG. 5 is a section view of the embodiment shown in FIG. 4,
wherein the lockout sleeve 10 is expanded into substantial contact
with an inner diameter of the safety valve 39. The lockout sleeve
10 in its expanded condition is substantially greater than or equal
to the smallest inner diameter of the safety valve 39 or a tubular
(not shown) disposed between the safety valve 39 and the wellbore.
This allows the locked out safety valve 39 to maintain its full
open inner diameter and ensure that no flow capacity is lost with
the addition of the lockout sleeve.
[0031] FIG. 6 is a section view of a flapper type surface
controlled subsurface safety valve 30, having an expanded lockout
sleeve 10 disposed therein. Hydraulic fluid is provided to the
safety valve 30 via a control line 34 operated by a control panel
32 on the earth's surface. A valve operator 35, such as a rod
piston, moves downward in response to increasing fluid pressure in
the control line 34. A flow tube 40 moves downward in tandem with
the movement of the valve operator 35, thereby opening the flapper
34. A return means 38, such as a spring, a gas charge, or a
combination thereof, biases the safety valve 30 in the closed
position by acting to urge the flow tube 40 upwards, opposing the
force of hydraulic pressure. Lowering (or loss of) the hydraulic
fluid pressure in the control line 34 serves to move the flow tube
40 upwards thereby closing the safety valve 30. The lockout sleeve
10 has been expanded into a recess 42 above the flow tube 40,
thereby prohibiting an upward movement of the flow tube 40. This
causes the flapper to remain in the open position, permanently
locking out the safety valve 30.
[0032] FIG. 7 is a section view of a ball type surface controlled
subsurface safety valve, having an expanded tubular according to
the invention disposed therein. A valve operator 35, such as an
annular piston, moves downward in response to increasing fluid
pressure in the control line 34. A flow tube 40 moves downward in
tandem with the movement of the valve operator 35, thereby rotating
and opening the ball closure mechanism 44. A return means 38, such
as a spring, a gas charge, or a combination thereof, biases the
safety valve 31 to the closed position by acting to move the flow
tube 40 upwards, opposing the force of hydraulic pressure. Reduced
hydraulic fluid pressure in the control line 34 serves to move the
flow tube 40 upwards thereby closing the safety valve 30. The
lockout sleeve 10 has been expanded into a recess 42 above the flow
tube 40, thereby preventing any upward movement of the flow tube
40. This causes the ball 44 to remain in the open position,
permanently locking out the safety valve 30.
[0033] As illustrated by the forgoing, the present invention solves
problems associated with wellbore valves, especially subsurface
safety valves by providing an easy means to permanently opening the
valves without substantially restricting the flow capacity of the
valve.
[0034] While the foregoing is directed to the preferred embodiment
of the present invention, other and further embodiments of the
invention may be devised without departing from the basic scope
thereof, and the scope thereof is determined by the claims that
follow.
* * * * *