U.S. patent application number 10/462941 was filed with the patent office on 2003-11-06 for connections for wellhead equipment.
Invention is credited to Duhn, Rex E., Meek, Robert K..
Application Number | 20030205385 10/462941 |
Document ID | / |
Family ID | 46282437 |
Filed Date | 2003-11-06 |
United States Patent
Application |
20030205385 |
Kind Code |
A1 |
Duhn, Rex E. ; et
al. |
November 6, 2003 |
Connections for wellhead equipment
Abstract
A wellhead assembly is provided having a first tubular member,
and a second tubular member at least partially extending over a
first end of the first tubular member defining an annular space
there between. An arcuate lock member such as a lock ring is
located within the annular space. At least one load applying member
penetrates the second tubular member and urges the arcuate lock
member against the first tubular member. A lock nut is coupled to
an inner surface of the second tubular member. A method for
coupling the first tubular member to the second tubular member is
also provided.
Inventors: |
Duhn, Rex E.; (Bakersfield,
CA) ; Meek, Robert K.; (Bakersfield, CA) |
Correspondence
Address: |
CHRISTIE, PARKER & HALE, LLP
P.O. BOX 7068
PASADENA
CA
91109-7068
US
|
Family ID: |
46282437 |
Appl. No.: |
10/462941 |
Filed: |
June 17, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10462941 |
Jun 17, 2003 |
|
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|
10369070 |
Feb 19, 2003 |
|
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60357939 |
Feb 19, 2002 |
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Current U.S.
Class: |
166/380 ;
166/75.13 |
Current CPC
Class: |
E21B 33/068 20130101;
E21B 33/03 20130101 |
Class at
Publication: |
166/380 ;
166/75.13 |
International
Class: |
E21B 019/16 |
Claims
1. A wellhead assembly comprising: a first tubular member; a second
tubular member at least partially extending over a first end of the
first tubular member defining an annular space there between; an
arcuate lock member located within the annular space; and at least
one load applying member penetrating the second tubular member and
urging the arcuate lock member against the first tubular
member.
2. The wellhead assembly of claim 1 further comprising a lock nut
coupled to an inner surface of the second tubular member, said lock
nut overlapping at least a portion of said arcuate lock member.
3. The wellhead assembly of claim 2 wherein the arcuate lock member
comprises a first set of wickers and wherein the first tubular
member comprises a second set of wickers, wherein when the at least
one load applying member is urging the arcuate lock member, the
first set of wickers mesh with the second set of wickers.
4. The wellhead assembly of claim 3 wherein the first set of
wickers is complementary to the second set of wickers.
5. The wellhead assembly of claim 3 wherein the arcuate lock member
is a segmented lock ring.
6. The wellhead assembly of claim 5 wherein the segmented lock ring
comprises a plurality of segments.
7. The wellhead assembly of claim 6 wherein a fastener urges each
of said plurality of segments against the first tubular member.
8. The wellhead assembly of claim 6 wherein a segmented lock ring
segment comprises a slot extending to an edge of the segment and to
an outer surface of the segment and wherein said at least one load
applying member penetrates said slot.
9. The wellhead assembly of claim 8 wherein the fastener interlocks
with the segment.
10. The wellhead assembly of claim 9 wherein the slot comprises a
wider section and a narrower section over the wider section and
extending to the outer surface of the segment defining a dove tail
geometry slot geometry in cross section.
11. The wellhead assembly of claim 10 wherein the load applying
member comprises a tip section having a width smaller than the
width of the slot wider section and greater than the width of the
slot narrower section and a neck portion having a width narrower
than the width of the slot narrower section, wherein the load
applying member tip is slidably fitted in the slot wider section
and the load applying member neck is slidably fitted in the slot
narrower section interlocking the load applying member to the
segment.
12. A method for interlocking a first tubular member with a second
tubular member comprising: mounting the second tubular member over
the first tubular member; and coupling a load applying member on
the second tubular member urging an arcuate lock member against the
first tubular member.
13. The method of claim 12 further comprising coupling a lock nut
on the inner surface of the second tubular member overlapping at
least a portion of said arcuate lock member.
14. The method of claim 13 wherein the arcuate lock member
comprises a first set of wickers on its inner surface and the first
tubular member comprises a second set of wickers on its outer
surface and wherein coupling comprises meshing the first set of
wickers with the second set of wickers.
15. The method as recited in claim 14 wherein the arcuate lock
member is a segmented lock ring.
16. The method as recited in claim 15 wherein the segmented lock
ring comprises a plurality of segments.
17. The method as recited in claim 16 further comprising
interlocking the load applying member with the segment prior to
coupling.
18. The method as recited in claim 13 wherein coupling comprises
threading the load applying member on the second tubular member.
Description
CROSS-REFERENCED TO RELATED APPLICATION
[0001] This application in a continuation-in-part application of
U.S. patent application Ser. No. 10/369,070, filed on Feb. 19,
2003, which claims priority and is based upon Provisional
Application No. 60/357,939, filed on Feb. 19, 2002, the contents of
both of which are fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to wellhead equipment, and to
a wellhead tool for isolating wellhead equipment from the extreme
pressures and abrasive materials used in oil and gas well
stimulation.
[0003] Oil and gas wells often require remedial actions in order to
enhance production of hydrocarbons from the producing zones of
subterranean formations. These actions include a process called
fracturing whereby fluids are pumped into the formation at high
pressures in order to break up the product bearing zone. This is
done to increase the flow of the product to the well bore where it
is collected and retrieved. Abrasive materials, such as sand or
bauxite, called propates are also pumped into the fractures created
in the formation to prop the fractures open allowing an increase in
product flow. These procedures are a normal part of placing a new
well into production and are common in older wells as the formation
near the well bore begins to dry up. These procedures may also be
required in older wells that tend to collapse in the subterranean
zone as product is depleted in order to maintain open flow paths to
the well bore.
[0004] The surface wellhead equipment is usually rated to handle
the anticipated pressures that might be produced by the well when
it first enters production. However, the pressures encountered
during the fracturing process are normally considerably higher than
those of the producing well. For the sake of economy, it is
desirable to have equipment on the well rated for the normal
pressures to be encountered. In order to safely fracture the well
then, a means must be provided whereby the elevated pressures are
safely contained and means must also be provided to control the
well pressures. It is common in the industry to accomplish these
requirements by using a `stinger` that is rated for the pressures
to be encountered. The `stinger` reaches through the wellhead and
into the tubing or casing through which the fracturing process is
to be communicated to the producing subterranean zone. The
`stinger` also commonly extends through a blow out preventer (BOP)
that has been placed on the top of the wellhead to control well
pressures. Therefore, the `stinger`, by its nature, has a reduced
bore which typically restricts the flow into the well during the
fracturing process. Additionally, the placement of the BOP on the
wellhead requires substantial ancillary equipment due to its size
and weight.
[0005] It would, therefore, be desirable to have a product which
does not restrict the flow into a well during fracturing and a
method of fracturing whereby fracturing may be safely performed,
the wellhead equipment can be protected from excessive pressures
and abrasives and the unwieldy BOP equipment can be eliminated
without requiring the expense of upgrading the pressure rating of
the wellhead equipment. It would also be desirable to maintain an
upper profile within the wellhead that would allow the use of
standard equipment for the suspension of production tubulars upon
final completion of the well.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to connections for
wellhead equipment and to wellhead assemblies incorporating the
same. The present invention in an exemplary embodiment provides a
wellhead assembly having a wellhead isolation tool, also referred
to as a "frac mandrel" that cooperates with a relatively low
pressure wellhead to accommodate the elevated pressures encountered
during the fracturing process by taking advantage of the heavier
material cross-section present in the lower end of wellhead
equipment and by isolating the weaker upper portions of the
wellhead from high fracturing pressures. Said tool provides a full
diameter access into the well bore, thus enhancing the fracturing
process, and may be used with common high pressure valves to
provide well pressure control. The invention further provides for
retention of standard profiles within the upper portion of the
wellhead allowing the use of standard tubing hangers to support
production tubing within the completed well.
[0007] In another exemplary embodiment, a wellhead assembly is
provided having a first tubular member and a second tubular member
at least partially extending over a first end of the first tubular
member defining an annular space there between. At least one
fastener penetrates the second tubular member and urges an arcuate
lock member against the first tubular member. In another exemplary
embodiment, a lock nut is coupled to an inner surface of the second
tubular member overlapping at least part of the arcuate lock ring.
In one exemplary embodiment, the arcuate lock member comprises a
first set of wickers and the first tubular member comprises a
second set of wickers. When the fastener(s) urges the lock ring,
the first set of wickers mesh with the second set of wickers. The
wickers may be complementary to each other. In a further exemplary
embodiment, the arcuate member is a segmented lock ring having a
plurality of segments.
[0008] In another exemplary embodiment each lock ring segment has a
slot extending to an edge of the segment and to an outer surface of
the segment. A fastener penetrates the slot and interlocks with the
segment. In one exemplary embodiment, the slot has a wider section
and a narrower section over the wider section extending to the
outer surface of the segment defining a dove tail geometry slot
geometry in cross section. The fastener has a tip section having a
width smaller than the width of the slot wider section and greater
than the width of the slot narrower section and a neck portion
having a width narrower than the width of the slot narrower
section. The fastener tip is slidably fitted in the slot wider
section and the fastener neck is slidably fitted in the slot
narrower section interlocking the fastener to the segment.
[0009] In another exemplary embodiment, a method is provided for
interlocking a first tubular member with a second tubular member.
The method includes mounting the second tubular member over the
first tubular member and coupling a fastener on the second tubular
member urging an arcuate lock member against the first tubular
member. A further exemplary embodiment includes coupling a lock nut
on the inner surface of the second tubular member overlapping at
least a portion of the arcuate lock member. In an alternate
exemplary embodiment, the arcuate lock member has a first set of
wickers on its inner surface and the first tubular member has a
second set of wickers on its outer surface and wherein threading
includes meshing the first set of wickers with the second set of
wickers. In another exemplary embodiment, the arcuate lock member
is a segmented lock ring having a plurality of segments, and the
fastener is interlocked with a segment prior to threading.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a partial cross-sectional view of a typical
wellhead assembly with an exemplary embodiment wellhead isolation
tool of the present invention and a fracturing tree assembly.
[0011] FIG. 2 is a partial cross-sectional view of a typical
wellhead assembly with another exemplary embodiment wellhead
isolation tool of the present invention and a fracturing tree
assembly.
[0012] FIG. 3 is an enlarged cross-sectional view encircled by
arrow 3-3 in FIG. 1 .
[0013] FIG. 4A is an enlarged cross-sectional view encircled by
arrow 4A-4A in FIG. 1.
[0014] FIG. 4B is the same view as FIG. 4A with the cooperating
lock screws shown in a retracted position.
[0015] FIG. 5 is an enlarged cross-sectional view of the section
encircled by arrow 5-5 in FIG. 2.
[0016] FIG. 6 is an enlarged cross-sectional view of the section
encircled by arrow 6-6 in FIG. 2.
[0017] FIG. 7A is a partial cross-sectional view of an exemplary
embodiment wellhead assembly incorporating an exemplary embodiment
wellhead isolation tool of the present invention.
[0018] FIG. 7B is an enlarged cross-sectional view of the are
encircled by arrow 7B-7B in FIG. 7A;
[0019] FIG. 8 is apartial cross-sectional view of another exemplary
embodiment wellhead assembly incorporating another exemplary
embodiment wellhead isolation tool of the present invention.
[0020] FIG. 9 is a partial cross-sectional view of an exemplary
embodiment connection between an annular nut and a body member of
an exemplary embodiment wellhead assembly.
[0021] FIG. 10 is a perspective view of an exemplary embodiment
segment of a segmented lock ring incorporated in the connection
shown in FIG. 9.
DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION
[0022] Referring now to the drawings and, particularly, to FIG. 1,
a representation of an exemplary embodiment wellhead assembly 1 of
the present invention is illustrated. The exemplary embodiment
wellhead assembly 1 includes a lower housing assembly 10 also
referred to herein as a casing head assembly; an upper assembly 80
also referred to herein as a fracturing tree; an intermediate body
member assembly 20 also referred to herein as a tubing head
assembly; and a wellhead isolation tool or member 60, which is an
elongate annular member, also referred to herein as a frac mandrel.
It will be recognized by those skilled in the art that there may be
differing configurations of wellhead assembly 1. The casing head
assembly includes a casing head 13 defining a well bore 15. The
lower end 26 of casing head 13 is connected and sealed to surface
casing 12 either by a welded connection as shown or by other means
such as a threaded connection (not shown).
[0023] The tubing head assembly 20 includes a body member referred
to herein as the "tubing head" 22. The upper end 14 of casing head
13 cooperates with a lower end 24 of body member 22 whether by a
flanged connection as shown or by other means. A production casing
18 is suspended within the well bore 15 by hanger 16. The upper end
of production casing 18 extends into the body member and cooperates
with the lower bore preparation 28 of body member 22. The juncture
of production casing 18 and lower bore preparation 28 is sealed by
seals 32. The seals 32 which may be standard or specially molded
seals. In an exemplary embodiment, the seals are self energizing
seals such as for example O-ring, T-seal or S-seal types of seals.
Self-energizing seals do not need excessive mechanical forces for
forming a seal.
[0024] Grooves 33 may be formed on the inner surface 35 of the body
member 22 to accommodate the seals 32, as shown in FIG. 3, so that
the seals seal against an outer surface 37 of the production casing
18 and the grooves 33. In this regard, the seals 32 prevent the
communication of pressure contained within the production casing
inner bore 34 to the cavity 38 defined in the upper portion of the
well bore 15 of the casing head 13. In an alternative exemplary
embodiment not shown, grooves may be formed on the outer surface 37
of the production casing 18 to accommodate the seals 32. With this
embodiment, the seals seal against the inner surface 35 of the body
member. In further alternate exemplary embodiments, other seals or
methods of sealing may be used to prevent the communication of
pressure contained within the production casing inner bore 34 to
cavity 38 defined in the upper portion of the well bore 15 of the
casing head 13.
[0025] It will be recognized by those skilled in the art that the
production casing 18 may also be threadedly suspended within the
casing head 13 by what is known in the art as an extended neck
mandrel hanger (not shown) whereby the extended neck of said
mandrel hanger cooperates with the lower cylindrical bore
preparation 28 of body member 22 in same manner as the upper end of
production casing 18 and whose juncture with lower cylindrical bore
preparation 28 of body member 22 is sealed in the same manner as
previously described.
[0026] In the exemplary embodiment shown in FIG. 1, the body member
22 includes an upper flange 42. A secondary flange 70 is installed
on the upper flange 42 of body member utilizing a plurality of
studs 44 and nuts 45. A spacer 50 cooperates with a groove 46 in
secondary flange 70 and a groove 48 in the upper flange 42 of body
member 22 in order to maintain concentricity between secondary
flange 70 and upper flange 42.
[0027] Now referring to FIGS. 4A and 4B, lock screws 40 having
frustum conical ends 66 threadedly cooperate with retainer nuts 68
which, in turn, threadedly cooperate with radial threaded ports 72
in upper flange 42 of body member 22 and radial threaded ports 74
in secondary flange 70. The lock screws 40 may be threadedly
retracted to allow unrestricted access through bore 92 defined
through the secondary flange 70 as for example shown in FIG.
4B.
[0028] With the lock screw retracted, an exemplary embodiment
wellhead isolation tool 60 is installed through cylindrical bore 92
in secondary flange 70 and into the body member 22. The exemplary
embodiment wellhead isolation tool shown in FIG. 1 is a generally
elongated annular member having an inner surface 200 having a first
section 202 having a first diameter and a second section 204
extending below the first section and having diameter smaller than
that of the first section (FIG. 4A). Consequently, a shoulder 206
is defined between the two sections as for example shown in FIG.
4A.
[0029] A radial flange 208 extends from an upper end of the
wellhead isolation tool and provides an interface for connecting
the upper assembly or fracturing tree 80 as shown in FIG. 1. A
first annular groove 212 is formed over a second annular groove 214
on an outer surface 210 of the wellhead isolation tool, as for
example shown in FIGS. 4A and 4B. In cross-section the grooves are
frustum-conical, i.e., they have an upper tapering surface 215 and
a lower tapering surface 64 as shown in FIG. 4B. In an alternate
embodiments, instead of the grooves 212, 214, a first set of
depressions (not shown) is formed over as second set of depressions
(not shown) on the outer surface of the wellhead isolation tool.
Each set of depressions is radially arranged around the outer
surface of the wellhead isolation tool. These depressions also have
a frustum-conical cross-sectional shape.
[0030] The outer surface 210 of the well head isolation tool has an
upper tapering portion 54 tapering from a larger diameter upper
portion 218 to a smaller diameter lower portion 222. A lower
tapering portion 220 extends below the upper tapering portion 54,
tapering the outer surface of the wellhead isolation tool to a
smaller diameter lower portion 222.
[0031] When the wellhead isolation tool is fitted into the body
member through the secondary flange 70, the upper outer surface
tapering portion 54 of the wellhead isolation tool mates with a
complementary tapering inner surface portion 52 of the body member
22 as shown in FIG. 4B. A seal is provided between the wellhead
isolation tool and the body member 22. The seal may be provided
using seals 56, as for example self energizing seals such as for
example O-ring, T-seal and S-seal type seals fitted in grooves 58
formed on the upper tapering portion 54 of the outer surface of the
wellhead isolation tool. In an alternate embodiment not shown, the
seals are fitted in grooves on the tapering inner surface portion
of the body member. When the upper outer surface tapering portion
of the wellhead isolation tool is mated with the tapering inner
surface portion of the body member, the lock screws 40 penetrating
the secondary flange 70 are aligned with the upper groove 212
formed on the wellhead isolation tool outer surface and the lock
screws 40 penetrating the upper flange 42 of the body member 22 are
aligned with lower groove 214 formed on the outer surface of the
wellhead isolation tool. In an alternate embodiment, the mandrel
may have to be rotated such that the lock screws 40 penetrating the
secondary flange are aligned with a first set of depressions (not
shown) formed on the wellhead isolation tool outer surface and the
lock screws 40 penetrating the upper flange of the body member 22
are aligned with a second set depressions (not shown) formed on the
outer surface of the wellhead isolation tool.
[0032] Now referring to FIG. 4A, lock screws 40 are threadedly
inserted so that their frustum conical ends 66 engage the lower
tapering surfaces 64 of their respective grooves 212, 214 formed on
the outer surface of the exemplary wellhead isolation tool 60
thereby, retaining the wellhead isolation tool 60 within body
member 22. With this embodiment, excess loads on the wellhead
isolation tool 60 not absorbed by lock screws 40 installed in upper
flange 42 are absorbed by lock screws 40 installed in secondary
flange 70 and redistributed through studs 44 and nuts 45 to upper
flange 42.
[0033] Now referring to FIG. 3, with the wellhead isolation tool 60
installed in the body member 22, the outer cylindrical surface 78
of the wellhead isolation tool lower portion 222 cooperates with
inner surface 76 of the body member 22. Seals 82 are installed in
grooves 84 formed in outer surface 78 of the wellhead isolation
tool and cooperate with surfaces 76 to effect a seal between the
body member 22 and the wellhead isolation tool 60. In an exemplary
embodiment, the seals are self energizing seals such as for example
O-ring, T-seal or S-seal types of seals. Alternatively, the seals
may be fitted in the grooves formed on in the inner surface 76 of
the body member. Pipe port 88 is radially formed through body
member 22 and provides access for testing seals 82 prior to placing
the wellhead isolation tool 60 in service. Subsequent to testing,
pipe port 88 is sealed in an exemplary embodiment with pipe plug
90. Testing may be accomplished by applying air pressure through
the pipe port 88 and monitoring the pressure for a decrease. A
decrease in pressure of a predetermined amount over a predetermined
time period may be indicative of seal leakage.
[0034] Cylindrical bores 34, 36 and 86 defined through the
production casing 18, the exemplary embodiment wellhead isolation
tool 60, and through an annular lip portion 87 the body member 22,
respectively, are in an exemplary embodiment as shown in FIG. 3
equal in diameter thus providing an unrestricted passageway for
fracturing materials and/or downhole tools.
[0035] Referring again to FIG. 1, valve 96 is connected to body
member 22 by pipe nipple 94. Valve 96 may also be connected to the
body member 22 by a flanged or studded outlet preparation. Valve 96
may then be opened during the fracturing process to bleed high
pressures from cavity 98 in the event of leakage past seals 82.
[0036] FIG. 2 shows another exemplary embodiment wellhead assembly
2 consisting of a lower housing assembly 10 also referred to herein
as a casing head assembly; an upper assembly 80 also referred to
herein as a fracturing tree; an intermediate body member assembly
20 also referred to herein as a body member assembly; and another
exemplary embodiment wellhead isolation tool 100 also referred to
herein as a wellhead isolation tool. It will be recognized by those
practiced in the art that there may be differing configurations of
wellhead assembly 2. Since the exemplary embodiment shown in FIG. 2
incorporates many of the same elements as the exemplary embodiment
shown in FIG. 1, the same references numerals are used in both
figures for the same elements. For convenience only the differences
from the exemplary embodiment shown in FIG. 1 are described for
illustrating the exemplary embodiment of FIG. 2.
[0037] Now referring to FIG. 6, a secondary flange 110 is provided
in an exemplary embodiment with threads 118, preferably ACME
threads, on its inner cylindrical surface that cooperate with
threads 116, also in an exemplary embodiment preferably ACME, on
the outer cylindrical surface of wellhead isolation tool 100. In an
alternate exemplary embodiment, secondary flange 110 may be
incorporated as an integral part of wellhead isolation tool 100.
However, the assembled tool may be produced more economically with
a threaded on secondary flange 110 as for example shown in FIG. 6.
The assembly of secondary flange 110 and wellhead isolation tool
100 is coupled to on the upper flange 42 of body member 22
utilizing a plurality of studs 44 and nuts 45. A standard sealing
gasket 51 cooperates with a groove 108 formed in the wellhead
isolation tool 100 and groove 48 in the upper flange 42 of body
member 22 in order to maintain concentricity and a seal between
wellhead isolation tool 100 and upper flange 42. With this
embodiment, excess loads on the wellhead isolation tool 100 are
transmitted to the flange 110 and redistributed through studs 44
and nuts 45 to upper flange 42.
[0038] Now referring to FIG. 5, with the wellhead isolation tool
100 installed in body member 22, outer surface 106 of wellhead
isolation tool 100 cooperates with cylindrical bore surface 76 of
body member 22. Seals 112 installed in grooves 104 machined in
outer surface 106 of wellhead isolation tool 100 cooperate with
surfaces 76 to effect a seal between body member 22 and wellhead
isolation tool 100. Alternatively, the seals are fitted in grooves
formed on the inner bore surface 76 of body member 22 and cooperate
with the outer surface 106 of the wellhead isolation tool. In the
exemplary embodiment, the seals are self energizing seals as for
example O-ring, T-seal and S-seal type seals. Other sealing schemes
known in the art may also be used in lieu or in combination with
the sealing schemes described herein.
[0039] As with the embodiment, shown in FIG. 1, pipe port 88
radially formed through body member 22 provides access for testing
seals 112 prior to placing wellhead isolation tool 100 in service.
Subsequent to testing, pipe port 88 is sealed with pipe plug 90.
Cylindrical bores 34, 102 and 86 formed through the production
casing18, through the exemplary embodiment wellhead isolation tool
100, and through the annular lip portion on 87 of the body member
22, respectively, are in an exemplary embodiment equal in diameter
thus providing an unrestricted passageway for fracturing materials
and/or downhole tools.
[0040] Referring again to FIG. 2, valve 96 is connected to body
member 22 by pipe nipple 94. Alternatively, the valve 96 may also
be connected to body member 22 by a flanged or studded outlet
preparation. Valve 96 may then be opened during the fracturing
process to bleed high pressures from cavity 114 in the event of
leakage past seals 112.
[0041] While the wellhead isolation tool has been described with
having an upper tapering portion 54 formed on its outer surface
which mates with a complementary tapering inner surface 52 of the
body member 22, an alternate exemplary embodiment of the wellhead
isolation tool does not have a tapering outer surface mating with
the tapering inner surface portion 52 of the body member. With the
alternate exemplary embodiment wellhead isolation tool, as for
example shown in FIG. 2, the wellhead isolation tool has an outer
surface 250 which mates with an inner surface 252 of the body
member which extends below the tapering inner surface portion 52 of
the body member 22. Features of the exemplary embodiment wellhead
isolation tool shown in FIG. 1 can interchanged with features of
the exemplary embodiment wellhead isolation tool shown in FIG. 2.
For example, instead of being coupled to a threaded secondary
flange 110, the exemplary embodiment isolation tool may be coupled
to the secondary flange 70 in the way shown in relation to the
exemplary embodiment wellhead isolation tool shown in FIG. 1.
[0042] With any of the aforementioned embodiments, the diameter of
the tubing head inner surface 291 (shown in FIGS. 1 and 2)
immediately above the area where the lower portion of the wellhead
isolation tool seals against the inner surface head of the tubing
head is greater than the diameter of the inner surface of the
tubing head against which the wellhead isolation tool seals and is
greater than the outer surface diameter of the lower portion of the
wellhead isolation tool. In this regard, the wellhead isolation
tool with seals 32 can be slid into and seal against the body
member of the tubing head assembly without being caught.
[0043] A further exemplary embodiment assembly 300 comprising a
further exemplary embodiment wellhead isolation tool or frac
mandrel 302, includes a lower housing assembly 10 also referred to
herein as a casing head assembly, an upper assembly 80 also
referred to herein as a fracturing tree, and intermediate body
assembly 20 also referred to herein as a tubing head assembly, and
the intermediate wellhead isolation tool 302 also referred to
herein as a frac mandrel, as shown in FIGS.7A and 7B. The casing
head assembly includes a casing head 304 into which is seated a
mandrel casing hanger 306. The casing head 304 has an internal
annular tapering surface 308 on which is seated a complementary
outer tapering surface 310 of the mandrel casing hanger. The
tapering outer surface 310 of the mandrel casing hanger defines a
lower portion of the mandrel casing hanger. Above the tapering
outer surface of the mandrel casing hanger extends a first
cylindrical outer surface 312 which mates with a cylindrical inner
surface of the casing head 304. One or more annular grooves, as for
example two annular grooves 316 are defined in the first
cylindrical outer surface 312 of the mandrel casing hanger and
accommodate seals 318. In the alternative, the grooves may be
formed on the inner surface of the casing head port for
accommodating the seals.
[0044] The mandrel casing hanger 306 has a second cylindrical outer
surface 320 extending above the first cylindrical outer surface 312
having a diameter smaller than the diameter of the first
cylindrical outer surface. A third cylindrical outer surface 322
extends from the second cylindrical outer surface and has a
diameter slightly smaller than the outer surface diameter of the
second cylindrical outer surface. External threads 324 may be
formed on the outer surface of the third cylindrical surface of the
mandrel casing hanger. An outer annular groove 326 is formed at the
juncture between the first and second cylindrical outer surfaces of
the mandrel casing hanger. Internal threads 328 are formed at the
upper end of the inner surface of the casing head. An annular
groove 330 is formed in the inner surface of the mandrel casing
head.
[0045] The inner surface of the mandrel casing hanger has three
major sections. A first inner surface section 332 at the lower end
which may be a tapering surface, as for example shown in FIG. 7B. A
second inner surface 334 extends from the first inner surface
section 332. In the exemplary embodiment shown in FIG. 7B, a
tapering annular surface 336 adjoins the first inner surface to the
second major inner surface. A third inner surface 338 extends from
the second inner surface. An annular tapering surface 340 adjoins
the third inner surface to the second inner surface. An upper end
342 of the third inner surface of the mandrel casing hanger
increases in diameter forming a depression 343 and an annular
shoulder 344.
[0046] Body member 350 also known as a tubing head of the tubing
head assembly 20 has a lower cylindrical portion 352 having an
outer surface which in the exemplary embodiment threadedly
cooperates with outer surface 354 of the third inner surface
section of the mandrel casing hanger. A protrusion 356 is defined
in an upper end of the lower cylindrical section of the body member
350 for mating with the depression 343 formed at the upper end of
the third inner surface of the mandrel casing hanger. The body
member 350 has an upper flange 360 and ports 362. The inner surface
of the body member is a generally cylindrical and includes a first
section 363 extending to the lower end of the body member. In the
exemplary embodiment shown in FIGS. 7A and 7B, the first section
extends from the ports 362. A second section 365 extends above the
ports 362 and has an outer diameter slightly greater than that of
the first section.
[0047] The wellhead isolation tool has a first external flange 370
for mating with the flange 360 of the body member of the tubing
head assembly. A second flange 372 is formed at the upper end of
the wellhead isolation tool for mating with the upper assembly 80.
A generally cylindrical section extends below the first flange 370
of the wellhead isolation tool. The generally cylindrical section
has a first lower section 374 having an outer surface diameter
equal or slightly smaller than the inner surface diameter of the
first inner surface section of the body member of the tubing head
assembly. A second section 376 of the wellhead isolation tool
cylindrical section extending above the first lower section 374 has
an outer surface diameter slightly smaller than the inner surface
diameter of the second section 365 of the body member 350 and
greater than the outer surface diameter of the first lower section
374. Consequently, an annular shoulder 371 is defined between the
two outer surface sections of the wellhead isolation tool
cylindrical section. The well head isolation tool is fitted within
the cylindrical opening of the body member of the tubing head
assembly such that the flange 370 of the wellhead isolation tool
mates with the flange 360 of the body member 350. When that occurs,
the annular shoulder 371 defined between the two outer surface
sections of the cylindrical section of the wellhead isolation tool
mates with the portion of the first section inner surface 363 of
the body member 350.
[0048] Prior to installing the mandrel casing hanger into the
casing head, a spring loaded latch ring 380 is fitted in the outer
groove 326 of the mandrel casing hanger. The spring loaded latch
ring has a generally upside down "T" shape in cross section
comprising a vertical portion 382 and a first horizontal portion
384 for sliding into the outer annular groove 326 formed on the
mandrel casing hanger. A second horizontal portion 386 extends from
the other side of the vertical portion opposite the first
horizontal portion.
[0049] The spring loaded latch ring is mounted on the mandrel
casing hanger such that its first horizontal portion 384 is fitted
into the external groove 326 formed in the mandrel casing hanger.
The spring loaded latch ring biases against the outer surface of
the mandrel casing hanger. When fitted into the external annular
groove 326 formed in the mandrel casing hanger, the outer most
surface of the second horizontal portion 386 of the latch ring has
a diameter no greater than the diameter of the first outer surface
section 312 of the mandrel casing hanger. In this regard, the
mandrel casing hanger with the spring loaded latch ring can be
slipped into the casing head so that the tapering outer surface 310
of the mandrel casing hanger can sit on the tapering inner surface
portion 308 of the casing head.
[0050] In the exemplary embodiment, once the mandrel casing hanger
is seated onto the casing head, the body member 350 of the tubing
head assembly is fitted within the casing head such that the lower
section of the outer surface of the body member threads on the
third section inner surface of the mandrel casing hanger such that
the protrusion 356 formed on the outer surface of the body member
is mated within the depression 343 formed on the upper end of the
third section inner surface of the mandrel casing hanger. The
wellhead isolation tool is then fitted with its cylindrical section
within the body member 350 such that the flange 370 of the wellhead
isolation tool mates with the flange 360 of the body member. When
this occurs, the annular shoulder 371 formed on the cylindrical
section of the wellhead isolation tool mates with the first section
363 of the inner surface of the body member 350. Similarly, the
lower outer surface section of the cylindrical section of the
wellhead isolation tool mates with the inner surface second section
334 of the mandrel casing hanger. Seals 388 are provided in grooves
formed 390 on the outer surface of the lower section of the
cylindrical section of the wellhead isolation tool to mate with the
second section inner surface of the mandrel casing hanger. In the
alternative, the seals may be positioned in grooves formed on the
second section inner surface of the mandrel casing hanger. In the
exemplary embodiment, the seals are self-energizing seals, as for
example, O-ring, T-seal or S-seal type seals.
[0051] A top nut 392 is fitted between the mandrel casing hanger
upper end portion and the upper end of the casing head. More
specifically, the top nut has a generally cylindrical inner surface
section having a first diameter portion 394 above which extends a
second portion 396 having a diameter greater than the diameter of
the first portion. The outer surface 398 of the top nut has four
sections. A first section 400 extending from the lower end of the
top nut having a first diameter. A second section 402 extending
above the first section having a second diameter greater than the
first diameter. A third section 404 extending from the second
section having a third diameter greater than the second diameter.
And a fourth section 406 extending from the third section having a
fourth diameter greater than the third diameter and greater than
the inner surface diameter of the upper end of the mandrel casing
hanger. Threads 408 are formed on the outer surface of the second
section 402 of the top nut for threading onto the internal threads
328 formed on the inner surface of the upper end of the mandrel
casing head. The top nut first and second outer surface sections
are aligned with the first inner surface section of the top nut. In
this regard, a leg 410 is defined extending at the lower end of the
top nut.
[0052] The top nut is threaded on the inner surface of the casing
head. As the top nut moves down on the casing head, the leg 410 of
the top nut engages the vertical portion 382 of the spring loaded
latch ring, moving the spring loaded latch ring radially outwards
against the latch ring spring force such that the second horizontal
portion 386 of the latch ring slides into the groove 330 formed on
the inner surface of the casing head while the first horizontal
portion remains within the groove 326 formed on the outer surface
of the mandrel casing head. In this regard, the spring loaded latch
ring along with the top nut retain the mandrel casing hanger within
the casing head.
[0053] A seal 412 is formed on the third outer surface section of
the top nut for sealing against the casing head. In the alternative
the seal may be formed on the casing head for sealing against the
third section of the top nut. A seal 414 is also formed on the
second section inner surface of the top nut for sealing against the
outer surface of the mandrel casing hanger. In the alternative, the
seal may be formed on the outer surface of the casing hanger for
sealing against the second section of the inner surface of the top
nut.
[0054] To check the seal between the outer surface of the lower
section of the cylindrical section of the wellhead isolation tool
and the inner surface of the mandrel casing hanger, a port 416 is
defined radially through the flange 370 of the wellhead isolation
tool. The port provides access to a passage 415 having a first
portion 417 radially extending through the flange 370, a second
portion 418 extending axially along the cylindrical section of the
wellhead isolation tool, and a third portion 419 extending radially
outward to a location between the seals 318 formed between the
lower section of the wellhead isolation tool and the mandrel casing
hanger. Pressure, such as air pressure, may be applied to port 416
to test the integrity of the seals 318. After testing the port 416
is plugged with a pipe plug 413.
[0055] With any of the aforementioned exemplary embodiment wellhead
isolation tools, a passage such as the passage 415 shown in FIG.
7A, may be provided through the body of the wellhead isolation to
allow for testing the seals or between the seals at the lower end
of the wellhead isolation tool from a location on the wellhead
isolation tool remote from such seals.
[0056] The upper assembly is secured on the wellhead isolation tool
using methods well known in the art such as bolts and nuts.
Similarly, an exemplary embodiment wellhead isolation tool is
mounted on the tubing head assembly using bolts 409 and nuts
411.
[0057] In another exemplary embodiment assembly of the present
invention shown in FIG. 8, a combination tubing head/casing head
body member 420 is used instead of a separate tubing head and
casing head. Alternatively, an elongated tubing head body member
coupled to a casing head may be used. In the exemplary embodiment
shown in FIG. 8, the body member is coupled to the wellhead. A
wellhead isolation tool 422 used with this embodiment comprises an
intermediate flange 424 located below a flange 426 interfacing with
the upper assembly 80. An annular step 425 is formed on the lower
outer periphery of the intermediate flange. When the wellhead
isolation tool 422 is fitted in the body member 420, the annular
step 425 formed on the intermediate flange seats on an end surface
427 of the body member. A seal 429 is fitted in a groove formed on
the annular step seals against the body member 420. Alternatively
the groove accommodating the seal may be formed on the body member
420 for sealing against the annular step 425. Outer threads 428 are
formed on the outer surface of the intermediate flange 424. When
fitted into the body member 420, the intermediate flange 424 sits
on an end portion of the body member 420. External grooves 430 are
formed on the outer surface near an upper end of the body member
defining wickers. In an alternate embodiment threads may be formed
on the outer surface near the upper end of the body member.
[0058] With this exemplary embodiment, a mandrel casing hanger 452
is mated and locked against the body member 420 using a spring
loaded latch ring 432 in combination with a top nut 434 in the same
manner as described in relation to the exemplary embodiment shown
in FIGS. 7A and 7B. However, the top nut 434 has an extended
portion 436 defining an upper surface 438 allowing for the landing
of additional wellhead structure as necessary. For example, another
hanger (not shown) may be landed on the upper surface 438. In
another exemplary embodiment, internal threads 454 are formed on
the inner surface of the body member to thread with external
threads formed in a second top nut which along with a spring latch
ring that is accommodated in groove 456 formed on the inner surface
of the body member 420 can secure any additional wellhead structure
such as second mandrel seated on the top of the extended portion of
top nut 434.
[0059] Once the wellhead isolation tool 422 is seated on the body
member 420, a segmented lock ring 440 is mated with the wickers 430
formed on the outer surface of the body member. Complementary
wickers 431 are formed on the inner surface of the segmented lock
ring and intermesh with the wickers 430 on the outer surface of the
body member. In an alternate embodiment, the segmented lock ring
may be threaded to a thread formed on the outer surface of the body
member. An annular nut 442 is then threaded on the threads 428
formed on the outer surface of the intermediate flange 424 of the
wellhead isolation tool. The annular flange has a portion 444 that
extends over and surrounds the segmented lock ring. Fasteners
(i.e., load applying members) 446 are threaded through the annular
nut and apply pressure against the segmented lock ring 440 locking
the annular nut relative to the segmented lock ring.
[0060] In an exemplary embodiment, the segmented lock ring 440 is
formed from segments 500 as for example shown in FIGS. 9 and 10. On
their inner surface 502 the segments have wickers 504. A slot 506
is formed through the outer surface 508 of the segment 500. The
slot has a narrower portion 510 extending to the outer surface 508
and a wider portion 512 adjacent the narrower portion defining a
dove-tail type of slot in cross-section. In the exemplary
embodiment the slot extends from an upper edge 514 of the segment
to a location proximate the center of the segment. In alternate
embodiments, the slot an extend from any edge of the segment and
may extend to another edge or any other location on the segment.
With these exemplary embodiments, a fastener (i.e., a load applying
member) 516 as shown in FIG. 10 is used with each segment instead
of fastener 446. The fastener 516 has a tip 518 having a first
diameter smaller than the width of the slot wider portion but
greater than the width of the slot narrower portion. A neck 520
extends from the tip to the body 522 of the fastener. The neck has
diameter smaller than the width of the slot narrower portion. The
tip and neck slide within dove-tail slot 506, i.e. the tip slides
in the wider section of the slot and the neck slider in the slot
narrower section and mechanically interlock with the segment
500.
[0061] In some exemplary embodiments, as for example the exemplary
embodiment shown in FIG. 10, the wickers formed on the segment 500
have tapering upper surfaces 524 which mate with tapering lower
surfaces on the wickers formed on the body member 420.
Alternatively, the segment wicker lower surfaces are tapered for
mating with body member wicker upper surfaces. In other
embodiments, both the upper and lower surfaces of the wickers are
tapered. In yet further exemplary embodiments, the wickers do not
have tapering surfaces. By tapering the surfaces of the wickers, as
for example the upper surfaces of the segment wickers, more wicker
surface area becomes available for the transfer of load.
[0062] When one set of wicker surfaces are tapered, as for example,
the upper or lower surfaces, then, by orienting the slot 506 to
extend to one edge of the segment, as for example the upper edge as
shown in FIGS. 9 and 10, the segment installer will know that the
segment wicker tapered surfaces are properly oriented when the slot
506 is properly oriented. For example, when the segment 500 is
mounted with the slot 506 extending to the upper edge of the
segment, proper mating of the wicker tapered surfaces formed on the
segment and on the body member 420 is assured.
[0063] An internal thread 448 is formed on the lower inner surface
of the annular nut 442. A lock nut 450 is threaded onto the
internal thread 448 of the annular nut and is sandwiched between
the body member 420 and the annular nut 442. In the exemplary
embodiment shown in FIGS. 8 and 9, the lock nut 450 is threaded
until it engages the segmented locking ring 440. Consequently, the
wellhead isolation tool 422 is retained in place seated on the body
member 420.
[0064] The connection using the segmented lock ring 450 and lock
nut can be used to couple all types of wellhead equipment including
the body member 420 to the annular nut 442 as described herein. Use
of a segmented lock ring and lock nut allows for the quick coupling
and decoupling of the wellhead assembly members.
[0065] Seals 460 is formed between a lower portion of the wellhead
isolation tool 422 and an inner surface of the hanger 452. This is
accomplished by fitting seals 460 in grooves 462 formed on the
outer surface of the wellhead isolation tool 422 for sealing
against the inner surface of hanger 452. Alternatively the seals
may be fitted in grooves formed on the inner surface of the hanger
452 for sealing against the outer surface of the wellhead isolation
tool. To check the seal between the outer surface of the wellhead
isolation tool 422 and the inner surface of the hanger 452, a port
465 is defined through the flange 426 of the wellhead isolation
tool and down along the well head isolation tool to a location
between the seals 460 formed between the wellhead isolation tool
and the hanger 452.
[0066] With any of the aforementioned embodiment, one or more seals
may be used to provide the appropriate sealing. Moreover, any of
the aforementioned embodiment wellhead isolation tools and
assemblies provide advantages in that they isolate the wellhead or
tubing head body from pressures of refraction in process while at
the same time allowing the use of a valve instead of a BOP when
forming the upper assembly 80. In addition, by providing a seal at
the bottom portion of the wellhead isolation tool, each of the
wellhead isolation exemplary embodiment tools of the present
invention isolate the higher pressures to the lower sections of the
tubing head or tubing head/casing head combination which tend to be
heavier sections and can better withstand the pressure loads.
Furthermore, they allow for multiple fracturing processes and allow
the wellhead isolation tool to be used in multiple wells without
having to use a BOP between fracturing processes from wellhead to
wellhead. Consequently, multiple BOPs are not required when
fracturing multiple wells.
[0067] The wellhead isolation tools of the present invention as
well as the wellhead assemblies used in combination with the
wellhead tools of the present invention including, among other
things, the tubing heads and casing heads may be formed from steel,
steel alloys and/or stainless steel. These parts may be formed by
various well known methods such as casting, forging and/or
machining.
[0068] While the present invention will be described in connection
with the depicted exemplary embodiments, it will be understood that
such description is not intended to limit the invention only to
those embodiments, since changes and modifications may be made
therein which are within the full intended scope of this invention
as hereinafter claimed.
* * * * *