U.S. patent application number 10/827186 was filed with the patent office on 2004-10-07 for methods and apparatus for interconnecting well tool assemblies in continuous tubing strings.
Invention is credited to Connell, Michael L., Gano, John C., Laursen, Patrick E., Maerefat, Nicida, Restarick, Henry L..
Application Number | 20040194950 10/827186 |
Document ID | / |
Family ID | 25147045 |
Filed Date | 2004-10-07 |
United States Patent
Application |
20040194950 |
Kind Code |
A1 |
Restarick, Henry L. ; et
al. |
October 7, 2004 |
Methods and apparatus for interconnecting well tool assemblies in
continuous tubing strings
Abstract
A well tool assembly interconnection method is provided. In a
described embodiment, a continuous tubing string has connectors
positioned corresponding to desired locations for tool assemblies
in a well. The tubing string is wrapped on a reel and transported
to a well. As the tubing string is deployed from the reel into the
well, the tool assemblies are interconnected between the
connectors. A tool assembly having sensors embedded in a sidewall
thereof is also provided.
Inventors: |
Restarick, Henry L.;
(Carrollton, TX) ; Gano, John C.; (Carrollton,
TX) ; Laursen, Patrick E.; (Sugar Land, TX) ;
Connell, Michael L.; (Duncan, OK) ; Maerefat,
Nicida; (Houston, TX) |
Correspondence
Address: |
TIMOTHY E. NIEDNAGEL
BOSE McKINNEY & EVANS LLP
135 N. PENNSYLVANIA STREET
ROOM 2700
INDIANAPOLIS
IN
46204
US
|
Family ID: |
25147045 |
Appl. No.: |
10/827186 |
Filed: |
April 19, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10827186 |
Apr 19, 2004 |
|
|
|
10396590 |
Mar 25, 2003 |
|
|
|
6766853 |
|
|
|
|
10396590 |
Mar 25, 2003 |
|
|
|
09789249 |
Feb 20, 2001 |
|
|
|
6561278 |
|
|
|
|
Current U.S.
Class: |
166/66 |
Current CPC
Class: |
E21B 17/04 20130101;
E21B 17/028 20130101; E21B 17/206 20130101 |
Class at
Publication: |
166/066 |
International
Class: |
E21B 029/02 |
Claims
What is claimed is:
1. A sensor apparatus for interconnection in a tubular string in a
well, comprising: a generally tubular body having a sidewall
material; at least one line embedded in the sidewall material; and
at least one sensor embedded in the sidewall material and
operatively connected to the line.
2. The sensor apparatus according to claim 1 wherein the sidewall
material is nonmetallic.
3. The sensor apparatus according to claim 1 wherein the sidewall
material is a composite material.
4. The sensor apparatus according to claim 1 wherein the line is a
selected one of a hydraulic line, an electrical line and a fiber
optic line.
5. The sensor apparatus according to claim 1 wherein the line is a
selected one of a communication line, a power line, a control line
and a monitoring line.
6. The sensor apparatus according to claim 1 wherein the sensor
senses a parameter internal to the tubular body.
7. The sensor apparatus according to claim 1 wherein the sensor
senses a parameter external to the tubular body.
8. The sensor apparatus according to claim 1 wherein the sensor is
a seismic sensor.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of co-pending application
Ser. No. 10/396,590 filed Mar. 25, 2003, which is a divisional of
application Ser. No. 09/789,249 filed Feb. 20, 2001, now U.S. Pat.
No. 6,561,278 B2.
BACKGROUND
[0002] The present invention relates generally to operations
performed and equipment utilized in conjunction with a subterranean
well and, in an embodiment described herein, more particularly
provides methods and apparatus for interconnecting well tool
assemblies in continuous tubing strings.
[0003] Continuous tubing strings, such as coiled tubing strings,
have been used for many years in wells. However, one problem with
continuous tubing strings is how to interconnect well tool
assemblies in the tubing strings.
[0004] If a well tool assembly is to be interconnected in a
continuous tubing string then, of course, the tubing string must be
severed and connections must be made between the tool assembly and
the tubing at each end of the tool assembly. With present methods
and apparatus, this operation may require many hours to
perform.
[0005] Continuous tubing strings having lines embedded in their
sidewalls have recently become available for use in wells. An
example is FIBERSPAR composite coiled tubing available from
Fiberspar Spoolable Products, Inc. of Houston, Tex. The FIBERSPAR
composite coiled tubing is a composite coiled tubing with eight
conductors embedded in its sidewall. Making a connection between
this tubing and a tool assembly at a wellsite, where the tubing is
severed (i.e., there is no preexisting connector attached to the
tubing), typically takes approximately 12 hours to accomplish.
[0006] One solution that has been proposed is to interconnect well
tool assemblies in the tubing string, and then spool the well tool
assemblies on a reel along with the tubing. The reel is then
delivered to the wellsite with the tool assemblies already
interconnected therein, and the tubing string may be conveyed into
the well, without having to make connections at the wellsite. One
problem with this approach is that the well tool assemblies may
have an outer diameter greater than that of the tubing, in which
case spooling the tool assemblies on the reel with the tubing may
cause damaging stresses to be imparted to the tubing, and special
injector heads are needed to convey the large diameter tool
assemblies into the well. Another problem is that many tool
assemblies, such as well screens and packers, may be too long and
inflexible to be spooled onto the reel.
[0007] Therefore, it may be seen that there exists a need for
improved methods and apparatus for interconnecting well tool
assemblies in continuous tubing strings.
SUMMARY
[0008] In carrying out the principles of the present invention, in
accordance with embodiments thereof, methods and apparatus are
provided which solve the above problems in the art. In one
embodiment, a method is provided which permits well tool assemblies
to be rapidly interconnected in a continuous tubing string at a
wellsite.
[0009] In one aspect of the invention, a method is provided in
which tool connectors are attached to a tubing string at respective
predetermined downhole locations for tool assemblies. The tubing
string is wrapped onto a reel with the attached connectors. The
tubing string is then deployed into a well from the reel. As the
tubing string is deployed, the tool assemblies are connected to the
respective connectors.
[0010] In another aspect of the invention, a method is provided
which permits a line extending through a tubing string to be
extended through a tool assembly interconnected into the tubing
string. Connectors are used which both connect the line at each end
of the tool assembly and structurally attach the tool assembly to
the tubing. Such connectors are also used to connect between
portions of the tubing.
[0011] In a further aspect of the invention, a connector system is
provided. A connector of the system includes a gripping structure
for grippingly engaging the tubing string, an internal seal
structure for sealingly engaging an interior of the tubing string
and an external seal structure for sealingly engaging an exterior
of the tubing string. Where the tubing string has a line extending
therethrough, the connector includes a line connector attached to
the line in the tubing string.
[0012] In a still further aspect of the invention, a sensor
apparatus is provided. The sensor apparatus includes sensors
embedded in a sidewall material of a tubular body of the apparatus.
The sensors are connected to one or more lines also embedded in the
sidewall material.
[0013] These and other features, advantages, benefits and objects
of the present invention will become apparent to one of ordinary
skill in the art upon careful consideration of the detailed
description of representative embodiments of the invention
hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic partially cross-sectional side view of
an apparatus embodying principles of the present invention;
[0015] FIG. 2 is an elevational view of a tubing reel utilized in
the apparatus of FIG. 1;
[0016] FIGS. 3-5 are side elevational views of alternate connector
systems utilized in the apparatus of FIG. 1;
[0017] FIG. 6 is a quarter-sectional view of a first connector
embodying principles of the present invention;
[0018] FIG. 7 is a quarter-sectional view of a second connector
embodying principles of the present invention;
[0019] FIG. 8 is an enlarged cross-sectional view of an alternate
seal structure for use with the second connector;
[0020] FIG. 9 is a partially cross-sectional view of a sensor
apparatus embodying principles of the present invention; and
[0021] FIG. 10 is a schematic partially cross-sectional side view
of a variation of the apparatus of FIG. 1.
DETAILED DESCRIPTION
[0022] Representatively illustrated in FIG. 1 is an apparatus 10
which embodies principles of the present invention. In the
following description of the apparatus 10 and other apparatus and
methods described herein, directional terms, such as "above",
"below", "upper", "lower", etc., are used only for convenience in
referring to the accompanying drawings. Additionally, it is to be
understood that the various embodiments of the present invention
described herein may be utilized in various orientations, such as
inclined, inverted, horizontal, vertical, etc., and in various
configurations, without departing from the principles of the
present invention.
[0023] In the apparatus 10, a continuous tubing string 12 is
deployed into a well from a reel 14. Since the tubing string 12 is
initially wrapped on the reel 14, such continuous tubing strings
are commonly referred to as "coiled" tubing strings. As used
herein, the term "continuous" means that the tubing string is
deployed substantially continuously into a well, allowing for some
interruptions to interconnect tool assemblies therein, as opposed
to the manner in which segmented tubing is deployed piecemeal into
a well in "joints" or in "stands" limited in length by the height
of a rig at the well.
[0024] Tubing 16 comprises the vast majority of the tubing string
12. The tubing 16 may be made of a metallic material, such as
steel, or it may be made of a nonmetallic material, such as a
composite material. As described below, the present invention also
provides connectors which permit tool assemblies to be
interconnected in the tubing string 12 where the tubing 16 is made
of a composite material and has lines embedded in a sidewall
thereof.
[0025] In the past, tool assemblies in a continuous tubing string
have either been spliced into the tubing string just before being
deployed into a well, or have been wrapped on a reel with the
tubing, so that no splicing is needed when the tubing string is
deployed into the well. The former method is very time-consuming
and inconvenient to perform at the well, especially in those cases
where a composite tubing is used, or where lines extend through the
tubing string. The second method requires that the tool assemblies
be wrapped on the reel, which may be impossible for very long or
rigid assemblies, or for assemblies with diameters so large that
they interfere with the wrapping of the tubing on the reel, and
which requires special expandable injector heads, as described in
U.S. Pat. No. 6,082,454, the disclosure of which is incorporated
herein by this reference.
[0026] In the present apparatus 10, well tool assemblies 18 (a
packer), 20 (a valve), 22 (a sensor apparatus), 24 (a well screen)
and 26 (a spacer or blast joint) are interconnected in the tubing
string 12 without requiring splicing of the tubing 16 at the well,
and without requiring the tool assemblies to be wrapped on the reel
14. Instead, connectors 28, 30 are provided in the tubing string 12
above and below, respectively, each of the tool assemblies 18, 20,
22, 24, 26. These connectors 28, 30 are incorporated into the
tubing string 12 prior to, or as, it is being wrapped on the reel
14, with each connector's position in the tubing string 12 on the
reel 14 corresponding to a desired location for the respective tool
assembly in the well.
[0027] That is, the connectors 28, 30 are placed in the tubing
string 12 at appropriate positions, so that when the tool
assemblies 18, 20, 22, 24, 26 are interconnected to the connectors
28, 30 and the tubing string 12 is deployed into the well, the tool
assemblies will be at their respective desired locations in the
well. The tubing string 12 with the connectors 28, 30 is wrapped on
the reel 14 prior to being transported to the well. At the well,
the tool assemblies 18, 20, 22, 24, 26 are interconnected between
the connectors 28, 30 as the tubing string 12 is deployed into the
well from the reel 14. In this manner, the tool assemblies 18, 20,
22, 24, 26 do not have to be wrapped on the reel 14, and the tool
assemblies do not have to be spliced into the tubing 16 at the
well.
[0028] Referring additionally now to FIG. 2, a view of the reel 14
is depicted in which the connectors 28, 30 are shown wrapped with
the tubing 16 on the reel 14. In this view it may be clearly seen
that the connectors 28, 30 are interconnected to the tubing 16
prior to the tubing 16 being wrapped on the reel 14. As described
above, the connectors 28, 30 are positioned to correspond to
desired locations of particular tool assemblies in a well.
Placeholders 38 are used to substitute for the respective tool
assemblies between the connectors 28, 30 when the tubing 16 is
wrapped on the reel 14.
[0029] Referring additionally now to FIGS. 3-5, various alternate
connector systems 32, 34, 36 are representatively illustrated. In
the system 32 depicted in FIG. 3, both of the connectors 28, 30 are
male-threaded, and so a placeholder 40 used to connect the
connectors 28, 30 together while the tubing string 16 is on the
reel 14 has opposing female threads. In the system 34 depicted in
FIG. 4, the connector 28 has male threads, the connector 30 has
female threads, and so a placeholder 42 has both male and female
threads. In the system 36 depicted in FIG. 5, no placeholder is
used. Instead, the male-threaded connector 28 is directly connected
to the female-threaded connector 30 when the tubing 16 is wrapped
on the reel 14.
[0030] Thus, it may be clearly seen that a variety of methods may
be used to provide the connectors 28, 30 in the tubing string 12.
Of course, it is not necessary for the connectors 28, 30 to be
threaded, or for any particular type of connector to be used. Any
connector may be used in the apparatus 10, without departing from
the principles of the present invention.
[0031] Referring additionally now to FIG. 6, a connector 44
embodying principles of the present invention is representatively
illustrated. The connector 44 may be used for the connector 28 or
30 in the apparatus 10, or it may be used in other apparatus.
[0032] The connector 44 is configured for use with a composite
tubing 46, which has one or more lines 48 embedded in a sidewall
thereof. A slip, ferrule or serrated wedge 50, or multiple ones of
these, is used to grip an exterior surface of the tubing 46. The
slip 50 is biased into gripping engagement with the tubing 46 by
tightening a sleeve 58 onto a housing 60.
[0033] A seal 52 seals between the exterior surface of the tubing
46 and the sleeve 58. Another seal 54 seals between an interior
surface of the tubing 46 and the housing 60. A further seal 62
seals between the sleeve 58 and the housing 60. In this manner, an
end of the tubing 46 extending into the connector 44 is isolated
from exposure to fluids inside and outside the connector.
[0034] A barb 56 or other electrically conductive member is
inserted into the end of the tubing 46, so that the barb 56
contacts the line 48. A potting compound 72, such as an epoxy, may
be used about the end of the tubing 46 and the barb 56 to prevent
the barb 56 from dislodging from the tubing 46 and/or to provide
additional sealing for the electrical connection. Another conductor
64 extends from the barb 56 through the housing 60 to an electrical
contact 66. The barb 56, conductor 64 and contact 66 thus provide a
means of transmitting electrical signals and/or power from the line
48 to the lower end of the connector 44.
[0035] Shown in dashed lines in FIG. 6 is a mating connector or
tool assembly 68, which includes another electrical contact 70 for
transmitting the signals/power from the contact 66 to the connector
or tool assembly 68.
[0036] Although the line 48 has been described above as being an
electrical line, it will be readily appreciated that modifications
may be made to the connector 44 to accommodate other types of
lines. For example, the line 48 could be a fiber optic line, in
which case a fiber optic coupling may be used in place of the
contact 66, or the line 48 could be a hydraulic line, in which case
a hydraulic coupling may be used in place of the contact 66. In
addition, the line 48 could be used for various purposes, such as
communication, chemical injection, electrical or hydraulic power,
monitoring of downhole equipment and processes, and a control line
for, e.g., a safety valve, etc. Of course, any number of lines 48
may be used with the connector 44, without departing from the
principles of the present invention.
[0037] Referring additionally now to FIG. 7, an upper connector 74
and a lower connector 76 embodying principles of the present
invention are representatively illustrated. These connectors 74, 76
may be used for the connectors 28, 30 in the apparatus 10, or they
may be used in any other apparatus.
[0038] The connectors 74, 76 are designed for use with a composite
tubing 78. The tubing 78 has an outer wear layer 80, a layer 82 in
which one or more lines 84 is embedded, a structural layer 86 and
an inner flow tube or seal layer 88. This tubing 78 is similar to
the FIBERSPAR composite coiled tubing referred to above. One or
more lines 90 may also be embedded in the seal layer 88.
[0039] The wear layer 80 provides abrasion resistance to the tubing
78. The structural layer 86 provides strength to the tubing 78, but
the structural layer 86 may be somewhat porous. The layers 82, 88
isolate the structural layer 86 from contact with fluids internal
and external to the tubing 78, and provide sealed pathways for the
lines 84, 90 in a sidewall of the tubing 78. Thus, if the lines 84,
90 are electrical conductors, the layers 82, 88 provide insulation
for the lines. Of course, any type of line may be used for the
lines 84, 90, without departing from the principles of the
invention.
[0040] The upper connector 74 includes an outer housing 92, a
sleeve 94 threaded into the housing 92, a mandrel 96 and an inner
seal sleeve 98. The upper connector 74 is sealed to an end of the
tubing 78 extending into the upper connector 74 by means of a seal
assembly 100, which is compressed between the sleeve 94 and the
housing 92, and by means of sealing material 102 carried externally
on the inner seal sleeve 98.
[0041] The mandrel 96 grips the structural layer 86 with multiple
collets 104 (only one of which is visible in FIG. 7) having teeth
formed on inner surfaces thereof. Multiple inclined surfaces are
formed externally on each of the collets 104, and these inclined
surfaces cooperate with similar inclined surfaces formed internally
on the housing 92 to bias the collets 104 inward into engagement
with the structural layer 86. A pin 106 prevents relative rotation
between the mandrel 96 and the tubing 78.
[0042] The line 84 extends outward from the layer 82 and into the
upper connector 74. The line 84 passes between the collets 104 and
into a passage 108 formed through the mandrel 96. At a lower end of
the mandrel 96, the line 84 is connected to a line connector 110.
If the line 90 is provided in the seal layer 88, the line 90 may
also extend through the passage 108 in the mandrel 96 to the line
connector 110, or to another line connector
[0043] The line connector 110 is depicted as being a pin-type
connector, but it may be a contact, such as the contact 66
described above, or it may be any other type of connector. For
example, if the lines 84, 90 are fiber optic or hydraulic lines,
then the line connector 110 may be a fiber optic or hydraulic
coupling, respectively.
[0044] When the connectors 74, 76 are connected to each other, an
annular projection 112 formed on a lower end of the inner seal
sleeve 98 initially sealingly engages an annular seal 114 carried
on an upper end of an inner sleeve 116 of the lower connector 76.
Further tightening of a threaded collar 118 between the housing 92
and a housing 120 of the lower connector 76 eventually brings the
line connector 110 into operative engagement with a mating line
connector 122 (depicted in FIG. 7 as a socket-type connector) in
the lower connector 76, and then brings an annular projection 124
into sealing engagement with an annular seal 126 carried on an
upper end of the housing 120. The seals 114, 126 isolate the line
connectors 110, 122 (and the interiors of the connectors 74, 76)
from fluid internal and external to the connectors
[0045] Since the lower connector 76 is otherwise similarly
configured to the upper connector 74, it will not be further
described herein. Note that both of the connectors 74, 76 may be
connected to tool assemblies, such as the tool assemblies 18, 20,
22, 24, 26, so that connections to lines may be made on either side
of each of the tool assemblies. Thus, the lines 84, 90 may extend
through each of the tool assemblies from a connector above the tool
assembly to a connector below the tool assembly. This functionality
is also provided by the connector 44 described above
[0046] Referring additionally now to FIG. 8, an alternate seal
configuration 128 is representatively illustrated. The seal
configuration 128 may be used in place of either the projection 112
and seal 114, or the projection 124 and seal 126, of the connectors
74, 76.
[0047] The seal configuration 128 includes an annular projection
130 and an annular seal 132. However, the projection 130 and seal
132 are configured so that the projection 130 contacts shoulders
134, 136 to either side of the seal 132. This contact prevents
extrusion of the seal 132 due to pressure, and also provides
metal-to-metal seals between the projection 130 and the shoulders
134, 136.
[0048] Referring additionally now to FIG. 9, an example is
representatively illustrated of a tool assembly 138 which may be
interconnected in a continuous tubing string. The tool assembly 138
is a sensor apparatus. It includes sensors 140, 142, 144, 146
interconnected to lines 148, 150 embedded in a sidewall material of
a tubular body 152 of the tool assembly 138
[0049] The sensors 140, 142, 144, 146 are also embedded in the
sidewall material of the body 152. The sensors 140, 142, 144 sense
parameters internal to the body 152, and the sensor 146 senses one
or more parameter external to the body 152. Any type of sensor may
be used for any of the sensors 140, 142, 144, 146
[0050]
[0051] For example, pressure and temperature sensors may be used.
It would be particularly advantageous to use a combination of types
of sensors for the sensors 140, 142, 144, 146 which would allow
computation of values, such as multiple phase flow rates through
the tool assembly 138
[0052] As another example, it would be advantageous to use a
seismic sensor for one or more of the sensors 140, 142, 144, 146.
This would make available seismic information previously
unobtainable from the interior of a sidewall of a tubing
string.
[0053] Note that the sidewall material is preferably a nonmetallic
composite material, but other types of materials may be utilized,
in keeping with the principles of the invention. In particular, the
body 152 could be a section of composite tubing, in which the
sensors 140, 142, 144, 146 have been installed and connected to the
lines 148,150.
[0054] The lines 148, 150 may be any type of line, including
electrical, hydraulic, fiber optic, etc. Additional lines (not
shown in FIG. 9) may extend through or into the tool assembly 138.
Connectors 154, 156 permit the tool assembly 138 to be conveniently
interconnected in a tubing string. For example, the connector 76
described above may be used for the connector 154, and the
connector 74 described above may be used for the connector 156. Via
the connectors 154, 156, the lines 148, 150 are connected to lines
extending through tubing or other tool assemblies attached to each
end of the tool assembly 138
[0055] Referring additionally now to FIG. 10, the apparatus 10 is
representatively illustrated wherein a tool assembly 160 is being
interconnected into the tubing string 12. The tool assembly 160 is
too long, too rigid, or too large in diameter to be wrapped on the
reel 14 with the tubing 16.
[0056] Connectors 28, 30 are separated (and a placeholder 38 is
removed, if necessary) prior to interconnecting the tool assembly
160 in the tubing string 12. The tool assembly 160 is connected to
the lower connector 30, the tubing string 12 is lowered, and then
the tool assembly 160 is connected to the upper connector 28. As
described above, the connectors 28, 30 are provided already
connected to the tubing 16 when the tubing 16 is wrapped on the
reel 14 and transported to the well, so that when the tool assembly
160 is interconnected between the connectors 28, 30 and the tubing
string 12 is deployed into the well, the tool assembly 160 will be
appropriately positioned in the well.
[0057] In one embodiment of the present invention, the tool
assembly 160 is a spacer used to space out other equipment in the
tubing string 12. An example of this use is shown in FIG. 1,
wherein the tool assembly 26 may be used to correct or adjust the
spacing between, e.g., the well screen 24 and perforations in the
well. Such corrections or adjustments in tool spacings in the
tubing string 12 are conveniently made at the wellsite by means of
the tool assembly 160 or 26. Note that, when used in this manner,
the tool assembly 160 or 26 is not necessarily too long, too rigid,
or too large in diameter to be wrapped on the reel 14 with the
tubing 16.
[0058] Of course, a person skilled in the art would, upon a careful
consideration of the above description of representative
embodiments of the invention, readily appreciate that many
modifications, additions, substitutions, deletions, and other
changes may be made to these specific embodiments, and such changes
are contemplated by the principles of the present invention.
Accordingly, the foregoing detailed description is to be clearly
understood as being given by way of illustration and example only,
the spirit and scope of the present invention being limited solely
by the appended claims.
* * * * *