U.S. patent application number 11/941528 was filed with the patent office on 2008-05-22 for well barrier apparatus and associated methods.
This patent application is currently assigned to WEATHERFORD/LAMB, INC.. Invention is credited to ROBERT COON, Michael J. Foster.
Application Number | 20080115944 11/941528 |
Document ID | / |
Family ID | 38896574 |
Filed Date | 2008-05-22 |
United States Patent
Application |
20080115944 |
Kind Code |
A1 |
COON; ROBERT ; et
al. |
May 22, 2008 |
WELL BARRIER APPARATUS AND ASSOCIATED METHODS
Abstract
A barrier forming apparatus is deployable through a conduit
component in a well. The apparatus has a snap latch that removably
couples to a work string. A mandrel element in the apparatus is
selectively moveable with the coupling element. A plurality of
locator dogs on the apparatus are spring biased and are activated
when pressure is applied to a piston in the apparatus, which
release the locator dogs. Once activated, the locator dogs engage a
first grove the in the conduit component. When the work string is
pulled up while the apparatus is held by the locator dogs, a
plurality of locking dogs are activated by movement of a mandrel
element caused by the work string. The locking dogs engage second
grooves in the conduit component. Continued pulling of the work
string moves a cone attached to a distal end of the mandrel
element, and the moving cone deforms a barrier element positioned
between an end of the apparatus' housing and the cone. The deformed
barrier element forms a barrier in the conduit component between
upper and lower completions. Removal of the barrier is achieved by
reversing the steps. The apparatus can be used to isolate an
expandable sand screen section below the conduit component.
Inventors: |
COON; ROBERT; (Missouri
City, TX) ; Foster; Michael J.; (Katy, TX) |
Correspondence
Address: |
WONG, CABELLO, LUTSCH, RUTHERFORD & BRUCCULERI,;L.L.P.
20333 SH 249, SUITE 600
HOUSTON
TX
77070
US
|
Assignee: |
WEATHERFORD/LAMB, INC.
Houston
TX
|
Family ID: |
38896574 |
Appl. No.: |
11/941528 |
Filed: |
November 16, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60866902 |
Nov 22, 2006 |
|
|
|
Current U.S.
Class: |
166/387 ;
166/141 |
Current CPC
Class: |
E21B 33/12 20130101;
E21B 43/103 20130101 |
Class at
Publication: |
166/387 ;
166/141 |
International
Class: |
E21B 33/127 20060101
E21B033/127 |
Claims
1. A barrier forming apparatus deployable through a conduit in a
well, the apparatus comprising: a housing having a first end, a
second end, and a side, the side defining at least one first slot;
a coupler positioned at the first end of the housing and removably
coupling to a work string; a mandrel positioned in the housing and
moveable with the coupler, the mandrel having a distal end
extending beyond the second end of the housing; at least one first
dog positioned between the mandrel and the housing and being
moveable between a retracted position and an extended position
within the at least one first slot by movement of the mandrel; and
a barrier element positioned between the second end of the housing
and the distal end of the mandrel and being deformable by movement
of the distal end of the mandrel towards the second end of the
housing.
2. The apparatus of claim 1, wherein the distal end of the mandrel
comprises a body for at least partially expanding an expandable
sand screen in the well.
3. The apparatus of claim 1, wherein the coupler comprises a snap
latch latchable to a complimentary element on the work string.
4. The apparatus of claim 1, wherein the barrier element comprises
an elastomeric sleeve positioned about a portion of the
mandrel.
5. The apparatus of claim 4, wherein the elastomeric sleeve
comprises edge portions with a greater Durometer hardness than a
central portion.
6. The apparatus of claim 1, wherein the mandrel comprises a narrow
portion and a wide portion, the mandrel element being moveable to a
first position in which the narrow portion is adjacent the at least
one first dog and the at least one first dog is moveable to the
retracted position in the at least one first slot, the mandrel
being movable to a second position in which the wide portion is
adjacent the at least one first dog and the at least one first dog
is movable to the extended position in the at lease one first
slot.
7. The apparatus of claim 6, wherein the at least one first dog in
the extended position is engageable with at least one first groove
defined in an inner passage of the conduit.
8. The apparatus of claim 1, further comprising at least one second
dog positioned between the mandrel and the housing, the housing
defining at least one second slot, the at least one second dog
being movable between a retracted position and an extended position
within the at least one second slot.
9. The apparatus of claim 8, wherein the at least one second dog in
the extended position lockably engages at least one groove defined
in an inner passage of the conduit in a first direction toward the
first end of the housing.
10. The apparatus of claim 8, further comprising: a piston movable
from a first position to a second position on the mandrel by
pressure communicated from the work string coupled to the coupler,
the piston in the first position engaging the at least one second
dog in the retracted position, the piston in the second position
disengaging the at least one second dog; and a biasing element
biasing the at least one second dog from the retracted position
toward the extended position within the at least one second
slot.
11. The apparatus of claim 10, wherein the mandrel defines a
central bore communicating with the work string and defines a
passage communicating from the central bore to an outside surface
of the mandrel, the mandrel having a first seal on one side of the
passage and engaging the piston, the piston having a second seal
engaging the mandrel on another side of the passage.
12. A barrier forming system for a well, the system comprising: a
conduit deployable in the well, the conduit having an inner passage
and defining at least one first groove in the inner passage; and a
plug deployable through the conduit, the plug at least including: a
housing having a first end, a second end, and a side, the side
defining at least one first slot, a coupler positioned at the first
end of the housing and removably coupling to a work string, a
mandrel positioned in the housing and moveable with the coupler,
the mandrel having a distal end extending beyond the second end of
the housing, at least one first dog positioned between the mandrel
and the housing and being moveable between a retracted position and
an extended position within the at least one first slot by movement
of the mandrel, the at least one first dog in the extended position
being engagable with the at least one first groove in the inner
passage of the conduit, and a barrier element positioned between
the second end of the housing and the distal end of the mandrel,
the barrier element being deformable by movement of the distal end
of the mandrel towards the second end of the housing to engage the
inner passage of the conduit.
13. The system of claim 12, wherein the mandrel element comprises a
narrow portion and a wide portion, the mandrel element being
moveable to a first position in which the narrow portion is
adjacent the at least one first dog and the at least one first dog
is movable to the retracted position in the at least one first
slot, the mandrel being moveable to a second position in which the
wide portion is adjacent the at least one first dog and the at
least one first dog is movable to the extended position in the at
lease one first slot.
14. The system of claim 13, further comprising: a first lock
positioned on the mandrel and engageable with the housing when the
mandrel is in the first position; and a second lock positioned on
the mandrel and engageable with the housing when the mandrel is in
the second position.
15. The system of claim 12, further comprising at least one second
dog positioned in at least one second slot defined in the housing
and movable between a retracted position and an extended position
in the at least one second slot.
16. The system of claim 15, wherein the conduit defines at least
one second groove in the inner passage, and wherein the at least
one second dog in the extended position lockably engages the at
least one second groove in a first direction toward the first end
of the housing.
17. The system of claim 15, further comprising: a piston movable
from a first position to a second position on the mandrel by
pressure communicated from the work string coupled to the coupler,
the piston in the first position engaging the at least one second
dog in the retracted position, the piston in the second position
disengaging the at least one second dog; and a biasing element
biasing the at least one second dog from the retracted position
toward the extended position within the at least one second
slot.
18. The system of claim 17, wherein the mandrel defines a central
bore communicating with the work string and defines a passage
communicating from the central bore to an outside surface of the
mandrel, the mandrel having a first seal on one side of the passage
and engaging the piston, the piston having a second seal engaging
the mandrel on another side of the passage.
19. A well barrier method comprising the steps of: installing a
conduit in the well, the conduit defining one or more inner
grooves; deploying a plug in the well on an end of a work string;
engaging one or more dogs on the outside of the plug in the one or
more inner grooves to hold the plug in the conduit; deforming a
barrier element against the conduit by pulling up on the work
string; and disconnecting the end of the work string from the
plug.
20. The method of claim 19, wherein installing the conduit
comprises: installing the conduit below a liner hanger in the well,
and installing an expandable sand screen below the conduit.
21. The method of claim 20, wherein deploying the plug in the well
on the end of the work string further comprises using a cone shaped
portion on a distal end of the plug to at least partially expand
the expandable sand screen.
22. The method of claim 19, wherein engaging the one or more dogs
on the outside of the plug in the one or more inner grooves to hold
the plug in the conduit comprises: activating at least one of the
one or more dogs on the outside of the plug to engage at least one
of the one or more grooves by applying fluid pressure through the
work string.
23. The method of claim 22, wherein activating the at least one dog
comprises: biasing the at least one dog after applying fluid
pressure; and lockably engaging the at least one biased dog against
the at least one groove in only a first direction.
24. The method of claim 19, wherein deforming the barrier element
against the conduit by pulling up on the work string comprises
deforming the barrier element between an end of a mandrel of the
plug and a portion of a housing of the plug, the mandrel being
movable relative to the housing by the pulling up of the work
string.
25. The method of claim 19, wherein deforming the barrier element
against the conduit by pulling up on the work string comprises:
locking a movable mandrel within the plug; and locking the one or
more dogs in the one or more inner grooves with the locked movable
mandrel.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a non-provisional of U.S. Provisional Application
Ser. No. 60/866,902, filed 22 Nov. 2006, which is incorporated
herein by reference and to which priority is claimed.
BACKGROUND
[0002] Some wells may have an Expandable Sand Screen (ESS) system,
other type of screen, slotted liner, or other type of completion
open to the formation. In these wells, it is often necessary to use
a valve or other device between the upper and lower completions to
reduce or stop fluid loss to the formation. In many applications,
the valves are kept closed when needed and are then opened after
the upper completion is run, but the valves can never be closed
again. Although some valves (such as ball valves) can be opened and
closed multiple times, these types of valves typically have a
restricted inner diameter that prevents there use with an ESS
system. For example, the restricted inner diameter of such valves
cannot accommodate the various tools associated with the ESS
system, such as an expansion tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIGS. 1A-1L schematically illustrate a barrier plug
according to the present disclosure used with a lower completion
having expandable sand screen system.
[0004] FIG. 2 illustrates one embodiment of a barrier plug
according to the present disclosure.
[0005] FIGS. 3A-3C illustrate detailed sectional views of the
barrier plug of FIG. 2
[0006] FIG. 4 illustrates a detailed sectional view of an alternate
arrangement for the barrier plug of FIG. 2.
[0007] FIG. 5 illustrates a flowchart of a process for installing
and retrieving the barrier plug of FIG. 2.
[0008] FIGS. 6A-6F illustrate the barrier plug in various stages of
deployment during the process of FIG. 5.
[0009] FIGS. 7A-7F illustrate the barrier plug in various stages of
retrieval during the process of FIG. 5.
[0010] FIGS. 8A-8F schematically illustrate an alternative
embodiment of deployment and retrieval of the barrier plug in which
a landing section is used at the end of the expandable sand
screen.
DETAILED DESCRIPTION
[0011] Embodiments of the present disclosure include a barrier plug
having a plurality of dogs and a barrier element. In the well hole,
a nipple or conduit component is installed below the liner hanger
of the lower completion, and an expandable sand screen section is
installed below the nipple. The barrier plug is positioned on a
work string below an expansion tool for an expandable sand screen
(ESS) system, and the work string and plug are run in the well
hole. As the sting is lowered, the barrier plug and expansion tool
are passed through the nipple and are run through the expandable
sand screen section.
[0012] Once the screen has been expanded, the work string is pulled
up so that the barrier plug passes out of the screen and enters the
nipple. In one arrangement, locator dogs on the plug are activated
to engage corresponding grooves on the inside of the nipple to set
the plug, and locking dogs are activated to engage corresponding
grooves on the inside of the nipple to lock the plug in the nipple.
In another arrangement, one set of dogs is used for both locating
and locking the plug inside the nipple. The work string is then
pulled further up, and the force deforms the barrier element on the
plug against the inside of the nipple to create a sealed barrier in
both directions through the nipple. Later during production, the
barrier plug can be disengaged from the nipple and carried on a
running tool attached to the bottom of the upper completion. When
the upper completion is later pulled, the barrier plug and barrier
element can again be set in the nipple to create a sealed barrier.
Because the barrier plug can be set and removed as desired, it
provides flexibility for well operations.
[0013] The nipple in which the barrier plug is set and locked can
have a substantially large inside diameter so that well operations
can use various forms of equipment (e.g., an expansion tool) beyond
the nipple. In one alternative, a flow control bottom assembly can
be installed below the nipple so that fluid pumped off the bottom
can be used to open the barrier plug rather than unlocking the plug
and holding on to it with the upper completion. If the barrier plug
is installed on the upper completion and needs to be removed for
whatever reason, the barrier plug can be cut or knocked off the end
into the rathole. The foregoing summary is not intended to
summarize each potential embodiment or every aspect of the present
disclosure.
[0014] FIGS. 1A-1L schematically illustrate a barrier plug 50
according to the present disclosure as used with a lower completion
having an expandable sand screen (ESS) system. In FIGS. 1A-1F, the
barrier plug 50 is shown in deployment stages #1 through #6. In
these stages, the barrier plug 50 is used with an expansion tool 22
to expand an ESS section 26 and is then set to form a sealed
barrier between the upper and lower completions.
[0015] As shown in the first stage #1 of FIG. 1A, a liner hanger 12
has been set in a casing 12 of the well hole. A nipple 30, a
coupling 24, and ESS section 26 attach to the liner hanger 12 in
the lower completion, and the ESS section 26 extends beyond the
casing 10 into the open hole of the well. The ESS expansion tool 22
and the barrier plug 50 are attached to the end of a work string 20
and are lowered into the lower completion to start the expansion of
the ESS section 26. While the work string 20 is lowered, a
pre-expansion cone 52 on the barrier plug 50 and the ESS expansion
tool 22 expand the ESS section 26.
[0016] At the second stage #2 of FIG. 1B, expansion of the ESS
section 26 has been completed, and the work string 20 has started
to be pulled out of the hole. As shown, the inside surface of the
nipple 30 defines upper grooves 34 and lower grooves 36 that will
be used to set the barrier plug 50 within the nipple 30 during
subsequent stages.
[0017] At the third stage #3 in FIG. 1C, the barrier plug 50 has
been positioned relative to the nipple 30, and fluid pressure has
been applied down the work string 20 to the plug 50 to activate
locator dogs 54 on the outside of the barrier plug 50. As the
barrier plug 50 is raised by the work string 20, the activated
locator dogs 54 engage the upper grooves 34 on the inside of the
nipple 30 to set the barrier plug 50 properly in the nipple 30.
[0018] In the fourth stage #4 of FIG. 1D, while the locator dogs 54
and grooves 34 set the barrier plug 50 in the nipple 30, the work
string 20 is further pulled up to activate locking dogs 56 on the
outside of the barrier plug 50. When activated, the locking dogs 56
engage the lower grooves 36 in the nipple 30 and lock the barrier
plug 50 in place.
[0019] In the fifth stage #5 of FIG. 1E, while the barrier plug 50
remains locked in the nipple 30 by dogs 56, the work string 20 is
further pulled up, and the barrier element 58 is deformed and set
against the nipple 30. Once set, the barrier element 58 forms a
sealed barrier that isolates the lower completion having the ESS
section 26 from the upper completion. Finally, at the sixth stage
#6 of FIG. 1F, the end of the work string 20 is detached
(unlatched) from the barrier plug 50 and is pulled to the
surface.
[0020] With the barrier plug 50 locked in position and the barrier
element 58 set, various well operations can be performed while the
lower completion remains isolated from the upper completion. This
isolation can minimize fluid loss to the lower completion during
these well operations. Once ready, the barrier plug 50 can be
removed from the nipple 30 to allow production to proceed in the
lower completion. Accordingly, FIGS. 1G-1L show retrieval stages #7
through #12 in which the barrier plug 50 is attached to a
production stinger 40, is lowered into the ESS section 26, and is
then reset to form the sealed barrier between the upper and lower
completions.
[0021] In stage #7 of FIG. 1G, the stinger 40 of the upper
completion is run in the casing 10, and a snap latch 42 on the
stinger 40 is lowered into the end of the barrier plug 50 to
connect to the barrier plug 50. At stages #8 and #9 in FIGS. 1H-1I,
further lowering of the stinger 40 frees the barrier plug 50 by
releasing the barrier element 58, the locking dogs 56, and locator
dogs 54 from the nipple 30. (Stages #7 through #9 are essentially
the reverse of the deployment stages #3 through #6 shown in FIGS.
1C-1F).
[0022] At stage #10 of FIG. 1J, further lowering of the stinger 40
pushes the barrier plug 50 into the ESS section 26 of the lower
completion, and production can be started through the ESS section
26 and the perforations in the stinger 40. At stage #11 of FIG. 1K,
the upper completion is pulled up to set and lock the barrier plug
50 back into the nipple 30 using the previously described
deployment stages #3 through #6 in FIGS. 1C-1F. In this way, the
barrier plug 50 and barrier element 58 can once again be set at
stage #12 of FIG. 1L to isolate the upper completion from the lower
completion. The barrier plug 50 can also be retrieved and removed
from the well if desired.
[0023] Although the embodiment of the barrier plug 50 discussed
herein has been described as having two sets of dogs (i.e., locator
dogs 54 and locking dogs 56), an alternative embodiment of the
barrier plug 50 may only include one set of dogs positioned around
the plug 50. This one set of dogs may be used to both locate and
lock the plug 50 in the nipple 30 when activated. In addition, the
one set of dogs may be activated by spring bias, by moveable
mandrels, by hydraulic pressure pumped to the plug 50 via the work
string 20, or by any combination of these activation
techniques.
[0024] Given the above description of how the barrier plug 50 can
be used with an ESS system, we now turn to additional details of
the barrier plug 50 as shown in FIG. 2 and as detailed in FIGS.
3A-3C. As best shown in FIG. 2 and as discussed previously, the
barrier plug 50 includes the pre-expansion cone 52, the plurality
of locator dogs 54, the plurality of locking dogs 56, and the
barrier element 58. In addition to these previously described
elements, the barrier plug 50 includes a housing element 60
comprised of a top housing 120, a middle housing 130, and a lower
housing 160 connected together and defining an open conduit 62
therethrough. In addition, the barrier plug 50 includes a mandrel
element 70 that defines an internal passage 72 and is positioned in
the open conduit 62 of the housing element 60. The mandrel element
70 is comprised of an upper mandrel 140, an intermediate mandrel
190, and a lower mandrel 200.
[0025] As best shown in the detailed view of FIG. 3A, a snap latch
mechanism 110 is used to removably connect the barrier plug 50 to
well components, such as an expansion tool (22; FIG. 1A) or a
stinger (40; FIG. 1G). A distal end of the snap latch mechanism 110
can removably position in the upper housing 120, in which the upper
mandrel 140 and a sleeve 150 are positioned. A latch 112 and seals
114 on the snap latch mechanism 110 engage corresponding components
of the sleeve 150 using a conventional snap latch arrangement.
[0026] The upper mandrel 140 is moveable in the upper housing 120
and holds upper and lower stop dogs 142 and 144 that can be
selectively caught in catches 122 and 124 as discussed below. The
sleeve 150, which snap latches to the snap latch mechanism 110, is
moveable within the upper mandrel 140, and its movement is
restricted by engagement with the stop dogs 142 and 144 held by the
upper mandrel 140. In particular, upper and lower narrow portions
152 and 156 visible in FIGS. 3A-3B separated by a wider portion 154
visible in FIG. 3A on the sleeve 150 enable the stop dogs 142 and
144 to be pushed or retracted from upper and lower stop catches 122
and 124 depending on the position of the upper mandrel 140 and
sleeve 150. (As shown in FIG. 3A, the upper stop catch 122 is
formed in the inside diameter of the upper housing 120, while the
lower stop catch 124 is formed at the juncture of the upper housing
120 and the middle housing 130.)
[0027] As best shown in the detailed view of FIG. 3B, the bottom of
the upper mandrel 140 connects to the intermediate mandrel 190 that
in turn connects to the top of the lower mandrel 200. As best shown
in FIG. 3C, the bottom of the lower mandrel 200 connects to the
pre-expansion cone 52 at the lower end of the barrier plug 50. (As
best shown in FIG. 2, the pre-expansion cone 52 closes off the
inner passage 72 through the mandrel element 70.)
[0028] Several components are positioned on the intermediate and
lower mandrels 190 and 200 and include a piston 170, the locator
dogs 54, the locking dogs 56, and the barrier element 58. As shown
in FIG. 3B, the piston 170 is positioned on the intermediate
mandrel 190 and has a seal engaging the mandrel 190. The piston 170
is moveable in the annulus formed between the intermediate mandrel
190 and the housings 130, 160 when fluid pressure communicated from
the conduit of the intermediate mandrel through passages 194 forces
the piston 190 upwards towards the upper mandrel 140. A shoulder
192 on the intermediate mandrel 190 below the passages 194 has a
seal engaging the piston 170 and stops downward movement of the
piston 190.
[0029] The plurality of locator dogs 54 are positioned around the
intermediate mandrel 190 and are moveable in and out of slots 162
defined in the lower housing 160. Springs 184 push the locator dogs
54 out of the slots 162, but the spring force is not applied until
extended ends 182 of the locator dogs 54 are released by extended
ends 172 of the moveable piston 170. (The position in FIG. 3B shows
the extended ends 172 of the moveable piston 170 engaging the
extended ends 182 of the locator dogs 54, thereby holding the dogs
54 in the slots 162 against the force of the springs 184.) The
locator dogs 54 define upward orientated shoulders 181 to engage
complimentary shoulders of a groove in the nipple (30) when the
plug 50 is positioned in the nipple (30) and fluid pressure has
been applied to activate the dogs 54 (See e.g., FIG. 1C).
[0030] As shown at the bottom of FIG. 3B and at the top of FIG. 3C,
the plurality of locking dogs 56 are positioned around the lower
mandrel 200. When the lower mandrel 200 is moved up or down, a
narrow portion 202, a rise 204, and a wider portion 205 on the
mandrel 200 move the locking dogs 56 in and out of slots 164
defined in the lower housing 164.
[0031] As best shown in the detailed view of FIG. 3C, the barrier
element 58 is also positioned around the lower mandrel 200 and is
positioned between the lower housing 160 and the pre-expansion cone
52. The barrier element 58 may employ any of the sealing techniques
and devices known in the art. In one embodiment and as shown, the
barrier element 58 is composed of rubber or other suitable
elastomeric substance and preferably has upper and lower portions
222 with a greater Durometer hardness than a central portion 224.
Alternatively, for example, the barrier element 58 may be comprised
of plastic chevrons, a rubber cup, or a unitary rubber element with
a single Durometer hardness. As alluded to previously, the barrier
element 58 can be deformed between the cone 52 and the end of the
lower housing 160 to engage the inside surface of the nipple (30)
to form a sealed barrier. (See e.g., FIG. 1E).
[0032] In the arrangement of FIG. 2, the barrier plug 50 has two
sets of dogs 54 and 56 where the locator dogs 54 are used for first
locating and later locking into the nipple's upper grooves (34)
while the locking dogs 56 are used primarily for locking in the
lower grooves (36). In contrast to such a two set arrangement of
dogs, FIG. 4 shows an alternative arrangement for the barrier plug
50 having only one set of dogs 55 used for both locating and
locking into internal grooves of a nipple (30). In this
arrangement, fluid pressure in the central bore of the intermediate
mandrel 190 actuates the piston 170, releasing extended ends 182 of
the dogs 55 and allowing springs 184 to push the dogs 55 out of the
slots 162 in the housing 160. While the barrier plug 50 is moved
upward within the nipple (30), the biased and extended dogs 54 can
thereby engage a corresponding groove in the nipple (30) to set the
plug 50 in its proper location in the nipple (30). Further upward
pulling on the mandrel 190 then brings the lower mandrel 200 with
its angled shoulder 205 behind the extended dogs 55 to lock the
dogs 55 in place in the grooves on the nipple (30). Therefore, as
can be seen in this alternate arrangement, only one set of dogs 55
can be used on the barrier plug 50 for both locating and locking
the plug 50 in the nipple (30).
[0033] Given the above details of the barrier plug 50, we now turn
to a process 300 of deploying and retrieving the barrier plug 50 as
shown in the flowchart of FIG. 5. The arrangement of the components
of the barrier plug 50 during the various stages of the process 300
are illustrated in FIGS. 6A-6F and 7A-7F. In particular, FIG. 6A
shows an expansion stage 310 where the plug 50 is run on a work
string, and FIGS. 6B-6F show deployment stages 321 through 325
where the plug 50 is installed in the nipple 30 to form a barrier.
FIG. 7A shows a barrier stage 330 where the installed barrier plug
50 prevents fluid communication through the nipple 30, and FIGS.
7B-7F show various retrieval stages 341 through 345 where the
barrier plug 50 can be connected to upper completion
components.
[0034] As discussed previously, the plug 50 is initially positioned
on a work string along with an expansion tool (e.g., 22 of FIG.
1A), and the pre-expansion cone 52 is used in the procedures to
expand an expandable sand screen section (e.g., 26 of FIG. 1A).
During these procedures, the components of the barrier plug 50 are
arranged as shown in the expansion stage 310 of FIG. 6A. The snap
latch mechanism 100 is connected to the snap latch 112, the dogs 54
and 56 are retracted into the housing 160, and the barrier element
58 remains undeformed between the housing 160 and the cone 52.
[0035] Once expansion is complete, the barrier plug 50 is run to a
desired position relative to the nipple 30 as shown in the first
deployment stage 321 in FIG. 6B. Here, the piston 170, which holds
the locator dogs 54, is activated by pumping fluid pressure through
the mandrels 140, 190, and 200. As mentioned previously, the fluid
pressure in the central bore of the intermediate mandrel 190 passes
through passages 194 and forces the piston 170 upwards. The upward
moving piston 170 releases the extended ends 182 of the locator
dogs 54 and allows the springs 184 to push the locator dogs 54 out
of the slots 162 in the housing 160. While the barrier plug 50 is
moved upward within the nipple 30, the extended locator dogs 54 can
engage corresponding grooves 34 in the nipple 30 to set the plug
50. The upward facing shoulders 181 on the locator dogs 54 allow
the dogs 54 to engage the grooves 34 when the plug 50 is moved
upward but not downward. Also, due to differences in shape, the
locator dogs 54 cannot engage the lower grooves 36 defined in the
nipple 30 intended for the locking dogs 56. At the end of this
first stage 321, the components of the barrier plug 50 are arranged
as shown in FIG. 6B.
[0036] In the second deployment stage 322 in FIG. 6C, upper
components (not shown) pull up on the snap latch mechanism 110,
which moves the sleeve 150 upward as well. Consequently, the lower
stop dogs 144 that originally engaged the lower catch 124 in the
previous stage 302 are allowed to retract into the lower narrow
portion 156 of the sleeve 150. Once the lower stop dogs 144 are
retracted, the mandrel 140, sleeve 150, and the snap latch
mechanism 110 are pulled within the housing 120, which is stopped
by the engagement of the locator dogs 54 with the nipple 30. At the
end of this second stage 322, the components of the barrier plug 50
are arranged as shown in FIG. 6C.
[0037] In the third deployment stage 323 in FIG. 6D, upper
components (not shown) continue to pull up on the snap latch
mechanism 110, which also now moves the mandrel 140 connected to
the intermediate mandrel 190 and the lower mandrel 200. With the
upward movement of the lower mandrel 200, the rise 204 and wider
portion 206 of the mandrel 200 push the locking dogs 56 out of the
slots 164, causing the dogs 56 to engage the locking grooves 36 in
the nipple 30. This engagement will hold the barrier plug 50 in
position within the nipple 30 during subsequent stages. At the end
of this third stage 323, the components of the barrier plug 50 are
arranged as shown in FIG. 6D.
[0038] In the fourth deployment stage 324 in FIG. 6E, the upper
components (not shown) continue to pull up on the snap latch
mechanism 110. The pulling causes the mandrels 140, 190, and 200 to
move upward relative to the housings 120, 130, and 160, which are
held to the nipple 30 by the dogs 54 and 56. The lower mandrel 200
further compresses the springs 184 for the locator dog 54, and the
wider portion 206 keeps the locking dogs 56 set. With the upward
movement of the lower mandrel 200, the pre-expansion cone 52
deforms the barrier element 58 against the end of the lower housing
160. The deformed barrier element 58 now tightly engages the inner
walls of the nipple 30, and the resulting seal or barrier prevents
fluid from passing through the nipple 30 and components of the plug
50. At the end of this fourth stage 324, the components of the
barrier plug 50 are arranged as shown in FIG. 6E.
[0039] In the fifth deployment stage 325 in FIG. 6F, the upper
components (not shown) continue to pull up on the snap latch
mechanism 110. Because the mandrels 140, 190, and 200 are now
prevented from further upward movement by the compressed barrier
element 58, the snap latch mechanism 110 moves the sleeve 150. As a
result, the upper stop dogs 142 are now pushed into the upper catch
122 in the upper housing 120 by the wider portion 154 of the sleeve
150. Also, the upper end of the upper mandrel 140 engages the upper
end of the upper housing 120. The compression ring 118 around the
upper part of the sleeve 150 has been moved into an expanded
portion of the upper mandrel 140. As a consequence of these various
actions, the snap latch 112 is disengaged, allowing the snap latch
mechanism 110 to disconnect from the sleeve 150. At the end of this
fifth stage 325, the components of the barrier plug 50 are arranged
as shown in FIG. 6F.
[0040] From this point, the upper components (not shown) and snap
latch mechanism 110 can be removed. Then, as shown in the barrier
stage 330 of FIG. 7A, various operations can be performed while the
barrier created by the remaining components of the barrier plug 50
prevent fluid from passing between upper and lower portions of the
well components through the nipple 30. When the barrier is no
longer needed, the remaining components of the barrier plug 50 can
be attached to the upper completion components by performing a
number of retrieval stages 341 through 345, which are essentially
the reverse of the previous deployment stages 321 through 325 so
that they are not described in detail.
[0041] FIGS. 8A-8F illustrate an alternative embodiment of
deployment and retrieval of the barrier plug 50 in which a landing
section 28 is used. In the present embodiment, the landing 28 is
installed on the distal end of ESS section 26 of the lower
completion and is adapted to hold or house the barrier plug 50
apart from any work string or the like. In a preferred embodiment,
the barrier plug 50 is shear pinned in the landing 28 by shear
screws (not shown) or the like. Alternatively, the landing 28 can
have grooves on its inner surface just like the nipple 30 so that
the barrier plug 50 can be set and locked into the landing 28 using
the same procedures used with respect to the nipple 30.
[0042] During an expansion stage #1 in FIG. 8A, the ESS expansion
tool 22 on the end of the work string 20 are lowered into the lower
completion to start the expansion of the ESS section 26, while the
barrier plug 50 remains in the landing 28. When expansion is
complete and it is desired to create the sealed barrier with plug
50 between the upper and lower completions, the snap latch 42 on
the work string 20 at stage #2 in FIG. 8B is connected (latched) to
the barrier plug 50 in the landing 28, and the barrier plug 50 is
removed from the landing 28. (How the plug 50 is removed from the
landing 28 depends on how it is initially installed therein. For
example and as preferred, if the plug 50 is shear pinned in the
landing 28, the plug 50 may simply be pulled from the landing 28 to
shear it away from the pins holding it. If it is locked in the
landing 28, the reverse of the deployment stages #3 through #6 in
FIGS. 1C-1F may be used to remove it).
[0043] At the third stage #3 in FIG. 8C, the barrier plug 50 is set
and locked in the nipple 30 to create the sealed barrier using the
procedures described previously. In the fourth stage #4 in FIG. 8D,
the barrier plug 50 remains locked in the nipple 30 and the work
string 20 has been detached (unlatched) so that various well
operations can be performed while the lower completion remains
isolated from the upper completion.
[0044] Once ready, the barrier plug 50 can be removed from the
nipple 30 to allow production to proceed in the lower completion.
Accordingly, in stage #5 in FIG. 8E, the production stinger 40 is
lowered to the barrier plug 50, and the barrier plug 50 is unlocked
from the nipple 30 using previously described procedures. Then, as
shown, the stinger 40 and plug 50 are lowered into the ESS section
26. Finally, at stage #6 in FIG. 8F, the barrier plug 50 is again
positioned in the landing 28. In this way, the barrier plug 50 can
be positioned out of the way so that production can be started
through the ESS section 26.
[0045] With the benefit of the present disclosure, it will be
appreciated that various modifications can be made to the
components. For example, the barrier plug 50 has been described as
being used in conjunction with an Expandable Sand Screen system.
However, the barrier plug 50 can be used for various other purposes
to form a barrier in a well. For example, the barrier plug 50 can
generally be used in applications where the completion is open to
the formation. In addition, the barrier plug 50 has been described
as being used in conjunction with a nipple 30 having inner grooves,
where the nipple 30 is positioned below a liner hanger in a well.
However, the nipple can install above a liner hanger, can install
on a separate run below a packer in the well, or can install in
other locations.
[0046] Furthermore, it will be appreciated that the barrier plug 50
can be used with any type of conduit element having grooves and
that the conduit element can be positioned in various locations of
a well. For example, the conduit element can be installed in a
position somewhere in the casing and not necessarily below a liner
hanger, and the conduit element can be installed on a separate run
in the well below a packer. Moreover, the conduit component can be
either a separate component such as the nipple 30 that attaches to
the liner hanger 12 and the expandable sand screen 26 or can be
integral with either one or both of these components.
[0047] The foregoing description of preferred and other embodiments
is not intended to limit or restrict the scope or applicability of
the inventive concepts conceived of by the Applicants. In exchange
for disclosing the inventive concepts contained herein, the
Applicants desire all patent rights afforded by the appended
claims. Therefore, it is intended that the appended claims include
all modifications and alterations to the full extent that they come
within the scope of the following claims or the equivalents
thereof.
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