U.S. patent application number 14/382780 was filed with the patent office on 2015-08-06 for gravel pack circulating sleeve with locking features.
This patent application is currently assigned to Halliburton Energy Services, Inc.. The applicant listed for this patent is Halliburton Energy Services, Inc.. Invention is credited to Christopher Robert Delzell, William Mark Richards.
Application Number | 20150218916 14/382780 |
Document ID | / |
Family ID | 53004756 |
Filed Date | 2015-08-06 |
United States Patent
Application |
20150218916 |
Kind Code |
A1 |
Richards; William Mark ; et
al. |
August 6, 2015 |
GRAVEL PACK CIRCULATING SLEEVE WITH LOCKING FEATURES
Abstract
Disclosed are circulating sleeves that can be opened and closed
and permanently closed. A disclosed completion system includes a
completion string having a circulating sleeve movably arranged
therein, the circulating sleeve having a locking profile defined on
an outer radial surface thereof and a shifting profile defined on
an inner radial surface thereof, a service tool configured to be
arranged at least partially within the completion string and
including a shifting tool having one or more shifting keys
configured to mate with the shifting profile, wherein, when the
shifting keys locate and mate with the shifting profile, an axial
load applied on the service tool axially moves the circulating
sleeve, and a release shoulder assembly arranged within the
completion string and comprising a release shoulder that defines a
channel configured to receive a locking mechanism occluded within
the channel until the release shoulder is moved axially.
Inventors: |
Richards; William Mark;
(Flower Mound, TX) ; Delzell; Christopher Robert;
(Plano, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Halliburton Energy Services, Inc. |
Houston |
TX |
US |
|
|
Assignee: |
Halliburton Energy Services,
Inc.
Houston
TX
|
Family ID: |
53004756 |
Appl. No.: |
14/382780 |
Filed: |
October 29, 2013 |
PCT Filed: |
October 29, 2013 |
PCT NO: |
PCT/US2013/067260 |
371 Date: |
September 4, 2014 |
Current U.S.
Class: |
166/278 ;
166/51 |
Current CPC
Class: |
E21B 34/102 20130101;
E21B 34/14 20130101; E21B 43/04 20130101; E21B 43/045 20130101;
E21B 2200/06 20200501 |
International
Class: |
E21B 43/04 20060101
E21B043/04 |
Claims
1. A completion system, comprising: a completion string having a
circulating sleeve movably arranged therein, the circulating sleeve
having a locking profile defined on an outer radial surface thereof
and a shifting profile defined on an inner radial surface thereof;
a service tool configured to be arranged at least partially within
the completion string and including a shifting tool having one or
more shifting keys configured to mate with the shifting profile,
wherein, when the shifting keys locate and mate with the shifting
profile, an axial load applied on the service tool axially moves
the circulating sleeve; and a release shoulder assembly arranged
within the completion string and comprising a release shoulder that
defines a channel configured to receive a locking mechanism
disposed on the completion string, the locking mechanism being
occluded within the channel until the release shoulder is moved
axially, thereby allowing the locking mechanism to engage the
locking profile and secure the circulating sleeve in a permanent
closed position.
2. The completion system of claim 1, wherein the shifting tool is a
first shifting tool and the service tool includes a second shifting
tool axially offset from the first shifting tool.
3. The completion system of claim 1, wherein the shifting tool is
configured to move the circulating sleeve between an open position,
where one or more circulation ports defined in the completion
string are exposed, and a closed position, where the circulating
sleeve occludes the one or more circulation ports.
4. The completion system of claim 1, wherein each shifting key has
a beveled first axial end configured to urge the one or more
shifting keys radially inward upon axially engaging the release
shoulder and thereby allowing the shifting tool to axially traverse
the release shoulder.
5. The completion system of claim 1, wherein the locking mechanism
is a body lock ring configured to receive and secure the locking
profile.
6. The completion system of claim 1, wherein the release shoulder
assembly further comprises one or more securing devices configured
to axially secure the release shoulder with respect to the
completion string.
7. The completion system of claim 6, wherein the one or more
securing devices are devices selected from the group consisting of
a shear pin, a shear ring, and a spring.
8. The completion system of claim 1, wherein the release shoulder
assembly further comprises: a hydraulic chamber cooperatively
defined by the completion string and the release shoulder; a
pressure block arranged within the hydraulic chamber and dividing
the hydraulic chamber into an upper chamber and a lower chamber,
the pressure block having a fluid conduit defined therethrough that
places the upper and lower chambers in fluid communication; and a
floating piston arranged in the upper chamber.
9. The completion system of claim 8, further comprising a fluid
metering valve arranged within the fluid conduit and configured to
meter the flow of hydraulic fluid between the upper and lower
chambers via the fluid conduit.
10. The completion system of claim 8, further comprising a biasing
device arranged in the upper chamber and interposing an upper end
wall of the hydraulic chamber and the floating piston, the biasing
device being configured to urge the floating piston toward the
pressure block.
11. The completion system of claim 8, wherein the hydraulic fluid
is a ferrofluid and the release shoulder assembly further
comprises: a magnetic sleeve axially movable with respect to the
release shoulder and having a first set of magnets disposed
thereon; a second set of magnets disposed on the release shoulder;
and a third set of magnets arranged on the service tool and
configured to magnetically attract the first set of magnets in
response to the axial load and thereby axially move the magnetic
sleeve such that the first set of magnets are brought into magnetic
interaction with the second set of magnets, wherein, when the first
set of magnets are arranged adjacent the lower chamber, a magnetic
field produced by the first set of magnets prevents the ferrofluid
from passing through the fluid conduit, and wherein, when the first
set of magnets magnetically interact with the second set of
magnets, a closed magnetic circuit is generated, thereby enabling
the ferrofluid to pass through the fluid conduit.
12. A method, comprising: introducing a service tool at least
partially into a completion string, the service tool including a
shifting tool having one or more shifting keys and the completion
string providing a circulating sleeve movably arranged therein,
wherein the circulating sleeve has a locking profile defined on an
outer radial surface thereof and a shifting profile defined on an
inner radial surface thereof; mating the one or more shifting keys
with the shifting profile; applying an axial load on the service
tool in a first direction to move the circulating sleeve to a
closed position; engaging the circulating sleeve on a release
shoulder of a release shoulder assembly arranged within the
completion string, the release shoulder defining a channel
configured to receive and occlude a locking mechanism disposed on
the completion string; axially moving the release shoulder in the
first direction with the axial load applied on the service tool and
the circulating sleeve and thereby exposing the locking mechanism;
and engaging the locking profile on the locking mechanism and
thereby securing the circulating sleeve in a permanent closed
position.
13. The method of claim 12, wherein engaging the circulating sleeve
on the release shoulder is preceded by applying an axial load on
the service tool in a second direction opposite the first direction
and thereby moving the circulating sleeve back to an open position
where one or more circulation ports defined in the completion
string are exposed.
14. The method of claim 12, wherein each shifting key has a beveled
first axial end, the method further comprising: engaging the
beveled first axial end of each shifting key against the release
shoulder; and urging the one or more shifting keys radially inward
and thereby allowing the shifting tool to axially traverse the
release shoulder.
15. The method of claim 12, wherein the release shoulder assembly
further comprises one or more securing devices that axially secure
the release shoulder with respect to the completion string, the
method further comprising shearing the one or more securing devices
as the axial load is transferred to the release shoulder from the
circulating sleeve.
16. The method of claim 12, wherein the release shoulder assembly
further comprises a hydraulic chamber cooperatively defined by the
completion string and the release shoulder, and a pressure block
arranged within the hydraulic chamber and dividing the hydraulic
chamber into an upper chamber and a lower chamber, and wherein
axially moving the release shoulder in the first direction further
comprises: flowing hydraulic fluid from the lower chamber to the
upper chamber through a fluid conduit defined in the pressure
block; and axially displacing a floating piston in arranged in the
upper chamber with the hydraulic fluid entering the upper
chamber.
17. The method of claim 16, further comprising: metering a flow of
the hydraulic fluid through the fluid conduit with a fluid metering
valve arranged within the fluid conduit; and gradually exposing the
locking mechanism at a rate corresponding to a flow rate of the
hydraulic fluid through the fluid conduit.
18. The method of claim 16, wherein the release shoulder assembly
further comprises a biasing device arranged in the upper chamber
and interposing an upper end wall of the hydraulic chamber and the
floating piston, the method further comprising: engaging and
compressing the biasing device with the with the floating piston as
the floating piston is displaced by the hydraulic fluid; releasing
the axial load in the first direction; allowing the biasing device
to expand; and forcing the hydraulic fluid to flow back into the
lower chamber via the fluid conduit with the floating piston as the
biasing device expands.
19. The method of claim 16, wherein the hydraulic fluid is a
ferrofluid and the release shoulder assembly further comprises a
magnetic sleeve axially movable with respect to the release
shoulder and having a first set of magnets disposed thereon, a
second set of magnets disposed on the release shoulder, and a third
set of magnets arranged on the service tool, the method further
comprising: generating a magnetic field that extends into the lower
chamber with the first set of magnets and thereby preventing the
ferrofluid from passing through the fluid conduit.
20. The method of claim 19, further comprising: magnetically
attracting the first set of magnets with the third set of magnets
as the service tool moves in the first direction; axially moving
the magnetic sleeve in the first direction with the third set of
magnets magnetically attracted to the first set of magnets; placing
the first set of magnets in magnetic interaction with the second
set of magnets; and generating a closed magnetic circuit when the
first set of magnets magnetically interact with the second set of
magnets, and thereby enabling the ferrofluid to pass through the
fluid conduit.
21. The method of claim 20, further comprising: metering a flow of
the ferrofluid through the fluid conduit with a fluid metering
valve arranged within the fluid conduit; and gradually exposing the
locking mechanism at a rate corresponding to a flow rate of the
ferrofluid through the fluid conduit.
Description
BACKGROUND
[0001] The present disclosure relates to the treatment of
subterranean production intervals and, more particularly, to gravel
packing circulating sleeves that can be opened and closed and
permanently closed.
[0002] In the oil and gas industry, particulate materials such as
sand and other wellbore debris are often produced to the surface
during the extraction of hydrocarbons from a well that traverses
unconsolidated or loosely consolidated subterranean formations.
Producing such particulate matter can cause abrasive wear to
components within the well, such as tubing, pumps, and valves, and
can sometimes partially or fully clog the well creating the need
for an expensive workover operation. Also, if the particulate
matter is produced to the surface, it must be removed from the
extracted hydrocarbons by various processing equipment at the
surface.
[0003] To prevent the production of such particulate material to
the surface, unconsolidated or loosely consolidated production
intervals in the well are often gravel packed. In a typical gravel
pack operation, a completion string including a packer, a
circulation valve, a fluid loss control device and one or more sand
control screens, is lowered into the wellbore to a position
proximate the desired production interval. A service tool is then
positioned within the completion string and a fluid slurry that
includes a liquid carrier and a particulate material (i.e., gravel)
is then pumped through the circulation valve and into the well
annulus formed between the sand control screens and the perforated
well casing or open hole production zone. The liquid carrier either
flows into the adjacent formation or returns to the surface by
flowing through the sand control screens, or both. In either case,
the gravel is deposited around the sand control screens to form a
gravel pack, which is highly permeable to the flow of hydrocarbon
fluids but simultaneously blocks the flow of the particulate
material often carried in the hydrocarbon fluids. As such, gravel
packs can successfully prevent the problems associated with the
production of particulate materials from the formation.
[0004] During the gravel packing operation, the service tool is
often moved between various positions with respect to the
completion string. For instance, the service tool typically has one
or more shifting tools that can be used to move sliding sleeves
associated with the completion string between open and closed
configurations. Opening a circulating sleeve arranged in the
circulation valve, for example, may expose one or more
corresponding circulation ports that place the interior of the
service tool in fluid communication with an annulus defined between
the completion string and an adjacent formation. Upon removing the
service tool from the completion string, it is often required to
move various sleeves to their corresponding closed positions. In
some cases, a well operator may require or otherwise desire that
the circulating sleeve be permanently locked in a closed position
so that fluids from the annulus are prevented from entering the
completion via the circulation ports.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following figures are included to illustrate certain
aspects of the present disclosure, and should not be viewed as
exclusive embodiments. The subject matter disclosed is capable of
considerable modifications, alterations, combinations, and
equivalents in form and function, without departing from the scope
of this disclosure.
[0006] FIG. 1 illustrates an exemplary completion system that may
employ the principles of the present disclosure, according to one
or more embodiments.
[0007] FIGS. 2A-2C illustrate progressive cross-sectional views of
an exemplary service tool, according to one or more
embodiments.
[0008] FIGS. 3A-3C illustrate progressive cross-sectional views of
another exemplary service tool, according to one or more
embodiments.
[0009] FIGS. 4A-4C illustrate progressive cross-sectional views of
another exemplary service tool, according to one or more
embodiments.
[0010] FIG. 5 illustrates a cross-sectional view of another
exemplary service tool, according to one or more embodiments.
[0011] FIGS. 6A and 6B illustrate progressive cross-sectional views
of another exemplary service tool, according to one or more
embodiments.
DETAILED DESCRIPTION
[0012] The present disclosure relates to the treatment of
subterranean production intervals and, more particularly, to gravel
packing circulating sleeves that can be opened and closed and
permanently closed.
[0013] The shifting tools disclosed herein allow an operator to
open and close circulating sleeves multiple times during a single
run-in into a wellbore, and ultimately lock the circulating sleeves
in a permanently closed position when desired. Release shoulders
are described that hide corresponding locking mechanisms that, when
exposed after shifting the particular release shoulder, are able to
engage a locking profile defined on a corresponding circulating
sleeve and thereby secure the circulating sleeve in its axially
closed position. Various configurations of shifting tools,
including various designs of shifting keys, are used to interact
and otherwise mate with corresponding shifting profiles defined on
the circulating sleeves. Once a particular shifting key design
successfully locates a corresponding shifting profile, the shifting
tool is able to axially move the circulating sleeve, and
potentially lock the circulating sleeve in a permanently closed
position. Advantageously, there is no way to accidently place a
circulating sleeve in a permanently closed position without using a
correspondingly designed shifting tool.
[0014] Referring to FIG. 1, illustrated is an exemplary completion
system 100 that may employ the principles of the present
disclosure, according to one or more embodiments. As illustrated,
the system 100 may include a completion string 102 that may be
coupled to a work string 104 configured to extend longitudinally
within a wellbore 106. The wellbore 106 may penetrate multiple
subterranean formation zones 108a, 108b, and 108c, and the
completion string 102 may be extended into the wellbore 106 until
being arranged or otherwise disposed generally adjacent the
formation zones 108a-c. The formation zones 108a-c may be portions
of a common subterranean formation or hydrocarbon-bearing
reservoir. Alternatively, one or more of the formation zones 108a-c
may be portion(s) of separate subterranean formations or
hydrocarbon-bearing reservoirs. The term "zone" as used herein,
however, is not limited to one type of rock formation or type, but
may include several types, without departing from the scope of the
disclosure.
[0015] The completion string 102 may be deployed within the
wellbore 106 and used to hydraulically fracture and gravel pack the
various formation zones 108a-c, and subsequently regulate
hydrocarbon production from each production interval or formation
zone 108a-c. Although only three formation zones 108a-c are
depicted in FIG. 1, it will be appreciated that any number of
formation zones 108a-c may be treated or otherwise serviced using
the completion system 100. For instance, while the completion
system 100 is depicted as being arranged to treat multiple zones
108a-c, it is also contemplated to position a variation of the
completion system 100 at a single zone, without departing from the
scope of the disclosure.
[0016] As depicted in FIG. 1, portions of the wellbore 106 may be
lined with casing 110 and cemented therein, as known in the art.
The remaining portions of the wellbore 106, including the portions
encompassing the formation zones 108a-c, may form part of an open
hole section 112 of the wellbore 106 and the completion string 102
may be configured to be generally arranged therein during
operation. In other embodiments, however, the casing 110 may extend
further into the wellbore 106 and otherwise encompass one or more
of the formation zones 108a-c, without departing from the scope of
the disclosure.
[0017] Several perforations 114 may be initiated at or in each
formation zone 108a-c and configured to provide fluid communication
between each respective formation zone 108a-c and the annulus
124a-c (shown as a first annulus 124a, a second annulus 124b, and a
third annulus 124c) formed between the completion string 102 and
walls of the open hole section 112. Particularly, a first annulus
124a may be generally defined between the first formation zone 108a
and the completion string 102. Second and third annuli 124b and
124c may similarly be defined between the second and third
formation zones 108b and 108c, respectively, and the completion
string 102. In embodiments where the casing 110 extends across the
formation zones 108a-c, the casing 110 may also be perforated to
allow fluid flow into each annulus 124a-c.
[0018] The completion string 102 may include a top packer 116
including slips (not shown) configured to support the completion
string 102 within the casing 110 when properly deployed. In some
embodiments, the top packer 116 may be a VERSA-TRIEVE.RTM. hangar
packer commercially available from Halliburton Energy Services of
Houston, Tex., USA. Disposed below the top packer 116 may be one or
more isolation packers 118 (three shown as packers 118a, 118b, and
118c) and a sump packer 128, which cooperatively define individual
production intervals corresponding to the various formation zones
108a-c between adjacent packers 118a-c and 128.
[0019] One or more circulating sleeves 120 (three shown in phantom
as circulating sleeves 120a, 120b, and 120c) and one or more sand
screens 122 (three shown as sand screens 122a, 122b, and 122c) may
be arranged in each production interval. Each circulating sleeve
120a-c may be movably arranged within the completion string 102
and, as will be discussed below, may be configured to axially
translate between open and closed positions and a permanently
closed or fixed position. First, second, and third circulation
ports 126a, 126b, and 126c may be defined in the completion string
102 at the first, second, and third circulating sleeves 120a-c,
respectively. When the circulating sleeves 120a-c are moved into
their respective open positions, the circulation ports 126a-c are
exposed and may thereby provide fluid communication between the
interior of the completion string 102 and the corresponding annuli
124a-c.
[0020] A service tool (not visible in FIG. 1), also known as a
gravel pack service tool or a completion service tool, may be
extended from a surface location and arranged within the completion
string 102 to regulate the gravel packing and hydraulic fracturing
processes of each zone 108a-c. As will be discussed below, the
service tool may include one or more shifting tools (not shown)
used to open and close the circulating sleeves 120a-c. The service
tool may also include a valve (not shown) that helps facilitate the
introduction of a gravel pack within each annulus 124a-c and also
facilitate the hydraulic fracturing process through the
corresponding circulation ports 126a-c.
[0021] In some embodiments, the completion system 100 may further
include one or more control lines 130 (one shown) extending
externally along the completion string 102 and within each annulus
124a-c. The isolation packers 118a-c may include or otherwise be
configured for control line bypass, which allows the control line
132 to pass therethrough external to the completion string 102. The
control line 132 may be representative of or otherwise include one
or more electrical lines, one or more fiber optic lines, and/or one
or more hydraulic lines used to actuate various downhole tools or
otherwise report various fluid properties and well environment
parameters within each annulus 124a-c during both the gravel
packing and fracking operations.
[0022] Even though FIG. 1 depicts a vertical well, it will be
appreciated by those skilled in the art that the principles of the
present disclosure are equally well-suited for use in deviated
wells, inclined wells, or horizontal wells. Additionally, even
though FIG. 1 has been described with reference to a fracking and
gravel packing operation, it should be noted that the principles of
the present disclosure are equally well-suited for use in a variety
of treatment operations where it is desirable to selectively move
the circulating sleeves 120a-c between open and closed positions
and permanently lock them in place.
[0023] Referring now to FIGS. 2A-2C, with continued reference to
FIG. 1, illustrated are progressive cross-sectional views of an
exemplary service tool 202, according to one or more embodiments.
The service tool 202 is depicted as being generally arranged within
the completion string 102 and may be configured to manipulate the
axial position of the first circulating sleeve 120a to thereby open
or occlude the first circulation port 126a. While the service tool
202 is depicted as generally interacting with the first circulating
sleeve 120a, those skilled in the art will readily appreciate that
the service tool 202 may equally interact with any of the other
circulating sleeves 120a-c of FIG. 1, or all of them, without
departing from the scope of the disclosure.
[0024] As illustrated, the service tool 202 may include a first
shifting tool 204 operatively coupled to the service tool 202 or
otherwise forming an integral part thereof. The shifting tool 204
may include one or more shifting keys 206 (one shown) arranged
within a groove 208 defined in the service tool 202. The shifting
key 206 may be radially supported within the groove 208 using one
or more biasing devices 210, such as helical compression springs or
the like. When not radially constrained, the biasing devices 210
may be configured to urge the shifting key 206 radially outward in
order to engage and otherwise interact with the circulating sleeve
120a. The circulating sleeve 120a may define or otherwise provide a
shifting profile 212 configured to mate with the shifting keys 206.
As depicted, the shifting profile 212 may be defined on an inner
radial surface of the circulating sleeve 120a.
[0025] The shifting key 206 may include or provide a first or
uphole axial end 214a and a second or downhole axial end 214b. At
least a portion of the first and second axial ends 214a,b may be
beveled or otherwise chamfered in order to ease transition of the
shifting tool 204 past axial and/or radial obstructions within the
completion string 102, including the circulating sleeve 120a, when
needed. The shifting key 206 may further include or provide a
central channel 216 defined between the first and second axial ends
214a,b. The central channel 216 may be configured to receive a
portion of the circulating sleeve 120a therein or otherwise mate
with the shifting profile 212 when the shifting key 206 locates the
shifting profile 212. Similar to the first and second axial ends
214a,b, an uphole shoulder 218 of the central channel 216 may be
beveled or chamfered in order to ease transition of the shifting
tool 204 past axial and/or radial obstructions within the
completion string 102 when needed, including the portion of the
circulating sleeve 120a configured to be received therein.
[0026] In FIG. 2A, the circulating sleeve 120a is depicted in a
first or open position, where the circulating port 126a is
uncovered and thereby able to provide fluid communication between
the interior of the completion string 102 and the surrounding
annulus 124a. A sealing element 219 may be arranged between the
completion string 102 and the circulating sleeve 120a and
configured to provide a sealed interface as the circulating sleeve
120a is shifted axially and while it remains stationary.
[0027] In some embodiments, the shifting tool 204 may first be
extended past the circulating sleeve 120a in a first or downhole
direction, as indicated by the arrow A, and then retrieved uphole
in a second direction, as indicated by the arrow B, in order to
locate the shifting profile 212. More particularly, the beveled
surfaces of the second axial end 214b and the uphole shoulder 218
may allow the shifting tool 204 to bypass the shifting profile 212
of the circulating sleeve 120a in the first direction A. Upon
encountering the proximal end of the circulating sleeve 120a, the
beveled surfaces may help the shifting key 206 flex radially inward
into the groove 208 against the spring force of the biasing devices
210, and thereby allow the shifting key 206 to axially traverse
such axial and/or radial obstructions.
[0028] Upon moving back uphole in the second direction B, however,
the shifting key 206 may be configured to locate and engage the
shifting profile 212 of the circulating sleeve 120a. The beveled
surface of the first axial end 214a of the shifting key 206 may
help the shifting key 206 axially traverse any axial obstructions,
including the proximal end of the circulating sleeve 120a. Once the
shifting key 206 has successfully located the shifting profile 212,
an axial load in the second direction B may be transferred to the
circulating sleeve 120a at a downhole shoulder 220 of the central
channel 216 in order to move the circulating sleeve 120a.
[0029] In FIG. 2B, the circulating sleeve 120a is depicted in a
second or closed position, where the circulating sleeve 120a
occludes the circulating port 126a and thereby prevents fluid
communication between the interior of the completion string 102 and
the surrounding annulus 124a. In some embodiments, the shifting
tool 204 may be moved in the second direction B until the first
axial end 214a of the shifting key 206 engages or otherwise comes
into contact with a release shoulder 222 arranged within the
completion string 102 uphole from the circulating port 126a. The
release shoulder 222 will be described in more detail with respect
to FIGS. 3A-3C below.
[0030] Upon engaging the release shoulder 222, the beveled surface
of the first axial end 214a may help the shifting key 206 flex
radially inward against the spring force of the biasing devices
210, and thereby allow the shifting tool 204 to axially traverse
the release shoulder 222 therebelow. This is shown in FIG. 2C,
where the shifting tool 204 has move further uphole in the second
direction B such that the shifting key 206 has been moved radially
inward and at least partially beneath the release shoulder 222. To
accomplish this, the biasing devices 210 are compressed with the
shifting key 206 until the shifting key 208 is seated within the
groove 208. The built up spring force of the biasing devices 210
may be released once the shifting key 206 is moved out of radial
engagement with the release shoulder 222. Accordingly, the first
shifting tool 204 may be resettable and therefore configured to
axial traverse the completion string 102 and close the circulating
sleeve 120a multiple times during a single run-in downhole.
[0031] Referring now to FIGS. 3A-3C, with continued reference to
FIGS. 1 and 2A-2C, illustrated are progressive cross-sectional
views of another exemplary service tool 302, according to one or
more embodiments. The service tool 302 may be similar in some
respects to the service tool 202 of FIGS. 2A-2C, and therefore may
be best understood with reference thereto, where like numerals
represent like elements not described again. As illustrated, the
service tool 302 may include a second shifting tool 304 operatively
coupled to the service tool 302 or otherwise forming an integral
part thereof. In some embodiments, the service tools 202 and 302
may be the same service tool and the first shifting tool 204 of
FIGS. 2A-2C may be included in the service tool 302 and
axially-offset from the second shifting tool 304, without departing
from the scope of the disclosure.
[0032] The shifting tool 304 may include one or more shifting keys
306 (one shown) arranged within a groove 308 defined in the service
tool 302. The shifting key 306 may be radially supported within the
groove 308 using one or more biasing devices 310, such as helical
compression springs or the like. The biasing devices 310 may be
configured to urge the shifting key 206 radially outward in order
to engage and otherwise interact with the circulating sleeve
120a.
[0033] The circulating sleeve 120a may define or otherwise provide
a selective shifting profile 312 configured to mate with the
shifting keys 306. As illustrated, the selective shifting profile
312 may include or otherwise define a radial protrusion 314 that
extends radially from the inner radial surface of the circulating
sleeve 120a. The radial protrusion 314 may be configured to be
received into a central channel 316 defined in the shifting key
306. Advantageously, the selective shifting profile 312 may be
designed and otherwise configured to mate with the shifting keys
306 of the shifting tool 304 and with no other shifting tool unless
similarly designed. Accordingly, other shifting tools may bypass
and otherwise not locate the selective shifting profile 312 for
axial movement of the circulating sleeve 120a.
[0034] The shifting key 306 may have a first or uphole axial end
318a and a second or downhole axial end 318b. Similar to the first
and second axial ends 214a,b of the first shifting tool 204, at
least a portion of the first and second axial ends 318a,b may be
beveled or otherwise chamfered in order to ease transition of the
shifting tool 304 past axial and/or radial obstructions within the
completion string 102, including the circulating sleeve 120a. The
central channel 316 may be defined between the first and second
axial ends 318a,b and sized to receive the radial protrusion 314
upon locating the selective shifting profile 312.
[0035] The circulating sleeve 120a may include a locking profile
320 defined on an outer radial surface thereof. The locking profile
320 may be, for example, a series of threads or grooves. In some
embodiments, as depicted, the grooves 320 may be provided at the
proximal end of the circulating sleeve 120. In other embodiments,
the locking profile 320 may be provided at an intermediate location
of the circulating sleeve 120a, without departing from the scope of
the disclosure. The locking profile 320 may be configured to
interact with and otherwise engage a locking mechanism 322 disposed
on the inner radial wall of the completion string 102. In some
embodiments, the locking mechanism 322 may be a body lock ring
configured to receive the locking profile 320 as the circulation
sleeve 120a moves in the second direction B and thereafter prevent
the circulating sleeve 120a from axial translation in the first
direction A. In other embodiments, the locking mechanism 322 may be
a c-ring, or the like, configured to engage a corresponding groove
(not shown) defined on the circulating sleeve 120a. Accordingly,
once the locking mechanism 322 successfully engages the locking
profile 320, the circulating sleeve 120a may be placed in a
permanent closed position, as will be described in more detail
below.
[0036] The release shoulder 222 may be arranged within the
completion string 102 uphole from the circulating port 126a and
axially secured in place with respect to the completion string 102
using one or more securing devices 324 (one shown). In some
embodiments, for example, the securing device 324 may be a
shearable device, such as a shear pin, a shear ring, or the like.
In other embodiments, however, the securing device 324 may be a
spring or other type of biasing device that urges the release
shoulder 222 to maintain a predetermined axial position with
respect to the completion string 102.
[0037] In FIG. 3A, the circulating sleeve 120a is depicted in the
open position and the shifting tool 304 is shown as having located
the selective shifting profile 312 with the shifting key 306.
Similar to the shifting tool 204 of FIGS. 2A-2C, the shifting tool
304 may also first be extended past the circulating sleeve 120a in
the first direction A, and then retrieved uphole in the second
direction B in order to locate the selective shifting profile 312.
Once successfully locating and engaging the selective shifting
profile 312, an axial load applied on the service tool 302 in the
second direction B may be transferred to the circulating sleeve
120a at the radial protrusion 314 via a downhole shoulder 326 of
the central channel 316, thereby moving the circulating sleeve 120a
in the second direction B.
[0038] In FIG. 3B, the circulating sleeve 120a is depicted as
having moved to the second or closed position, where the
circulating sleeve 120a occludes the circulating port 126a and
thereby prevents fluid communication between the interior of the
completion string 102 and the surrounding annulus 124a. In at least
one embodiment, the shifting tool 304 may also be used to re-open
the circulating sleeve 120a by applying an axial load on the
service tool 302 in the first direction A. The axial load in the
first direction A may be transferred to the circulating sleeve 120a
at the radial protrusion 314 via an uphole shoulder 328 defined in
the central channel 316, and thereby moving the circulating sleeve
120a. Accordingly, the shifting tool 304 may prove advantageous in
being able to selectively open and close the circulating sleeve
120a multiple times in a single trip downhole.
[0039] Once the shifting tool 304 moves the circulating sleeve 120a
into axial engagement with the release shoulder 222, continued
application of the axial load on the service tool 302 in the second
direction B results in the shearing or breakage of the securing
device 324 that secures the release shoulder 222 against axial
movement. For example, a predetermined axial load may be applied on
the service tool 302 to shear the securing device 324, where the
predetermined axial load corresponds to a break point or shear
point for the securing device 324. Again, however, as mentioned
above, the securing device 324 may instead be replaced with a
spring or other type of biasing device, without departing from the
scope of the disclosure. In such embodiments, the spring may be
configured to be compressed upon assuming the predetermined axial
load as transferred through the release shoulder from the
circulation sleeve 120a.
[0040] Once the securing device 324 is sheared or otherwise allows
the release shoulder 222 to axially translate with respect to the
completion string 102, continued application of the axial load on
the service tool 302 in the second direction B may result in the
release shoulder 222 also moving in the second direction B. As the
release shoulder 222 moves in the second direction B, the locking
mechanism 322 may become exposed and able to engage the locking
profile 320 of the circulating sleeve 120a. As illustrated, the
locking mechanism 322 may be situated within a channel 330 defined
by the release shoulder 222, and the channel 330 may occlude or
otherwise hide the locking mechanism 322 until the release shoulder
222 is moved.
[0041] In FIG. 3C, the circulating sleeve 120a is depicted in the
permanent closed position. As the release shoulder 222 moves in the
second direction B, the locking mechanism 322 may receive the
locking profile 320 of the circulating sleeve 120a, and thereby
permanently lock the circulating sleeve 120a in place with respect
to the completion string 102. Continued axial load on the service
tool 302 in the second direction B may then help the shifting key
306 to flex radially inward against the spring force of the biasing
devices 310, and thereby allow the shifting tool 304 to axially
traverse the release shoulder 222. More particularly, the beveled
surface of the first axial end 318a of the shifting key 306 may
engage an upper end wall 332 of the shifting profile 312 as the
service tool 302 continues in the second direction B. In some
embodiments, as depicted, the upper end wall 332 may also be
beveled or otherwise chamfered to help facilitate the shifting key
306 slide out of axial engagement with the shifting profile
312.
[0042] The shifting tool 304 may further include a securing
mechanism 334 generally arranged adjacent a cavity 336 defined in
the shifting tool 304 and otherwise forming at least a part of the
groove 308. The securing mechanism 334 may be a shear ring or one
or more shear pins configured to shear or break upon assuming a
predetermined axial load. Engaging the first axial end 318a against
the upper end wall 332 may transfer the axial load in the second
direction B through the shifting key 306 and to the securing
mechanism 334. Once a predetermined axial load is assumed, the
securing mechanism 334 may shear or otherwise break and thereby
allow the shifting key 306 to radially collapse inward and
otherwise slide out of radial and axial engagement with the
shifting profile 312.
[0043] After disengaging from the shifting profile 312, the
shifting key 306 may axially engage at least a portion of the
release shoulder 222. The beveled first end 318a may help the
shifting key 306 radially collapse even further into the groove 308
as axially forced against the release shoulder 222. In some
embodiments, as illustrated, a portion of the distal end 338 of the
release shoulder 222 may also be beveled or otherwise chamfered to
help the shifting key 306 slide out of axial engagement with the
release shoulder 222. As the shifting key 306 radially collapses
into the groove 308, and with the securing mechanism 334 no longer
secured, the shifting key 306 may be configured to extend into or
otherwise be inserted within the cavity 336. The beveled second end
318b of the shifting key 306 may help the shifting key 306 slide
into the cavity 336 axially as the service tool 302 continues to
move in the second direction B. Once in the cavity 336, the
shifting key 306 may be secured therein until the shifting tool 304
is returned to the surface.
[0044] In other embodiments, the securing mechanism 334 may be
replaced with a spring or other type of biasing device that acts to
urge the shifting key 306 out of the cavity 336 and otherwise
maintain its axial position within the groove 308. In such
embodiments, the shifting key 306 may radially collapse into the
groove 308 and compress the spring as it axially enters the cavity
336. After axially traversing the release shoulder 222 and other
radial obstructions in the second direction B, the shifting tool
304 may be urged back out of the cavity 336 with the spring.
Moreover, once past the release shoulder 222 and other radial
obstructions, the biasing devices 310 may be configured to radially
expand the shifting key 306. As will be appreciated, the second
shifting tool 304 in such an embodiment may be resettable and
therefore configured to axial traverse the completion string 102
and open and close the circulating sleeve 120a multiple times, and
also permanently close multiple circulating sleeves during a single
run-in downhole.
[0045] Referring now to FIGS. 4A-4C, with continued reference to
FIGS. 3A-3C, illustrated are progressive cross-sectional views of
another exemplary service tool 402, according to one or more
embodiments. The service tool 402 may be substantially similar to
the service tool 302 of FIGS. 3A-3C, and therefore may be best
understood with reference thereto, where like numerals represent
like elements not described again. As illustrated, the service tool
402 may include a third shifting tool 404 operatively coupled to
the service tool 402 or otherwise forming an integral part thereof.
In some embodiments, the service tools 202 (FIGS. 2A-2C), 302
(FIGS. 3A-3C), and 402 may be the same and the first and second
shifting tools 204 and 304 of FIGS. 2A-2C and 3A-3C, respectively,
may be included in or otherwise form part of the service tool 402
as axially offset from the third shifting tool 404, without
departing from the scope of the disclosure.
[0046] The third shifting tool 404 may be a variation of the second
shifting tool 304 of FIGS. 3A-3C. At least one difference between
the second and third shifting tools 304, 404, however, is that the
central channel 316 of the shifting keys 306 (one shown) may be
enlarged axially such that the downhole shoulder 326 may be axially
spaced further from the uphole shoulder 328 as opposed to the
central channel of the second shifting tool 304. As a result, the
radial protrusion 314 may be able to axially shift a short distance
within the central channel 316 before engaging either shoulder 326,
328.
[0047] Moreover, the selective shifting profile 312 of the
circulating sleeve 120a in FIGS. 4A-4C may be slightly different
than the selective shifting profile 312 of the circulating sleeve
120a in FIGS. 3A-3C. More specifically, and in conjunction with the
enlarged central channel 316, the first end 318a of the shifting
key 306 may be able to extend past the proximal end 406 of the
circulating sleeve 120a, thereby providing a variation of the
selective shifting profile 312 of FIGS. 3A-3C. Again, the selective
shifting profile 312 may be configured to mate with the shifting
keys 306 of the shifting tool 404 and any other similarly designed
shifting keys. Accordingly, differently configured or designed
shifting tools may bypass the selective shifting profile 312
without locating the shifting profile 312 for axial movement of the
circulating sleeve 120a.
[0048] In FIG. 4A, the circulating sleeve 120a is depicted in the
open position and the shifting tool 404 is shown as having located
the selective shifting profile 312 with the shifting key 306. An
axial load may be applied on the service tool 402 in the second
direction B and the axial load may be transferred to the
circulating sleeve 120a at the radial protrusion 314 via the
downhole shoulder 326, thereby correspondingly moving the
circulating sleeve 120a in the second direction B to the closed
position. In at least one embodiment, the shifting tool 404 may
also be used to re-open the circulating sleeve 120a by applying an
axial load on the service tool 402 in the first direction A. The
axial load in the first direction A may be transferred to the
circulating sleeve 120a at the radial protrusion 314 via the uphole
shoulder 328, and thereby moving the circulating sleeve 120a.
Accordingly, the shifting tool 404 may be able to selectively open
and close the circulating sleeve 120a multiple times in a single
trip downhole.
[0049] In FIG. 4B, the circulating sleeve 120a is depicted in the
second or closed position, where the circulating sleeve 120a has
occluded the circulating port 126a and thereby preventing fluid
communication between the interior of the completion string 102 and
the surrounding annulus 124a. Since the shifting key 306 extends
past the proximal end 406 of the circulating sleeve 120a, the
shifting tool 404 may be moved in the second direction B until the
first axial end 318a of the shifting key 306 engages or otherwise
comes into contact with the release shoulder 222. Continued axial
load on the service tool 402 in the second direction B may then
force the shifting key 306 flex radially inward against the spring
force of the biasing devices 310, and thereby allow the shifting
tool 404 to axially traverse the release shoulder 222 without
shearing the securing device 324 that axially secures release
shoulder 222.
[0050] The beveled surface of the first axial end 318a of the
shifting key 306 may engage the release shoulder 222 and radially
collapse beneath the release shoulder 222 as the service tool 402
continues in the second direction B. The beveled portion of the
distal end 338 of the release shoulder 222 may help the shifting
key 306 slide out of axial engagement with the release shoulder 222
and collapse radially into the groove 308.
[0051] In FIG. 4C, the shifting key 306 is shown as being radially
collapsed or contracted into the groove 308 and otherwise able to
axially traverse the release shoulder 222 therebelow. In the
present embodiment, the securing mechanism 334 may not be sheared
or otherwise broken in order to have the shifting key 306 pass
below the release shoulder 222. Instead, the securing mechanism 334
may remain intact until the shifting tool 404 possibly encounters
another circulating sleeve having a different shifting profile that
requires the shifting key 306 to shear the securing mechanism 334
in order to axially traverse a radial obstruction. In such
embodiments, another release shoulder (not shown) may be axially
moved in order to permanently lock the other circulating sleeve in
the closed position, as generally described above.
[0052] Referring now to FIG. 5, with continued reference to the
preceding figures, illustrated is a cross-sectional view of another
service tool 502, according to one or more embodiments. The service
tool 502 may be similar in some respects to the services tools 202,
302, and 402 described above. Like numerals used in prior figures
that are used in FIG. 5 correspond to like elements or components
not described again in detail. As illustrated, the service tool 502
may include a shifting tool 504 operatively coupled to the service
tool 502 or otherwise forming an integral part thereof. The
shifting tool 504 may include one or more shifting keys 506 (one
shown) arranged within a groove 508 defined in the service tool
502. The shifting key 506 may be radially supported within the
groove 508 using one or more biasing devices 510 (one shown)
configured to urge the shifting key 506 radially outward in order
to engage and otherwise mate with a shifting profile 512 provided
or otherwise defined by the circulating sleeve 120a.
[0053] An exemplary release shoulder assembly 514 is depicted in
FIG. 5 and includes the release shoulder 222 as being associated
therewith. As part of the release shoulder assembly 514, the
completion string 102 and the release shoulder 222 may
cooperatively provide or otherwise define a hydraulic chamber 516,
and a pressure block 518 may be arranged within the hydraulic
chamber 516. The pressure block 518 may be generally secured
against axial movement with respect to the completion string 102.
In some embodiments, for example, a leg 520 may extend
longitudinally from the pressure block 518 and engage an upper end
wall 522 of the hydraulic chamber 516. In other embodiments, the
leg 520 may be omitted and instead replaced with snap rings (not
shown) arranged on either axial end of the block 518, or one of
said snap rings may be alternatively replaced with a radial
shoulder that biases one axial end of the pressure block 518. In
yet other embodiments, the pressure block 518 may instead be
threaded to the completion string 102 to prevent its axial
movement, without departing from the scope of the disclosure.
[0054] One or more inner and outer sealing elements 524 may be
included on the pressure block 518 and configured to provide a
hydraulic seal such that hydraulic fluids are unable to migrate in
either axial direction past the pressure block 518 at the
interfaces of the pressure block 518 with the completion string 102
and the release shoulder 522. The sealing elements 524 may be
O-rings, for example, or another type or design of elastomeric
sealing element known to those skilled in the art. As depicted, one
or more additional sealing elements 524 (one shown) may also be
provided at the interface between the release shoulder 222 and the
completion string 102 such that a dynamic seal is provided at the
interface when the release shoulder 222 is axially moved with
respect to the completion string 102.
[0055] The pressure block 518 generally separates or divides the
hydraulic chamber 516 into an upper chamber 526a and a lower
chamber 526b, and controls a flow of hydraulic fluid between the
upper and lower chambers 526a,b. To accomplish this, the pressure
block 518 may define or otherwise provide a fluid conduit 528 that
extends through the pressure block 518 and thereby places the upper
and lower chambers 526a,b in fluid communication. In some
embodiments, a fluid metering valve 530 may be arranged within the
fluid conduit 528 and may be configured to control the flow of
hydraulic fluid between the upper and lower chambers 516a,b via the
fluid conduit 528. The fluid metering valve 530 may be, for
example, a restriction or a check valve that allows a metered
amount of hydraulic fluid to bypass the pressure block 518 at a
predetermined flow rate determined by the parameters of the fluid
metering valve 530.
[0056] While virtually any incompressible fluid may be used as the
hydraulic fluid in the release shoulder assembly 514, in accordance
with the present disclosure, one suitable hydraulic fluid that may
be used is high-grade automatic transmission fluid (ATF), available
at any automotive parts retailer. However, other hydraulic fluids
may be used, such as oils or silicon fluids and the like, which are
known and used by those of ordinary skill in the art.
[0057] The release shoulder assembly 514 may further include a
floating piston 532 and a biasing device 534 arranged in the upper
chamber 526a of the hydraulic chamber 516. Similar to the pressure
block 518, the floating piston 532 may include one or more inner
and outer sealing elements 524 configured to provide a hydraulic
seal such that hydraulic fluids are unable to migrate in either
axial direction past the floating piston 532. The biasing device
534, which may be a helical compression spring or the like, may
interpose the upper end wall 522 and the floating piston 532 and
generally urge the floating piston 532 toward the pressure block
518 with a predetermined spring force.
[0058] In exemplary operation, the shifting tool 504 may locate the
shifting profile 512 of the circulating sleeve 120a, as
illustrated, and an axial load applied on the service tool 502 in
the second direction B may serve to close the circulating sleeve
120a and otherwise bring the circulating sleeve 120a into axial
contact with the release shoulder 222. Continued application of the
axial load in the second direction B may begin to force hydraulic
fluid present within the lower chamber 526b to flow through the
fluid conduit 528 to the upper chamber 526a at a steady flow rate.
As will be appreciated, the time and axial load required to move
the releasing shoulder 222 will depend on the size and length of
the fluid conduit 528 and the parameters of the fluid metering
valve 530 (if used). As the hydraulic fluid enters the upper
chamber 526a, the floating piston 532 may be forced axially against
the biasing device 534 toward the upper end wall 522, thereby
compressing the biasing device 534 and otherwise building up spring
force therein.
[0059] The steady rate of flow through the fluid conduit 528
translates into a steady and predictable rate of movement of the
release shoulder 222 in the second direction B, thereby gradually
exposing the locking mechanism 322 encompassed by the channel 330.
As a result, an operator may be able to approximately gauge how
much time is required to move the release shoulder 222 so that the
locking profile 320 may successfully engage the locking mechanism
322 and permanently lock the circulating sleeve 120a in the closed
position. Consequently, the axial load in the second direction B
may be applied for a predetermined period of time until enough
hydraulic fluid had passed from the lower chamber 526b to the upper
chamber 526a, thereby allowing the locking mechanism 322 to
permanently lock the circulating sleeve 120a in place.
[0060] In some embodiments, it may not be desired to permanently
lock the circulating sleeve 120a in the closed position, but
instead only axially move the release shoulder 222 a short distance
(e.g., not enough to engage the locking mechanism 322 with the
locking profile 320). In such embodiments, the axial load applied
on the service tool 502 in the second direction B may be reduced,
removed, or otherwise changed into an axial load in the first
direction A prior to the locking mechanism 322 engaging the locking
profile 320. Without the circulating sleeve 120a forcing the
release shoulder 222 in the second direction B, the spring force of
the biasing device 534 may be released and otherwise urge the
floating piston 532 back toward the pressure block 528. As the
floating piston 532 moves back toward the pressure block 528, the
hydraulic fluid within upper chamber 526a steadily flows into the
lower chamber 526b via the fluid conduit 528. As a result, the
release shoulder 222 may be re-set and hide or occlude the locking
mechanism 322 once again. As will be appreciated, the re-setting
capability of the release shoulder assembly 514 may prove useful
when a shifting tool needs to axially bypass the release shoulder
222 and in the process moves the release shoulder 222 a short
distance.
[0061] Referring now to FIGS. 6A and 6B, with continued reference
to the prior figures, illustrated are progressive cross-sectional
views of another exemplary service tool 602, according to one or
more embodiments. The service tool 602 may be similar in some
respects to the service tools 302 and 502 of FIGS. 3A-3C and 5,
respectively, and therefore may be best understood with reference
thereto, where like numerals represent like elements not described
again. As illustrated, the service tool 602 may include a shifting
tool 604 operatively coupled to the service tool 602 or otherwise
forming an integral part thereof. As with prior embodiments, the
service tools 202 (FIGS. 2A-2C), 302 (FIGS. 3A-3C), 402 (FIGS.
4A-4C), 502 (FIG. 5), and 602 may be one and the same and the
shifting tools 204, 304, 404, and 504 described herein may be
included in or otherwise form part of the service tool 602 as
axially offset from the presently described shifting tool 604,
without departing from the scope of the disclosure.
[0062] The shifting tool 604 may be substantially similar to the
shifting tool 304 of FIGS. 3A-3C, thereby including the one or more
shifting keys 306 (one shown) arranged within the groove 308. The
shifting keys 306 may be radially supported within the groove 308
using one or more biasing devices 310. The circulating sleeve 120a
may define or otherwise provide a shifting profile 606 configured
to mate with the shifting keys 306. As illustrated, the shifting
profile 606 may include or otherwise define a radial protrusion 608
that extends radially from the inner radial surface of the
circulating sleeve 120a. The radial protrusion 608 may be
configured to be received into the central channel 316 defined in
the shifting keys 306.
[0063] An exemplary release shoulder assembly 610 is depicted in
FIGS. 6A and 6B and includes the release shoulder 222 as being
associated therewith. A hydraulic chamber 612 may be cooperatively
defined by the completion string 102 and the release shoulder 222,
and a pressure block 614 may be arranged within the hydraulic
chamber 612. The pressure block 614 may be generally secured
against axial movement with respect to the completion string 102 in
the uphole or second direction B using, for example, a snap ring
616. In other embodiments, the snap ring 616 may be replaced with a
radial shoulder or another type of radial profile that prevents the
pressure block 614 from moving toward an uphole end wall 618 of the
hydraulic chamber 612.
[0064] Inner and outer sealing elements 524 may be included on the
pressure block 614 and configured to provide a hydraulic seal such
that hydraulic fluids within the hydraulic chamber 612 are unable
to migrate in either axial direction past the pressure block 614 at
the interface of the pressure block 614 with the completion string
102 and the release shoulder 522.
[0065] The pressure block 614 generally separates the hydraulic
chamber 612 into an upper chamber 620a and a lower chamber 620b,
and controls the flow of hydraulic fluid between the upper and
lower chambers 620a,b. Similar to the pressure block 518 of FIG. 5,
the pressure block 614 may define or otherwise provide a fluid
conduit 622 that extends through the pressure block 614 and thereby
places the upper and lower chambers 620a,b in fluid communication.
Moreover, a fluid metering valve 624 similar to the fluid metering
valve 530 of FIG. 5 may be arranged within the fluid conduit 622
and configured to control the flow of fluid between the upper and
lower chambers 620a,b via the fluid conduit 622. A floating piston
626 may be arranged in the upper chamber 620a of the hydraulic
chamber 612. Inner and outer sealing elements 524 may provide a
hydraulic seal such that hydraulic fluids are unable to migrate in
either axial direction past the floating piston 626.
[0066] The release shoulder assembly 610 may further include a
magnetic sleeve 628 axially movable with respect to the release
shoulder 222. The magnetic sleeve 628 may include a first or inner
set of magnets 630 that is arranged on the magnetic sleeve 628 and
therefore configured to move therewith. The inner magnets 630 may
be configured to magnetically interact with or otherwise attract a
second or outer set of magnets 632 disposed on the release shoulder
222. A third or shifting set of magnets 634 may be arranged on the
service tool 602 and configured to magnetically interact with and
otherwise attract the inner magnets 630. The inner, outer, and
shifting magnets 630, 632, 634 may each be rare earth magnets, for
example, samarium-cobalt magnets. While a certain number of magnets
are shown in FIGS. 6A-6C for each of the inner, outer, and shifting
magnets 630, 632, 634, those skilled in the art will readily
appreciate that any number of magnets (including one) may be used
for each.
[0067] The hydraulic chamber 612 may be filled with a hydraulic
fluid that is able to be conveyed between the upper and lower
chambers 620a,b when the release shoulder 222 moves. More
particularly, the fluid in the hydraulic chamber 612 may be any
fluid that becomes strongly magnetized in the presence of a
magnetic field. For example, the fluid may be a ferromagnetic fluid
or a magnetorheological fluid (collectively "ferrofluid"), or any
fluid that includes ferrous particles suspended in a carrier fluid.
When placed in the presence of a magnetic field, such ferrofluids
may exhibit a high viscosity, thereby substantially preventing the
fluid from being able to pass through the pressure block 614 via
the fluid conduit 622. In the absence of the magnetic field,
however, such ferrofluids exhibit a low viscosity, thereby being
able to pass through the pressure block 614 via the fluid conduit
622.
[0068] In FIG. 6A, the magnetic sleeve 628 is arranged such that
the inner magnets 630 magnetically interact with the ferrofluid
disposed within the lower chamber 620b. In other words, the
magnetic field produced by the inner magnets 630 extends radially
into the lower chamber 620b and thereby magnetizes and otherwise
increases the viscosity of the ferrofluid therein. As a result, in
such a configuration the ferrofluid is kept in a high viscosity
state and therefore substantially prevented from passing through
the fluid conduit 622, and thereby maintaining the release shoulder
222 in place axially.
[0069] In exemplary operation, the shifting tool 604 may locate the
shifting profile 606 of the circulating sleeve 120a and an axial
load applied on the service tool 602 in the second direction B may
begin to move the circulating sleeve 120a to the closed position.
The shifting magnets 634 arranged on the service tool 602 may
locate and magnetically couple to the inner magnets 630 as the
service tool 602 continues in the second direction B, thereby
correspondingly shifting or otherwise moving the magnetic sleeve
628 in the second direction B. As will be appreciated, the shifting
magnets 634 may couple to the inner magnets 630 before, during, or
after the shifting tool 604 locates the shifting profile 612.
[0070] In FIG. 6B, the circulating sleeve 120a is depicted in the
permanent closed position. To accomplish this, the service tool 602
is moved in the second direction B until the proximal end of the
circulating sleeve 120a is brought into axial contact with the
release shoulder 222. The magnetic sleeve 628 may also
correspondingly move or shift in the second direction B until the
inner magnets 630 are moved into a position radially offset from or
otherwise axially adjacent to the outer magnets 632. In such a
configuration, a closed magnetic circuit may be generated by the
inner and outer magnets 630, 632, such that the magnetic field
produced by the inner magnets 630 may become substantially choked
and otherwise unable to interact with the ferrofluid in the
hydraulic chamber 612. As a result, the viscosity of the ferrofluid
dramatically decreases, thereby enabling the ferrofluid to pass
through the fluid conduit 622 if required.
[0071] Accordingly, continued application of the axial load in the
second direction B on the circulating sleeve 120a as engaged with
the release shoulder 222 may begin to force the ferrofluid present
within the lower chamber 620b to flow through the fluid conduit 622
and into the upper chamber 620a at a steady flow rate. As will be
appreciated, the time and axial load required to move the releasing
shoulder 222 will depend on the size and length of the fluid
conduit 622, the parameters of the fluid metering valve 624 (if
used), and/or the fluid properties of the ferrofluid. As the
ferrofluid enters the upper chamber 620a, the floating piston 626
may be moved toward the upper end wall 618 to accommodate the
influx of fluid.
[0072] The steady rate of flow translates into a steady and
predictable rate of movement of the release shoulder 222 in the
second direction B, thereby gradually exposing the locking
mechanism 322 encompassed by the channel 330. As a result, an
operator may be able to approximately gauge how much time is
required to move the release shoulder 222 so that the locking
profile 320 may engage the locking mechanism 322 and permanently
lock the circulating sleeve 120a in the closed position.
Consequently, the axial load in the second direction B may be
applied for a predetermined period of time until enough ferrofluid
had passed from the lower chamber 620b to the upper chamber 620a,
thereby allowing the locking mechanism 322 to lock the circulating
sleeve 120a in place.
[0073] Continued axial load on the service tool 602 in the second
direction B may then help the shifting key 306 to flex radially
inward against the spring force of the biasing devices 310, and
thereby allow the shifting tool 604 to axially traverse the release
shoulder 222. More particularly, continued axial load on the
service tool 602 in the second direction B may transfer the axial
load to the second axial end 318b of the shifting key as secured to
the circulating sleeve 120a at the radial protrusion 608. The
second axial end 318b may then engage and shear the securing
mechanism 334 upon assuming a predetermined axial load, thereby
allowing the shifting keys 306 to radially collapse inward and
otherwise slide out of radial and axial engagement with the
shifting profile 606.
[0074] As the shifting key 306 radially collapses into the groove
308, and with the securing mechanism 334 no longer secured, the
shifting key 306 may be configured to extend into or otherwise be
inserted within the cavity 336. The beveled second end 318b of the
shifting key 306 may help the shifting key 306 slide or shift into
the cavity 336 axially. As the service tool 602 continues to move
in the second direction B, the first axial end 318a of the shifting
keys 306 may axially engage at least a portion of the release
shoulder 222. The beveled first end 318a may help the shifting key
306 radially collapse even further into the groove 308 as axially
forced against the release shoulder 222. In some embodiments, as
illustrated, a portion of the distal end 338 of the release
shoulder 222 may also be beveled or otherwise chamfered to help the
shifting key 306 slide out of axial engagement with the release
shoulder 222.
[0075] In other embodiments, as with prior embodiments, the
securing mechanism 334 may be replaced with a spring or other type
of biasing device that acts to urge the shifting key 306 out of the
cavity 336 and otherwise maintain its axial position within the
groove 308. In such embodiments, the shifting key 306 may radially
collapse into the groove 308 and compress the spring as it axially
enters the cavity 336. After axially traversing the release
shoulder 222 and other radial obstructions in the second direction
B, the shifting tool 604 may be urged back out of the cavity 336
with the spring. Moreover, once past the release shoulder 222 and
other radial obstructions, the biasing devices 310 may be
configured to radially expand the shifting key 306. Accordingly,
the shifting tool 604 in such an embodiment may be resettable and
therefore configured to axial traverse the completion string 102
and open and close the circulating sleeve 120a multiple times, and
also permanently close multiple circulating sleeves during a single
run-in downhole.
[0076] Embodiments disclosed herein include:
[0077] A. A completion system that may include a completion string
having a circulating sleeve movably arranged therein, the
circulating sleeve having a locking profile defined on an outer
radial surface thereof and a shifting profile defined on an inner
radial surface thereof, a service tool configured to be arranged at
least partially within the completion string and including a
shifting tool having one or more shifting keys configured to mate
with the shifting profile, wherein, when the shifting keys locate
and mate with the shifting profile, an axial load applied on the
service tool axially moves the circulating sleeve, and a release
shoulder assembly arranged within the completion string and
comprising a release shoulder that defines a channel configured to
receive a locking mechanism disposed on the completion string, the
locking mechanism being occluded within the channel until the
release shoulder is moved axially, thereby allowing the locking
mechanism to engage the locking profile and secure the circulating
sleeve in a permanent closed position.
[0078] B. A method that may include introducing a service tool at
least partially into a completion string, the service tool
including a shifting tool having one or more shifting keys and the
completion string providing a circulating sleeve movably arranged
therein, wherein the circulating sleeve has a locking profile
defined on an outer radial surface thereof and a shifting profile
defined on an inner radial surface thereof, mating the one or more
shifting keys with the shifting profile, applying an axial load on
the service tool in a first direction to move the circulating
sleeve to a closed position, engaging the circulating sleeve on a
release shoulder of a release shoulder assembly arranged within the
completion string, the release shoulder defining a channel
configured to receive and occlude a locking mechanism disposed on
the completion string, axially moving the release shoulder in the
first direction with the axial load applied on the service tool and
the circulating sleeve and thereby exposing the locking mechanism,
and engaging the locking profile on the locking mechanism and
thereby securing the circulating sleeve in a permanent closed
position.
[0079] Each of embodiments A and B may have one or more of the
following additional elements in any combination: Element 1:
wherein the shifting tool is a first shifting tool and the service
tool includes a second shifting tool axially offset from the first
shifting tool. Element 2: wherein the shifting tool is configured
to move the circulating sleeve between an open position, where one
or more circulation ports defined in the completion string are
exposed, and a closed position, where the circulating sleeve
occludes the one or more circulation ports. Element 3: wherein each
shifting key has a beveled first axial end configured to urge the
one or more shifting keys radially inward upon axially engaging the
release shoulder and thereby allowing the shifting tool to axially
traverse the release shoulder. Element 4: wherein the locking
mechanism is a body lock ring configured to receive and secure the
locking profile. Element 5: wherein the release shoulder assembly
further comprises one or more securing devices configured to
axially secure the release shoulder with respect to the completion
string. Element 6: wherein the one or more securing devices are
devices selected from the group consisting of a shear pin, a shear
ring, and a spring. Element 7: wherein the release shoulder
assembly further comprises a hydraulic chamber cooperatively
defined by the completion string and the release shoulder, a
pressure block arranged within the hydraulic chamber and dividing
the hydraulic chamber into an upper chamber and a lower chamber,
the pressure block having a fluid conduit defined therethrough that
places the upper and lower chambers in fluid communication, and a
floating piston arranged in the upper chamber. Element 8: further
comprising a fluid metering valve arranged within the fluid conduit
and configured to meter the flow of hydraulic fluid between the
upper and lower chambers via the fluid conduit. Element 9: further
comprising a biasing device arranged in the upper chamber and
interposing an upper end wall of the hydraulic chamber and the
floating piston, the biasing device being configured to urge the
floating piston toward the pressure block. Element 10: wherein the
hydraulic fluid is a ferrofluid and the release shoulder assembly
further comprises a magnetic sleeve axially movable with respect to
the release shoulder and having a first set of magnets disposed
thereon, a second set of magnets disposed on the release shoulder,
and a third set of magnets arranged on the service tool and
configured to magnetically attract the first set of magnets in
response to the axial load and thereby axially move the magnetic
sleeve such that the first set of magnets are brought into magnetic
interaction with the second set of magnets, wherein, when the first
set of magnets are arranged adjacent the lower chamber, a magnetic
field produced by the first set of magnets prevents the ferrofluid
from passing through the fluid conduit, and wherein, when the first
set of magnets magnetically interact with the second set of
magnets, a closed magnetic circuit is generated, thereby enabling
the ferrofluid to pass through the fluid conduit.
[0080] Element 11: wherein engaging the circulating sleeve on the
release shoulder is preceded by applying an axial load on the
service tool in a second direction opposite the first direction and
thereby moving the circulating sleeve back to an open position
where one or more circulation ports defined in the completion
string are exposed. Element 12: wherein each shifting key has a
beveled first axial end, the method further comprising engaging the
beveled first axial end of each shifting key against the release
shoulder, and urging the one or more shifting keys radially inward
and thereby allowing the shifting tool to axially traverse the
release shoulder. Element 13: wherein the release shoulder assembly
further comprises one or more securing devices that axially secure
the release shoulder with respect to the completion string, the
method further comprising shearing the one or more securing devices
as the axial load is transferred to the release shoulder from the
circulating sleeve. Element 14: wherein the release shoulder
assembly further comprises a hydraulic chamber cooperatively
defined by the completion string and the release shoulder, and a
pressure block arranged within the hydraulic chamber and dividing
the hydraulic chamber into an upper chamber and a lower chamber,
and wherein axially moving the release shoulder in the first
direction further comprises flowing hydraulic fluid from the lower
chamber to the upper chamber through a fluid conduit defined in the
pressure block, and axially displacing a floating piston in
arranged in the upper chamber with the hydraulic fluid entering the
upper chamber. Element 15: further comprising metering a flow of
the hydraulic fluid through the fluid conduit with a fluid metering
valve arranged within the fluid conduit, and gradually exposing the
locking mechanism at a rate corresponding to a flow rate of the
hydraulic fluid through the fluid conduit. Element 16: wherein the
release shoulder assembly further comprises a biasing device
arranged in the upper chamber and interposing an upper end wall of
the hydraulic chamber and the floating piston, the method further
comprising engaging and compressing the biasing device with the
with the floating piston as the floating piston is displaced by the
hydraulic fluid, releasing the axial load in the first direction,
allowing the biasing device to expand, and forcing the hydraulic
fluid to flow back into the lower chamber via the fluid conduit
with the floating piston as the biasing device expands. Element 17:
wherein the hydraulic fluid is a ferrofluid and the release
shoulder assembly further comprises a magnetic sleeve axially
movable with respect to the release shoulder and having a first set
of magnets disposed thereon, a second set of magnets disposed on
the release shoulder, and a third set of magnets arranged on the
service tool, the method further comprising generating a magnetic
field that extends into the lower chamber with the first set of
magnets and thereby preventing the ferrofluid from passing through
the fluid conduit. Element 18: further comprising magnetically
attracting the first set of magnets with the third set of magnets
as the service tool moves in the first direction, axially moving
the magnetic sleeve in the first direction with the third set of
magnets magnetically attracted to the first set of magnets, placing
the first set of magnets in magnetic interaction with the second
set of magnets, and generating a closed magnetic circuit when the
first set of magnets magnetically interact with the second set of
magnets, and thereby enabling the ferrofluid to pass through the
fluid conduit. Element 19: further comprising metering a flow of
the ferrofluid through the fluid conduit with a fluid metering
valve arranged within the fluid conduit, and gradually exposing the
locking mechanism at a rate corresponding to a flow rate of the
ferrofluid through the fluid conduit.
[0081] Therefore, the disclosed systems and methods are well
adapted to attain the ends and advantages mentioned as well as
those that are inherent therein. The particular embodiments
disclosed above are illustrative only, as the teachings of the
present disclosure may be modified and practiced in different but
equivalent manners apparent to those skilled in the art having the
benefit of the teachings herein. Furthermore, no limitations are
intended to the details of construction or design herein shown,
other than as described in the claims below. It is therefore
evident that the particular illustrative embodiments disclosed
above may be altered, combined, or modified and all such variations
are considered within the scope of the present disclosure. The
systems and methods illustratively disclosed herein may suitably be
practiced in the absence of any element that is not specifically
disclosed herein and/or any optional element disclosed herein.
While compositions and methods are described in terms of
"comprising," "containing," or "including" various components or
steps, the compositions and methods can also "consist essentially
of" or "consist of" the various components and steps. All numbers
and ranges disclosed above may vary by some amount. Whenever a
numerical range with a lower limit and an upper limit is disclosed,
any number and any included range falling within the range is
specifically disclosed. In particular, every range of values (of
the form, "from about a to about b," or, equivalently, "from
approximately a to b," or, equivalently, "from approximately a-b")
disclosed herein is to be understood to set forth every number and
range encompassed within the broader range of values. Also, the
terms in the claims have their plain, ordinary meaning unless
otherwise explicitly and clearly defined by the patentee. Moreover,
the indefinite articles "a" or "an," as used in the claims, are
defined herein to mean one or more than one of the element that it
introduces. If there is any conflict in the usages of a word or
term in this specification and one or more patent or other
documents that may be incorporated herein by reference, the
definitions that are consistent with this specification should be
adopted.
[0082] As used herein, the phrase "at least one of" preceding a
series of items, with the terms "and" or "or" to separate any of
the items, modifies the list as a whole, rather than each member of
the list (i.e., each item). The phrase "at least one of" does not
require selection of at least one item; rather, the phrase allows a
meaning that includes at least one of any one of the items, and/or
at least one of any combination of the items, and/or at least one
of each of the items. By way of example, the phrases "at least one
of A, B, and C" or "at least one of A, B, or C" each refer to only
A, only B, or only C; any combination of A, B, and C; and/or at
least one of each of A, B, and C.
[0083] The use of directional terms such as above, below, upper,
lower, upward, downward, left, right, uphole, downhole and the like
are used in relation to the illustrative embodiments as they are
depicted in the figures, the upward direction being toward the top
of the corresponding figure and the downward direction being toward
the bottom of the corresponding figure, the uphole direction being
toward the surface of the well and the downhole direction being
toward the toe of the well.
* * * * *