U.S. patent application number 14/647590 was filed with the patent office on 2015-10-29 for downhole setting tool.
The applicant listed for this patent is WELLTEC A/S. Invention is credited to Jorgen HALLUNDB K, Ivan Sciera JENSEN, Lars ST HR, Ricardo Reves VASQUES.
Application Number | 20150308240 14/647590 |
Document ID | / |
Family ID | 47294789 |
Filed Date | 2015-10-29 |
United States Patent
Application |
20150308240 |
Kind Code |
A1 |
HALLUNDB K; Jorgen ; et
al. |
October 29, 2015 |
DOWNHOLE SETTING TOOL
Abstract
The present invention relates to a downhole setting tool for
setting an annular sealing structure in an openhole part of a well,
comprising: a tool body (5) having a tool axis, a shaft (7) having
a first end and a second end, connected to the tool body at the
second end, an expandable pipe (10) having a transport position in
which the expandable pipe has an unexpanded diameter, and an
expanded position in which the expandable pipe has an expanded
diameter, an annular sealing element (11), and a pipe expansion
element (12) arranged at the first end of the shaft for expanding
at least the pipe, wherein the expandable pipe and the annular
sealing element are arranged in succession along the tool axis in a
non-overlapping manner. The tool further comprises a second
expansion (14) with an inclined surface on which annular seal
slides when being pushed by expansion element (12) onto the outside
of the expandable pipe (10).
Inventors: |
HALLUNDB K; Jorgen; (Gr.ae
butted.sted, DK) ; VASQUES; Ricardo Reves; (Holte,
DK) ; ST HR; Lars; (Glostrup, DK) ; JENSEN;
Ivan Sciera; (Hellerup, DK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WELLTEC A/S |
Allerod |
|
DK |
|
|
Family ID: |
47294789 |
Appl. No.: |
14/647590 |
Filed: |
December 6, 2013 |
PCT Filed: |
December 6, 2013 |
PCT NO: |
PCT/EP2013/075772 |
371 Date: |
May 27, 2015 |
Current U.S.
Class: |
166/387 ;
166/179 |
Current CPC
Class: |
E21B 23/06 20130101;
E21B 43/103 20130101; E21B 33/128 20130101; E21B 43/105
20130101 |
International
Class: |
E21B 43/10 20060101
E21B043/10; E21B 33/128 20060101 E21B033/128; E21B 23/06 20060101
E21B023/06 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 7, 2012 |
EP |
12196155.1 |
Claims
1. A downhole setting tool for setting an annular base structure in
an openhole part of a well comprising: a tool body having a tool
axis, a shaft having a first end and a second end, connected to the
tool body at the second end, an expandable pipe having a transport
position in which the expandable pipe has an unexpanded diameter
(d.sub.u), and an expanded position in which the expandable pipe
has an expanded diameter (d.sub.e), an annular sealing element, and
a pipe expansion element arranged at the first end of the shaft for
expanding at least the pipe, wherein the expandable pipe and the
annular sealing element are arranged in succession along the tool
axis in a non-overlapping manner.
2. A downhole setting tool according to claim 1, wherein the
annular sealing element is arranged between the pipe expansion
element and the expandable pipe.
3. A downhole setting tool according to claim 1, further comprising
a second expansion element having an inclining outer face on which
the annular sealing element slides for providing the annular
sealing element with an inner diameter (d.sub.i) which is larger
than the unexpanded outer diameter of the expandable pipe.
4. A downhole setting tool according to claim 3, wherein the second
expansion element is hollow and extends around the shaft.
5. A downhole setting tool according to claim 1, further comprising
a pushing element wherein the annular sealing element has a first
end and a second end, the pushing element being arranged at the
second end of the annular sealing element, and the second expansion
element being arranged at the first end of the annular sealing
element.
6. A downhole setting tool according to claim 5, wherein the
pushing element is the expandable pipe element.
7. A downhole setting tool, further comprising a hydraulic cylinder
for pulling the shaft into the tool body.
8. A downhole setting tool according to claim 7, wherein the
hydraulic cylinder comprises a cylinder housing and a piston, and
the shaft comprises the piston or the cylinder housing.
9. A downhole setting tool according to claim 1, wherein expandable
rings are arranged at the first end and the second end of the
annular sealing element.
10. A downhole setting tool according to claim 1, further
comprising an expandable tubular arranged around the shaft between
the tool body and the expandable pipe.
11. A downhole setting tool according to claim 1, wherein the pipe
expansion element comprises several cone segments movable in a
radial direction.
12. A downhole setting tool according to claim 1, wherein the
annular sealing element has an inclining surface facing the
inclining outer face of the second expansion element.
13. An annular base structure according to claim 1, comprising: the
annular sealing element made of an elastomeric material or natural
or synthetic rubber, and the expandable pipe of metal arranged
inside the annular sealing element, pressing the annular sealing
element radially outwards when in an expanded position.
14. A downhole sealing system for sealing off a production zone in
an openhole part of a well, comprising: a first and a second
annular base structure set by the downhole setting tool according
to claim 1, a tubular having a first tubular end and a second
tubular end and being arranged between the two annular base
structures so that the first tubular end overlaps the first annular
base structure and the second tubular end overlaps the second
annular base structure, and two packers arranged between the
annular base structure and the tubular.
15. A method of expanding an annular base structure in an openhole
part of a well, comprising the steps of: inserting a downhole tool
according to claim 1 into the openhole part of a well, moving the
second expansion element for expanding and sliding the annular
sealing element on an outside of the expandable pipe, expanding the
expandable pipe and the annular sealing element by means of the
pipe expansion element, and retracting the tool from the expandable
pipe.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a downhole setting tool for
setting an annular base structure in an openhole part of a well.
The present invention also relates to an annular base structure, a
downhole sealing system and a method of expanding an annular base
structure in an openhole part of a well.
BACKGROUND ART
[0002] A well may be partly cased and partly openhole, meaning that
the part of the well furthest away from the top of the well is an
openhole part of the well. Most often, the production zone in which
the hydrocarbon-containing fluid flows out of the reservoir is
arranged in the openhole part of the well. In the event of a water
breakthrough in the openhole part of the well, the production zone
needs to be sealed off. Due to the fact the openhole part of the
well has a larger diameter than the cased part, it may be difficult
to set an annular sealing structure.
SUMMARY OF THE INVENTION
[0003] It is an object of the present invention to wholly or partly
overcome the above disadvantages and drawbacks of the prior art.
More specifically, it is an object to provide an improved downhole
tool capable of setting an annular sealing structure in an openhole
part of a well while being submergible through the cased part of
the well.
[0004] The above objects, together with numerous other objects,
advantages, and features, which will become evident from the below
description, are accomplished by a solution in accordance with the
present invention by a downhole setting tool for setting an annular
base structure in an openhole part of a well, comprising:
[0005] a tool body having a tool axis,
[0006] a shaft having a first end and a second end, connected to
the tool body at the second end,
[0007] an expandable pipe having a transport position in which the
expandable pipe has an unexpanded diameter, and an expanded
position in which the expandable pipe has an expanded diameter,
[0008] an annular sealing element, and
[0009] a pipe expansion element arranged at the first end of the
shaft for expanding at least the pipe,
[0010] wherein the expandable pipe and the annular sealing element
are arranged in succession along the tool axis in a non-overlapping
manner.
[0011] In an embodiment, the annular sealing element may be
arranged between the pipe expansion element and the expandable
pipe.
[0012] Also, the downhole setting tool as described above may
further comprise a second expansion element having an inclining
outer face on which the annular sealing element slides for
providing the annular sealing element with an inner diameter which
is larger than the unexpanded outer diameter of the expandable
pipe.
[0013] The second expansion element may be hollow and may extend
around the shaft.
[0014] Moreover, the downhole setting tool as described above may
further comprise a pushing element, wherein the annular sealing
element may have a first end and a second end, the pushing element
being arranged at the second end of the annular sealing element,
and the second expansion element being arranged at the first end of
the annular sealing element.
[0015] Said pushing element may be the expandable pipe element.
[0016] In addition, the downhole setting tool as described above
may further comprise a hydraulic cylinder for pulling the shaft
into the tool body.
[0017] Moreover, the hydraulic cylinder may be a stroking tool,
such as the Well Stroker.RTM..
[0018] Further, the hydraulic cylinder may comprise a cylinder
housing and a piston, and the shaft may comprise the piston or the
cylinder housing.
[0019] In an embodiment, the tool may comprise two hydraulic
cylinders, one for moving the second expansion element and one for
moving the shaft.
[0020] The above-mentioned pushing means may comprise several arms,
and the second expansion element may have fastening means for
engaging with the arms of the pushing means.
[0021] Also, expandable rings may be arranged at the first end and
the second end of the annular sealing element.
[0022] Additionally, the downhole setting tool as described above
may further comprise an expandable tubular arranged around the
shaft between the tool body and the expandable pipe.
[0023] The second expansion element may comprise radial cavities in
which an engagement means extends for engagement with the pipe
expansion element.
[0024] Furthermore, the second expansion element may comprise an
elongated part extending through the annular sealing element into
the pipe expansion element, enabling engagement of the engagement
means with the pipe expansion element.
[0025] In addition, the downhole setting tool may further comprise
a tool housing from which the second expansion element is
projectable.
[0026] Moreover, the pipe expansion element may comprise several
cone segments movable in a radial direction.
[0027] In an embodiment, the expandable pipe may be made of
metal.
[0028] Further, the annular sealing element may have an inclining
surface facing the inclining outer face of the second expansion
element.
[0029] Also, the annular sealing element may be made of an
elastomeric material or natural or synthetic rubber.
[0030] The present invention also relates to an annular base
structure as described above, comprising:
[0031] the annular sealing element made of an elastomeric material
or natural or synthetic rubber, and
[0032] the expandable pipe of metal arranged inside the annular
sealing element, pressing the annular sealing element radially
outwards when in an expanded position.
[0033] Furthermore, the present invention relates to a downhole
sealing system for sealing off a production zone in an openhole
part of a well, comprising:
[0034] a first and a second annular base structure set by the
downhole setting tool as described above,
[0035] a tubular having a first tubular end and a second tubular
end and being arranged between the two annular base structures so
that the first tubular end overlaps the first annular base
structure and the second tubular end overlaps the second annular
base structure, and
[0036] two packers arranged between the annular base structure and
the tubular.
[0037] Finally, the present invention relates to a method of
expanding an annular base structure in an openhole part of a well,
comprising the steps of:
[0038] inserting a downhole tool as described above into the
openhole part of a well,
[0039] moving the second expansion element for expanding and
sliding the annular sealing element on the outside of the
expandable pipe,
[0040] expanding the expandable pipe and the annular sealing
element by means of the pipe expansion element, and
[0041] retracting the tool from the expandable pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The invention and its many advantages will be described in
more detail below with reference to the accompanying schematic
drawings, which for the purpose of illustration show some
non-limiting embodiments and in which
[0043] FIG. 1 shows a production zone sealed off by two base
structures and a tubular arranged therebetween,
[0044] FIG. 2 shows a cross-sectional view of a downhole setting
tool according to the invention in its initial position,
[0045] FIG. 3 shows a cross-sectional view of the downhole setting
tool of FIG. 2 in which the annular sealing element has been partly
pushed on the outside of the expandable pipe,
[0046] FIG. 4 shows a cross-sectional view of the downhole setting
tool of FIG. 2 in which the pipe expansion element expands the
expandable pipe and the annular sealing element,
[0047] FIG. 5 shows a cross-sectional view of the downhole setting
tool of FIG. 2 in which the pipe expansion element has fully
expanded the expandable pipe and the annular sealing element,
[0048] FIG. 6 shows a cross-sectional view of another embodiment of
the downhole setting tool in its initial position,
[0049] FIG. 7 shows a cross-sectional view of the downhole setting
tool of FIG. 6 in which the second expansion element engages the
shaft to be ready to push the annular sealing element,
[0050] FIG. 8 shows a cross-sectional view of the downhole setting
tool of FIG. 6 in which the annular sealing element has been pushed
on the outside of the expandable pipe,
[0051] FIG. 9 shows a cross-sectional view of the downhole setting
tool of FIG. 6 in which the annular sealing element has been
compressed, and
[0052] FIG. 10 shows a cross-sectional view of the downhole setting
tool of FIG. 6 in which the pipe expansion element expands the
expandable pipe and the annular sealing element.
[0053] All the figures are highly schematic and not necessarily to
scale, and they show only those parts which are necessary in order
to elucidate the invention, other parts being omitted or merely
suggested.
DETAILED DESCRIPTION OF THE INVENTION
[0054] FIG. 1 shows a downhole sealing system 100 for sealing off a
production zone 30 producing water 61 in an openhole part 3 of a
well 4. The downhole sealing system 100 comprises a first and a
second annular base structure 2 and a tubular 31 arranged between
the two annular base structures so that a first tubular end 53 of
the tubular overlaps the first annular base structure and a second
tubular end 54 of the tubular overlaps the second annular base
structure. The system 100 further comprises two packers 32 arranged
between the annular base structure 2 and the tubular 31. The
annular base structures 2 press against a wall 3a of the openhole
part of the well and thus provide--together with the packers--an
annular barrier on the outside of the tubular 31, said annular
barrier sealing off the production zone 30. Each annular base
structure 2 comprises an annular sealing element 11 surrounding an
expandable pipe 10 pressing the annular sealing element towards the
wall 3a of the openhole part 3 of the well 4.
[0055] The annular base structure is set by a downhole setting tool
1, as shown in FIGS. 2-10. The downhole setting tool 1 comprises a
tool body 5 having a tool axis 6 and a shaft 7 connected to the
tool body at a second end 9 of the shaft. A first end 8 of the
shaft 7 projects from a tool housing 29 through the expandable pipe
10 in its transport position in which the expandable pipe has an
unexpanded diameter d.sub.u. In FIG. 1, the expandable pipe 10 has
an expanded position in which the expandable pipe has an expanded
diameter d.sub.e. As shown in FIGS. 2-10, the shaft 7 extends
further through the annular sealing element 11 and into a pipe
expansion element 12 arranged at the first end of the shaft 7 for
expanding the pipe 10 and the annular sealing element 11. Thus, the
expandable pipe 10 and the annular sealing element 11 are arranged
in succession along the tool axis 6, hence minimising the outer
diameter of the setting tool 1. The setting tool 1 is hereby
capable of passing down through the cased part of the well (not
shown) to the openhole part 3 of the well 4.
[0056] As shown in FIG. 2, the downhole setting tool 1 further
comprises a second expansion element 14 having an inclining outer
face 15 on which the annular sealing element 11 slides, as shown in
FIG. 3, for providing the annular sealing element with an inner
diameter d, which is larger than an unexpanded outer diameter
d.sub.u of the expandable pipe 10. The annular sealing element 11
has an inclining surface 34 facing the outer face 15 of the
expansion element 14, and upon retraction of the shaft 7 into the
tool body 5, the first end 8 of the shaft having a wider part 27
presses against the annular sealing element 11 and thereby pushes
the annular sealing element to slide on the inclining surface 34 of
the second expansion element 14. The second expansion element 14 is
hollow, extends around the shaft 7, is positioned partly under the
expandable pipe 10 and is fastened to the expandable pipe by a
breakable part 35, such as a shear pin. In this way, the annular
sealing element 11 is pushed onto an outside 36 of the expandable
pipe 10, as shown in FIG. 3. The expandable pipe element 12 is thus
a pushing element.
[0057] In order to retract the shaft 7, the downhole setting tool 1
further comprises a hydraulic cylinder 19, as shown in FIG. 2. The
hydraulic cylinder 19 comprises a cylinder housing 24 and a piston
23 forming part of the second end 9 of the shaft 7. The piston 23
divides the cylinder housing 24 into a first housing part 37 and a
second housing part 38, and when pressurised fluid is injected into
the first housing part, the piston on the shaft 7 moves and the
shaft is retracted into the tool body 5.
[0058] When the annular sealing element 11 has been pushed all the
way onto the expandable pipe 10, the shaft 7 is further retracted
into the tool body 5, as shown in FIG. 4. The pipe expansion
element 12 comprises several cone segments 20 which are movable in
a radial direction, and at this stage, the cones 20 have moved
radially outwards and thus climbed a stepwise, radially increasing
surface 28 on the wider part 27. In this way, the outer diameter of
the first end 8 of the shaft 7 is increased, and as the shaft is
further retracted, the expandable pipe 10 and the annular sealing
element 11 are expanded. The breakable part of the second expansion
element 14 is broken, and the second expansion element is allowed
to move onto the expandable pipe 10 as the wider part 27 of the
first end 8 of the shaft 7 moves towards the tool body 5.
[0059] As the pipe expansion element 12 is moved even further
towards the tool body 5, the expandable pipe 10 is fully expanded,
as shown in FIG. 5, and the second expansion element is also pushed
into the tool housing 29. In order to be able to fully expand the
expandable pipe 10, the downhole setting tool 1 further comprises
an expandable tubular in the form of a slotted liner 25 arranged
around the shaft 7 between the tool body 5 and the expandable pipe
10. As the pipe expansion element 12 moves further towards the tool
body 5, the slotted liner 25 is expanded by the pipe expansion
element 12, thereby making the pipe expansion element 12 capable of
passing under the slotted liner 25. In this way, the tool is
capable of fully expanding the expandable pipe 10 and the annular
sealing element 11 to press against the wall of the openhole part 3
of the well, as shown in FIG. 1, even though the openhole part of
the well has a greater diameter than the cased part of the well
because the annular sealing element 11 is pushed on the outside of
the expandable pipe 10 and the pipe keeps the annular sealing
element 11 pressed towards the wall of the openhole part 3 of the
well.
[0060] In FIG. 7, the second expansion element 14 comprises an
elongated part 50 arranged inside the tool housing. The second
expansion element 14 is slidably arranged around the shaft 7 inside
the expandable pipe 10. The shaft 7 extends from its second end in
the hydraulic cylinder inside the tool housing 29 through the
second expansion element 14 and the expandable pipe 10. The shaft 7
extends further through the annular sealing element 11 and through
a separate pushing means 18 in order to, at its first end,
penetrate a first and a second pipe expansion element 12, as shown
in FIG. 6. In this embodiment, the expansion element 12 thus
comprises two expansion sections. The first and second pipe
expansion elements 12 comprise several cone segments 20 which are
movable in a radial direction. When the cone segments 20 move
radially outwards in the first pipe expansion element 12, a gap is
created between two adjacent cone segments, and by arranging the
second expansion element 14 behind and angularly displaced in
relation to the first expansion element, the gaps from the first
expansion element are covered by the cone segments of the second
expansion element.
[0061] As shown in FIG. 10, the second expansion element 14 is
projectable from the tool housing for extending through the annular
sealing element 11 into the pipe expansion element 12, enabling
engagement of engagement means 44 with cavities 41 in the pipe
expansion element 12. When the engagement means 44 are arranged
opposite the cavities 41, the engagement means 44 are forced
outwards by springs (not shown) and to enter the cavities 41.
[0062] As shown in FIGS. 6 and 7, the annular sealing element 11
has a first end 16 and a second end 17, and the pushing element 18
is arranged at the second end 17 of the annular sealing element 11
and the second expansion element 14 is arranged at the first end of
the annular sealing element. Expandable rings 21 are arranged at
the first and the second end of the annular sealing element 11 so
that the pushing element 18 presses on one of the expandable rings
21 arranged therebetween.
[0063] In FIG. 7, the second expansion element 14 has moved through
the annular sealing element 11, expanding the expandable rings 21
and an inner diameter d, of the annular sealing element 11. The
second expansion element 14 comprises radial cavities in which
engagement means 45 are pressed outwards by means of a spring 46
engaging cavities 42 in the pushing element 18. The pushing element
18 comprises several arms 52 which are forced radially outwards due
to the inclining outer face 15 of the second expansion element 14
as the second expansion element 14 projects through the annular
sealing element 11. The arms 52 of the pushing element 18 are held
together by a flexible ring penetrating an opening in the arms. The
flexible ring is made of a spring material and will therefore
attempt to force the arms radially inwards.
[0064] When the second expansion element 14 has engaged the arms of
the pushing element 18, the second expansion element 14 is
retracted, pushing the annular sealing element 11 and the
expandable rings 21 onto the expandable pipe 10 on the outside of
the expandable pipe 10, as shown in FIG. 8. When the expandable
ring 21 reaches a stop 47 arranged on the outside of the expandable
pipe 10, the retraction of the second expansion element 14 is
continued for compressing the annular sealing element 11, as shown
in FIG. 9. In this way, the expandable pipe 10 is pressed into a
cavity of the arms 52, releasing the fastening means 45, and the
arms slide down the inclining outer face 15 of the second expansion
element 14 as the shaft 7 and the second expansion element 14 are
retracted even further, as shown in FIG. 10.
[0065] In FIG. 10, the first and second pipe expansion elements 12
have been pulled partly through the expandable pipe 10, and thus,
the pipe 10 and the annular sealing element 11 have been expanded.
The expansion process of the expandable pipe 10 is continued until
the pipe has been fully expanded and the expandable pipe and the
annular sealing element 11 have been set in such a way that the
annular sealing element 11 presses against the wall 3a of the
openhole part 3 of the well 4.
[0066] The downhole setting tool 1 of FIGS. 6-10 comprises a first
hydraulic cylinder and a second hydraulic cylinder. The first
hydraulic cylinder moves the second expansion element 14 between
its projected and retracted positions, and the second hydraulic
cylinder moves the shaft 7.
[0067] In order to keep the annular sealing element 11 in its
expanded position pressing against the wall of the openhole part of
the well, the expandable pipe 10 is made of metal. The annular
sealing element 11 is made of a flexible material such as an
elastomeric material or natural or synthetic rubber in order that
it can conform to the dented shape of the wall of the openhole part
of the well.
[0068] The setting tool 1 is thus capable of providing the openhole
part of the well with annular base structures comprising the
annular sealing element 11 made of an elastomeric material or
natural or synthetic rubber, and the expandable pipe 10 made of
metal arranged inside the annular sealing element 11, pressing the
annular sealing element radially outwards when in an expanded
position. Due to the arrangement of the expandable pipe 10 and the
annular sealing element 11 in succession along the tool axis, the
tool 1 can be designed with an outer diameter which is small enough
for the tool to pass the cased part of the well. Furthermore, by
arranging the annular sealing element 11 opposite the expandable
pipe 10 and subsequently expanding the pipe, the outer diameter of
the base structure is increased so that the sealing element 11 is
capable of reaching the wall of the openhole part of the well and
pressing against it.
[0069] The hydraulic cylinder may be a stroking tool, such as the
Well Stroker.RTM.. The stroking tool is a tool providing an axial
force. The stroking tool comprises an electrical motor for driving
a pump. The pump pumps fluid into a piston housing to move a piston
acting therein. The piston is arranged on the stroker shaft which
is the aforementioned shaft. The pump may pump fluid into the
piston housing on one side and simultaneously suck fluid out on the
other side of the piston.
[0070] By fluid or well fluid is meant any kind of fluid that may
be present in oil or gas wells downhole, such as natural gas, oil,
oil mud, crude oil, water, etc. By gas is meant any kind of gas
composition present in a well, completion, or openhole, and by oil
is meant any kind of oil composition, such as crude oil, an
oil-containing fluid, etc. Gas, oil, and water fluids may thus all
comprise other elements or substances than gas, oil, and/or water,
respectively.
[0071] By a casing is meant any kind of pipe, tubing, tubular,
liner, string etc. used downhole in relation to oil or natural gas
production.
[0072] In the event that the tool is not submergible all the way
into the casing, a downhole tractor can be used to push the tool
all the way into position in the well. The downhole tractor may
have projectable arms having wheels, wherein the wheels contact the
inner surface of the casing for propelling the tractor and the tool
forward in the casing. A downhole tractor is any kind of driving
tool capable of pushing or pulling tools in a well downhole, such
as a Well Tractor.RTM..
[0073] Although the invention has been described in the above in
connection with preferred embodiments of the invention, it will be
evident for a person skilled in the art that several modifications
are conceivable without departing from the invention as defined by
the following claims.
* * * * *