Tubular assembly and method of deploying a downhole device using a tubular assembly
09745838 · 2017-08-29
Assignee
Inventors
Cpc classification
E21B43/103
FIXED CONSTRUCTIONS
E21B23/00
FIXED CONSTRUCTIONS
E21B23/02
FIXED CONSTRUCTIONS
E21B29/08
FIXED CONSTRUCTIONS
E21B33/124
FIXED CONSTRUCTIONS
E21B17/00
FIXED CONSTRUCTIONS
International classification
E21B43/10
FIXED CONSTRUCTIONS
E21B23/02
FIXED CONSTRUCTIONS
E21B33/124
FIXED CONSTRUCTIONS
E21B29/00
FIXED CONSTRUCTIONS
E21B17/00
FIXED CONSTRUCTIONS
E21B23/00
FIXED CONSTRUCTIONS
E21B29/08
FIXED CONSTRUCTIONS
Abstract
A tubular assembly is disclosed for use in a wellbore (5) of an oil, gas or water well, typically for landing a downhole device in the wellbore. The assembly has a sleeve (1) adapted to receive the body of the downhole device. The sleeve is deployed into a conduit in the wellbore and expanded, so that the outer circumferential surface of the sleeve is radially expanded against the inner surface of the conduit. The sleeve has a bore with an inner circumferential surface comprising an inwardly facing formation adapted to engage with an outwardly facing formation on the body of the downhole device when the body of the downhole device is disposed in the bore of the sleeve. The sleeve is typically deployed in the wellbore at the desired location and is radially expanded by an expander device (2) that is deployed within the bore of the sleeve. The expanded sleeve plastically deforms and retains its expanded configuration after the radial expansion force is removed from the sleeve. The sleeve provides a modular anchoring or landing point in the wellbore that can be retrospectively set in the conduit at different locations, and various downhole devices can then be deployed into the sleeves at predictable depths and a reliable connection can be made with the sleeve. The assembly can typically pass through a smaller diameter before being morphed to seal and anchor in a larger diameter.
Claims
1. A tubular assembly for use in a wellbore of an oil, gas or water well, the tubular assembly comprising a downhole device having a body, and a sleeve adapted to receive the body of the downhole device, wherein the sleeve is adapted for retrospective deployment into a conduit in the wellbore so that the outer circumferential surface of the sleeve is radially expanded, by applying fluid pressure to an inner circumferential surface of the sleeve, against an inner surface of the conduit, the sleeve having a bore with the inner circumferential surface comprising an inwardly facing formation adapted to engage with an outwardly facing formation on the body of the downhole device as the body of the downhole device is disposed in the bore of the sleeve, and wherein said sleeve is not in a state of axial compression when said sleeve is radially expanded; wherein substantially the sleeve is not uniformly expandable and comprises at least one hyper-expandable region that is adapted to expand more than other regions; wherein the sleeve comprises first and second axially spaced hyper-expandable regions, and a central region, located between the first and second axially spaced hyper-expandable regions, which is relatively more resistant to radial expansion than the first and second axially spaced hyper-expandable regions, whereby as a radial expansion force is applied to the sleeve, the first and second axially spaced hyper-expandable regions expand radially to a greater extent than the central region; and wherein the inwardly facing formation on the sleeve is disposed on the central region.
2. The tubular assembly according to claim 1, wherein the conduit is a wellbore tubular selected from the group consisting of casing and liner, and wherein the wellbore tubular is cemented in place within the wellbore.
3. The tubular assembly according to claim 1, wherein the hyper expandable regions are formed of a weaker material than at least one other region of the sleeve.
4. The tubular assembly according to claim 1 wherein at least a region of the inwardly facing formation is reinforced and is adapted to deform to a different extent in response to radial expansion forces than another region of the sleeve.
5. The tubular assembly according to claim 1 including a seal device disposed between the body and the sleeve.
6. The tubular assembly according to claim 5, wherein the seal device comprises a radially expandable seal on the body, adapted to pass through the bore of the sleeve in a first non-expanded configuration, and adapted to seal in the bore of the sleeve in a second radially expanded configuration.
7. The tubular assembly according to claim 1, wherein the downhole device incorporates a cutting device, adapted to cut tubing forming the conduit below the sleeve, and wherein inter-engaging said formations on the downhole device and the sleeve connect the sleeve to a cut upper portion of the tubing after the cutting device has cut the tubing, thereby allowing retrieval of the cut upper portion of the tubing by axially retrieving the cutting device which remains attached to the cut upper portion.
8. A method of deploying a downhole device in a wellbore, the downhole device having a body, the method comprising inserting a sleeve into a conduit in the wellbore, the sleeve having a bore adapted to receive the body of the downhole device, the bore having an inner circumferential surface comprising an inwardly facing formation on the sleeve adapted to engage with the body, and the sleeve being radially expandable, wherein the method includes the steps of: radially expanding the sleeve, by applying fluid pressure to the inner circumferential surface of the sleeve, to engage an outer circumferential surface of the sleeve to an inner surface of the conduit, and wherein said sleeve is not in a state of axial compression when said sleeve is radially expanded; inserting the body of the downhole device into a radially expanded bore of the sleeve, and engaging an outwardly facing formation on the body of the downhole device with the inwardly facing formation of the inner circumferential surface of the sleeve, wherein the downhole device incorporates a cutting device, and wherein the method includes the step of deploying the cutting device to cut tubing forming the conduit below the sleeve after the downhole device has been locked in position in the sleeve.
9. The method as claimed in claim 8, including the step of expanding at least a portion of the sleeve to a greater extent than at least one other portion of the sleeve.
10. The method as claimed in claim 8, including the step of expanding two axially spaced annular portions of the sleeve more than a portion of the sleeve between the two axially spaced expanded portions.
11. The method as claimed in claim 8, wherein at least one of the sleeve and the downhole device has a seal adapted to seal an annulus between the sleeve and the downhole device, and wherein the method includes the step of sealing the annulus between the sleeve and the downhole device.
12. The method as claimed in claim 8, including the step of locating sealing the bore of the sleeve in at least two axially spaced locations in the wellbore thereby isolating one zone of the wellbore from another.
13. The method as claimed in claim 8, including performing wellbore operations selected from the group consisting of producing fluids from one of the zones, and injecting fluids into one of the zones.
14. The method according to claim 8, including the step of passing the sleeve to through a relatively small diameter bore in a small diameter configuration, and subsequently expanding the sleeve in a larger diameter bore of the wellbore.
15. A tubular assembly for use in a wellbore of an oil, gas or water well, the tubular assembly comprising a cutting tool having a body, and a sleeve adapted to receive the body of the cutting tool, wherein the sleeve is adapted for retrospective deployment into a conduit in the wellbore so that the outer circumferential surface of the sleeve is radially expanded, by applying fluid pressure to an inner circumferential surface of the sleeve, against an inner surface of the conduit, the sleeve having a bore with the inner circumferential surface comprising an inwardly facing formation adapted to engage with an outwardly facing formation on the body of the cutting tool as the body of the cutting tool is disposed in the bore of the sleeve, wherein the cutting tool is adapted to cut tubing forming the conduit below the sleeve, and wherein inter-engaging said formations on the cutting tool and the sleeve connect the sleeve to a cut upper portion of the tubing after the cutting tool has cut the tubing, thereby allowing retrieval of the cut upper portion of the tubing by axially retrieving the cutting tool which remains attached to the cut upper portion.
16. A method of cutting an upper length of tubing which is to be replaced in a conduit of a wellbore, the method comprising: deploying a cutting tool in the wellbore, the cutting tool having a body; inserting a sleeve into the conduit of the wellbore, the sleeve having a bore adapted to receive the body of the cutting tool, the bore having an inner circumferential surface comprising an inwardly facing formation on the sleeve adapted to engage with the body; radially expanding the sleeve, by applying fluid pressure to the inner circumferential surface of the sleeve, to engage an outer circumferential surface of the sleeve to an inner surface of the conduit; inserting the body of the cutting tool into a radially expanded bore of the sleeve; engaging an outwardly facing formation on the body of the cutting tool with the inwardly facing formation of the inner circumferential surface of the sleeve to lock the cutting tool in position in the sleeve; using the cutting tool to cut tubing forming the conduit below the sleeve; and retrieving a cut upper portion of the tubing by axially retrieving the cutting tool which remains attached to the cut upper portion.
Description
(1) Embodiments in accordance with the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:—
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(12) Referring now to the drawings,
(13) When the expander tool 2 is operated, very high pressure hydraulic fluid (not shown) is typically pumped out of the expander tool 2 through ports or apertures 17 into the annular chamber 18 between the tool 2 and the sleeve 1, and the very high pressure hydraulic fluid acts against the inner surface of the sleeve 1 in between the upper and lower seals 3 and expands the sleeve radially from its initial unexpanded configuration shown in
(14) The radial expansion force applied by the hydraulic fluid chamber 18 is sufficient to plastically deform the sleeve 1, so that when the radial force is removed by removal of the high pressure fluid and collapse of the expandable seals 3 (as shown in
(15) After the sleeve 1 has been radially expanded past its threshold of elastic deformation so that the sleeve 1 is plastically deformed and retains its expanded configuration, the expander tool 2 is collapsed and withdrawn from the bore of the sleeve 1 leaving the expanded sleeve 1 secured in place against the inner wall of the liner 5. The expander tool string 2s is withdrawn to surface and a new tool string is then run into the hole, which contains a downhole tool adapted to engage with the sleeve 1.
(16) In the first embodiment, the sleeve 1 is shown as having a central region 1c with a thicker wall diameter than the end sections 1e, which have a thinner diameter of wall thickness but the difference is exaggerated in the figures and in actual practice, there may only be a minimal difference or indeed there may be no difference at all such that the central region 1C and the end sections 1e have the same diameter. The sleeve is typically made of a single piece of metal by rolling or casting etc. The reinforced central section 1c of the sleeve 1 is optionally more or less resistant to radial expansion than the end sections 1e, which have thinner walls but could have thicker walls and which are therefore respectively easier or harder to expand radially. In the embodiment shown the amount of expansion of the sleeve 1 is constant along its length, but optionally the central section 1c can radially expand differently (i.e. more or less) than the end sections 1e.
(17) The inner surface of the central section 1c can either be smooth or polished such that it provides, after expansion, a Polished Bore Receptacle (PBR) which seals 8 can seal against (as will be described subsequently in terms of a fracturing operation) or a profiled surface against which tools can be latched/locked (as will also be described subsequently).
(18) A sealing downhole tool in the form of an annular packer 7 (as shown in
(19) Once the packer 7 has been run into the bore of the sleeve 1 it is radially expanded to push the seal members 8 against the smooth polished inner surface of the central region 1c of the sleeve, and a high pressure seal is created as a result. Typically more than one seal member 8 is provided in the axial stacked arranged shown in
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(24) The sleeve of any embodiment can be set at many different locations at the choosing of an operator either when the well is being completed and the liner is being installed with the sleeve preset in a defined location, or alternatively the sleeve can be installed later into a pre-existing liner (i.e. “retrofitted”) again at a location of the operator's choosing, with less regard for the physical condition and underlying structure of the liner at the desired location, since the forces during setting and use are mainly borne by the sleeve rather than the liner.
(25) Referring now to
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(27) As can be seen in
(28) Embodiments of the invention allow the sleeve to morph from one shape to another, usually expanding in response to hydraulic fluid pressure so that the diameter increases, allowing the sleeve to pass through a relatively small diameter bore in a small diameter configuration, and then once in place, the sleeve can be expanded to be set in a larger diameter bore.
(29) Embodiments of the invention provide a morphable tubular assembly that can be used in a gas, oil or water well for the deployment of a device or connection interface at any depth in an existing wellbore, in cased hole or open hole, passing through a restriction prior to being activated. The assembly can be used to provide anchoring points in one or multiple locations in a wellbore, or to provide seal bores for suitably sized packers or sealstems in one or more locations in the wellbore. Certain embodiments provide and anchoring and sealing support for a velocity string or similar hanging device. Some embodiments can be used to hang a downhole sensor such as a pressure gauge in a suitable location in the wellbore. The assembly can typically pass through a smaller diameter before being morphed to seal and anchor in a larger diameter. Typically the morphable assembly can adapt the final pressure used to secure the assembly in position to the strength and condition of the wellbore or other tubular where it is being set, so that in weak or damaged tubular it can still be set without damaging the existing well structure. The morphable sleeve is typically deployed on a tool and located in the correct position in a wellbore. The tool or device deployed in the sleeve typically has a seal means to contain and control the pressure used to morph the assembly in position. Typically the assembly can have a pressure generator, or a supply of pressurised fluid (gas or liquid) for generating hydraulic pressure. Certain embodiments can be deployed on wireline, coiled tubing or drill pipe. In some cases, the entire assembly can be expanded, or only the part that is used to secure it in position in the wellbore. The assembly can optionally include a latching profile that can be used for hanging a device, or locating a device in a particular desired position in the well. The profile could be used to locate a cutting device in the correct position, and the cutting device could cut the tubular below the profile allowing the cut section of tubular to be withdrawn from the well together with the cutting device.
(30) Modifications and improvements may be made to the embodiments without departing from the scope of the invention. For instance, the packer tool 7 of