Abstract
The present invention relates to a downhole double-acting positive displacement pump for delivering an increased pressure downhole at a location in a well to perform an operation, the well producing hydrocarbon-containing fluid streaming up the well, comprising a housing having a first end closest to a top of the well and a second end opposite the first end, the housing having a pump inlet and a pump outlet, where the pump outlet is arranged closer to the second end than to the first end, a first chamber arranged in the housing, the first chamber having a first outlet in fluid communication with the pump outlet, a first piston movable in the first chamber for pressing fluid out of the pump outlet, and a driving means for driving the first piston in a reciprocating movement between a first direction and an opposite second direction in the first chamber, and wherein the first piston divides the first chamber into a first chamber part and a second chamber part, the first chamber part comprising the first outlet and a first inlet, a first valve being arranged at the first outlet for allowing fluid to flow out of the first chamber part and preventing fluid from flowing into the first chamber part, a second valve being arranged in the first inlet for allowing fluid to flow into the first chamber part and preventing fluid from flowing out of the first chamber part, the second chamber part comprises a second outlet in fluid communication with the pump outlet and a second inlet, a third valve being arranged in the second outlet for allowing fluid to flow out of the second chamber part and preventing fluid from flowing into the second chamber part, and a fourth valve being arranged in the second inlet for allowing fluid to flow into the second chamber part and preventing fluid from flowing out of the second chamber part, and wherein the downhole double-acting positive displacement pump further comprises a control unit for controlling an output of the driving means into the movement of the first piston in the first direction or the second direction. The invention also relates to a downhole patch-setting tool for setting a patch within a well tubular metal structure.
Claims
1. Downhole double-acting positive displacement pump for delivering an increased pressure downhole at a location in a well to perform an operation, the well producing hydrocarbon-containing fluid streaming up the well, comprising: a housing having a first end closest to a top of the well and a second end opposite the first end, the housing having a pump inlet and a pump outlet, where the pump outlet is arranged closer to the second end than to the first end, a first chamber arranged in the housing, the first chamber having a first outlet in fluid communication with the pump outlet, a first piston movable in the first chamber for pressing fluid out of the pump outlet, and a driving means for driving the first piston in a reciprocating movement between a first direction and an opposite second direction in the first chamber, and wherein the first piston divides the first chamber into a first chamber part and a second chamber part, the first chamber part comprising the first outlet and a first inlet, a first valve being arranged at the first outlet for allowing fluid to flow out of the first chamber part and preventing fluid from flowing into the first chamber part, a second valve being arranged in the first inlet for allowing fluid to flow into the first chamber part and preventing fluid from flowing out of the first chamber part, the second chamber part comprises a second outlet in fluid communication with the pump outlet and a second inlet, a third valve being arranged in the second outlet for allowing fluid to flow out of the second chamber part and preventing fluid from flowing into the second chamber part, and a fourth valve being arranged in the second inlet for allowing fluid to flow into the second chamber part and preventing fluid from flowing out of the second chamber part, and wherein the downhole double-acting positive displacement pump further comprises a control unit for controlling an output of the driving means into the movement of the first piston in the first direction or the second direction.
2. Downhole double-acting positive displacement pump according to claim 1, wherein the driving means is a second pump or an electric motor.
3. Downhole double-acting positive displacement pump according to claim 1, wherein the first piston is connected to a piston rod, and a second piston is connected to the piston rod, the second piston being movable in a second chamber.
4. Downhole double-acting positive displacement pump according to claim 3, wherein the second piston divides the second chamber into a first chamber part and a second chamber part, the first chamber part comprising a first aperture, and the second chamber part comprising a second aperture.
5. Downhole double-acting positive displacement pump according to claim 4, wherein the control unit may, in a first position, direct pressurised fluid into the first chamber part of the second chamber and, in a second position, direct pressurised fluid into the second chamber part of the second chamber.
6. Downhole double-acting positive displacement pump according to claim 1, wherein the driving means being a first driving means is a second pump, and a discharge opening fluidly connected to the first aperture in a first position and fluidly connected to the second aperture in a second position.
7. Downhole double-acting positive displacement pump according to claim 6, further comprising a second driving means having the discharge opening.
8. Downhole double-acting positive displacement pump according to claim 6, wherein the control unit is a flow control unit directing the fluid from the discharge opening to either the first aperture or the second aperture for moving the second piston in the second chamber.
9. Downhole double-acting positive displacement pump according to claim 6, wherein the control unit comprises a valve unit comprising a valve chamber and a valve piston moving in the valve chamber between a first valve position and a second valve position, the valve chamber having a valve inlet fluidly connected with the discharge opening, a first valve outlet fluidly connected with the first aperture and a second valve outlet fluidly connected with the second aperture, and in the first valve position the valve inlet is fluidly connected with the first valve outlet, and in the second valve position the valve inlet is fluidly connected with the second valve outlet.
10. Downhole double-acting positive displacement pump according to claim 9, wherein the flow control unit further comprises a pivot arm having a first arm end part and a second arm end part, the second arm end part being connected with the valve piston in order to change between the first valve position and the second valve position.
11. Downhole double-acting positive displacement pump according to claim 10, wherein the pivot arm pivots around a pivot point.
12. Downhole double-acting positive displacement pump according to claim 8, wherein the control unit further comprises a first moving element and a second moving element, the second moving element moving the first moving element and the pivot arm so as to move the valve piston in order to change between the first valve position and the second valve position.
13. Downhole double-acting positive displacement pump according to claim 12, wherein the second moving element is connected with and driven by the piston rod.
14. Downhole double-acting positive displacement pump according to claim 8, wherein the control unit further comprises a first moving element, the first moving element having a projecting flange with a flange surface along which the first arm end part of the pivot arm moves.
15. Downhole double-acting positive displacement pump according to claim 14, wherein the flange surface has a first surface end and a second surface end, the flange surface inclining from an intermediate point towards the first surface end in order to move the valve piston from the first valve position to the second valve position, and the flange surface inclining from the intermediate point towards the second surface end in order to move the valve piston from the second valve position to the first valve position.
16. Downhole patch-setting tool for setting a patch within a well tubular metal structure, comprising a downhole double-acting positive displacement pump according to claim 1 and at least one inflatable packer arrangeable within a metal patch for expanding the metal patch in the well tubular metal structure.
Description
[0071] 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:
[0072] FIG. 1 shows a downhole positive displacement pump in a well for providing a high pressure of fluid in a confined space downhole,
[0073] FIG. 2 shows a partly cross-sectional view of a downhole positive displacement pump providing a high pressure of fluid in a confined space of a packer for setting a patch downhole,
[0074] FIG. 3 shows a partly cross-sectional view of another downhole positive displacement pump providing a high pressure of fluid in a confined space of a packer for setting a patch downhole,
[0075] FIG. 4 shows a partly cross-sectional view of a control unit for controlling an output of the driving means into the movement of the first piston in the first direction or the second direction,
[0076] FIG. 5 shows a partly cross-sectional view of another control unit for controlling an output of the driving means into the movement of the first piston in the first direction or the second direction,
[0077] FIG. 6 shows a partly cross-sectional view of yet another control unit for controlling an output of the driving means into the movement of the first piston in the first direction or the second direction,
[0078] FIG. 7 shows a side view of another downhole positive displacement pump providing a high pressure of fluid in a confined space of a packer for setting a patch downhole,
[0079] FIG. 8 shows a side view of another downhole positive displacement pump providing a high pressure of fluid in a confined space in each of two packers for isolating a zone down hole in order to fracture the formation,
[0080] FIG. 9 shows a side view of another downhole positive displacement pump providing a high pressure of fluid in a confined space in each of two packers for setting a patch downhole, and
[0081] FIG. 10 shows a side view of another downhole positive displacement pump providing a high pressure of fluid in a confined space in each of two packers for expanding an annular barrier outside the well tubular metal structure to provide zonal isolation in the annulus.
[0082] 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.
[0083] FIG. 1 shows a downhole positive displacement pump 1 for delivering an increased pressure in a confined space downhole at a location in a well 2 to perform an operation, such as expanding a patch, expanding an annular barrier or providing fractures in a formation. The confined space may thus be in a packer, an annular barrier or between two packers for expanding a patch. The well 2 is configured to produce a hydrocarbon-containing fluid streaming up the well 2. The downhole positive displacement pump 1 comprises a housing 3 having a first end 4 closest to a top 5 of the well 2 and a second end 6 facing opposite the first end 4, i.e. facing down the well 2. The housing 3 has a pump inlet 7 and a pump outlet 8, where the pump outlet 8 is arranged closer to the second end 6 than to the first end 4. The downhole positive displacement pump 1 further comprises a first chamber 9 arranged in the housing 3, and the first chamber 9 has a first outlet 10 in fluid communication with the pump outlet 8 for delivering the increased pressure in a confined space downhole. A first piston 11 is movable in the first chamber 9 for pressing fluid out of the pump outlet 8, and a driving means 12 is configured to drive the first piston 11 in a reciprocating movement in a first direction or an opposite second direction in the first chamber 9. The first piston 11 divides the first chamber 9 into a first chamber part 14 and a second chamber part 15. The first chamber part 14 comprises the first outlet 10 and a first inlet 16. A first valve 17 is arranged in or in connection with the first outlet 10 for allowing fluid to flow out of the first chamber part 14 and preventing fluid from flowing into the first chamber part 14. A second valve 18 is arranged in or in connection with the first inlet 16 for allowing fluid to flow into the first chamber part 14 and preventing fluid from flowing out of the first chamber part 14. In this way, fluid surrounding the tool is sucked into the first chamber part 14 from the well 2 via the first inlet 16 during the movement of the first piston 11 away from the first inlet 16. During the movement of the first piston 11 in the opposite direction towards the first outlet 10, the fluid in the first chamber 9 is pressed out of the first chamber 9 through the first outlet 10 and further out of the pump outlet 8 into the confined space, e.g. in an annular barrier, a packer or a patch. The downhole positive displacement pump 1 further comprises a control unit 20 for controlling an output of the driving means 12 into the movement of the first piston 11 in the first direction and/or the second direction. The control unit 20 thus controls the movement direction of the first piston 11. The pump outlet 8 is arranged downstream of the pump inlet 7; thus, the pump outlet 8 is arranged closer to the bottom of the well 2 than to the pump inlet 7. Down the well 2, the well pressure is higher than the surface pressure. The downhole positive displacement pump 1 is a single-acting or double-acting downhole positive displacement pump, and the downhole positive displacement pump 1 is connected to a wireline and is a downhole wireline positive displacement pump.
[0084] The driving means 12 is a second pump 21 in FIG. 3 or an electric motor 22 in FIG. 2. In FIG. 2, the control unit 20 comprises a first shaft 101 connected to a reversing spindle 102 (also called a self-reversing spindle) driven by an output shaft 103 of the electric motor 22, e.g. via a connecting gear 108.
[0085] In FIGS. 1-3 and 7-10, the downhole positive displacement pump 1 is connected to the top via a wireline 104 and a cable head 109. The downhole positive displacement pump 1 comprises an electrical control 105. In FIGS. 1, 3 and 7-10, the downhole positive displacement pump 1 comprises a motor 106 driving the second pump 21. The downhole positive displacement pump 1 may further comprise a compensator 107 for keeping a predetermined overpressure in the downhole positive displacement pump 1 compared to the surrounding pressure.
[0086] In FIGS. 2 and 3, the downhole positive displacement pump 1 is a downhole double-acting positive displacement pump, where the second chamber part 15 comprises a second outlet 24 in fluid communication with the pump outlet 8 and a second inlet 25. A third valve 26 is arranged in the second outlet 24 for allowing fluid to flow out of the second chamber part 15 and preventing fluid from flowing into the second chamber part 15. A fourth valve 27 is arranged in the second inlet 25 for allowing fluid to flow into the second chamber part 15 and preventing fluid from flowing out of the second chamber part 15. The second outlet 24 and the second inlet 25 are arranged in the part of the second chamber part 15 closest to the top 5 of the well 2. In the downhole double-acting positive displacement pump, the first piston 11, when moving in one direction, is able to suck fluid into the first chamber part 14 while pressing fluid in the second chamber part 15 out of the second outlet 24 and further out of the pump outlet 8, and when moving in the opposite direction the first piston 11 is able to suck fluid into the second chamber part 15 while pressing fluid in the first chamber part 14 out of the first outlet 10 and further out of the pump outlet 8. Thus, the pump is a downhole double-acting positive displacement pump using both an upstroke and a downstroke for providing fluid out of the pump outlet 8, and the pump is thus more efficient than a single-acting downhole positive displacement pump.
[0087] In FIG. 3, the driving means is a second pump 21. In order to drive the first piston 11, the first piston 11 is connected to a piston rod 28, and a second piston 29 is connected to another part of the piston rod 28; the second pump 21 pumps fluid into a second chamber 30 in which the second piston 29 is movable in the first direction and the opposite second direction. As the second piston 29 moves in the second chamber 30, it moves the first piston 11 back and forth, and in this way fluid is pumped into e.g. the packer 80 to inflate the packer 80. The second piston 29 divides the second chamber 30 into a first chamber part 31 and a second chamber part 32, and the first chamber part 31 comprises a first aperture 33, and the second chamber part 32 comprises a second aperture 34. A discharge opening 35 of a second driving means 19 in form of an oil pump 19 is fluidly connected with the first aperture 33 in a first position and fluidly connected with the second aperture 34 in a second position via the control unit 20 being a flow control unit.
[0088] The control unit 20 directs the fluid from the discharge opening 35 to either the first aperture 33 or the second aperture 34 for moving the second piston 29 in the second chamber 30 in the first direction or the second direction, respectively, and thereby controlling the movement of the first piston 11 in a first direction and a second opposite direction. The second pump 21 thus merely pumps fluid into the control unit 20, and the control unit 20 directs the fluid into the first chamber part 31 of the second chamber 30 to drive the first piston 11 away from the pump outlet 8 and into the second chamber part 32 of the second chamber 30 to drive the first piston 11 towards the pump outlet 8. The fluid in the first chamber 9 is well fluid, and the fluid in the second chamber 30 is tool fluid only flowing in the pump. By having a second pump 21 as a driving means 12, the pump can be made as a downhole double-acting positive displacement pump with a very small outer diameter, thus being energy-efficient. This is not possible in prior art pumps having a motor driving a gearing arrangement as known from e.g. U.S. Pat. No. 3,083,774.
[0089] The second pump 21 is thus a feed pump. In another embodiment, the driving means 12 may be a drill pipe or drill string for supplying pressurised fluid from the surface to drive the piston back and forth in the chamber.
[0090] As shown in FIGS. 4-6, the control unit 20 comprises a valve unit 36 comprising a valve chamber 37 and a valve piston 38 moving in the valve chamber 37 between a first valve position and a second valve position. The valve chamber 37 has a valve inlet 39 fluidly connected with the discharge opening of the oil pump 19, a first valve outlet 41 fluidly connected with the first aperture 33 and a second valve outlet 42 fluidly connected with the second aperture 34. In the first valve position, the valve inlet 39 is fluidly connected with the first valve outlet 41, and in the second valve position the valve inlet 39 is fluidly connected with the second valve outlet 42. In this way, the fluid is directed to the first or the second chamber part 14, 15 of the second chamber 30. The control unit 20 further comprises a pivot arm 51 having a first arm end part 52 and a second arm end part 53. The second arm end part 53 is connected with the valve piston 38 in order to change between the first valve position and the second valve position. The pivot arm 51 pivots around a pivot point 54. The control unit 20 further comprises a first moving element 57 and a second moving element 61. The second moving element 61 moves the first moving element 57 and the pivot arm 51 so as to move the valve piston 38 in order to change between the first valve position and the second valve position. The second moving element 61 is moved by the piston rod 28. By having a control unit 20 driven by the piston rod 28 for changing the moving direction of the valve piston 38, the control unit 20 is not dependent on any electric switching mechanism and is therefore less likely to fail downhole.
[0091] In FIG. 4, the pivot point 54 is fixedly connected with the housing 3, and the pivot arm 51 has a first projection 55 and a second projection 56. The control unit 20 further comprises the first moving element 57, and the first moving element 57 has a projecting flange 58 having a flange surface 59 along which the first arm end part 52 of the pivot arm 51 moves. The control unit 20 further comprises the second moving element 61 configured to move the first moving element 57, which rotates due to the first moving element 57 having a continuous groove 63 with at least two points 67 and at least two inclining parts 68, into which continuous groove 63 an element projection 62 of the second moving element 61 engages. When the second moving element 61 moves back and forth as it is connected with the second piston 29, the element projection 62 moves in the continuous groove 63, rotating the first moving element 57 and thus the projecting flange 58, which pushes either the first projection 55 or the second projection 56, as a result of which the pivot arm 51 moves the valve piston 38 between the first and the second valve position. The flange surface 59 has a first surface end 71 and a second surface end 72, and the flange surface 59 inclines from an intermediate point 73 towards the first surface end 71 in order to move the valve piston 38 from the first valve position to the second valve position by engaging the first and second projections of the pivot arm 51. As the second moving element 61 moves in one direction along the inclining part 68, the projecting flange 58 is rotated, and when the intermediate point hits the first projection or the second projection, the pivot arm pivots, changing the valve position of the valve. The first moving element 57 is rotatably connected to the housing 3. The element projection 62 may be provided with a wheel or roller so as to ease the moving engagement with the continuous groove 63.
[0092] In FIG. 5, the pivot arm 51 has a first arm end part 52 and a second arm end part 53, and between the arm end parts 52, 53 is a first projection 55. The pivot arm 51 pivots around a pivot point 54 arranged at the second arm end part 53. The control unit 20 further comprises the first moving element 57, and the first moving element 57 has, in a first end, a projecting flange 58 having a flange surface 59 along which the first arm end part 52 of the pivot arm 51 moves. In a second end of the first moving element 57, the first moving element 57 is connected to the valve piston 38 for moving the valve piston 38 between the first valve position and the second valve position. The first arm end part 52 of the pivot arm 51 may be provided with a wheel or roller so as to ease the moving engagement with the flange surface 59. The flange surface 59 has a first surface end 71 and a second surface end 72, and the flange surface 59 inclines from an intermediate point 73 towards the first surface end 71 in order to move the valve piston 38 from the first valve position to the second valve position, and the flange surface 59 inclines from the intermediate point towards the second surface end 72 in order to move the valve piston 38 from the second valve position to the first valve position. In order to move easily past the intermediate point 73, the wheel or roller may be spring-loaded. Thus, the intermediate point is closer to the pivot point 54 than the first surface end 71 and the second surface end 72. When the first arm end part 52 of the pivot arm 51 is at the first surface end 71 and the second surface end 72, it is in its outermost position. The control unit 20 further comprises the second moving element 61 configured to move the first moving element 57 by pulling or pushing the first projection 55 of the pivot arm 51, which again moves the first moving element 57 past the intermediate point, resulting in a change of valve position. The second moving element 61 is connected with the second piston 29 and follows the back-and-forth movement of the second piston 29, thus moving a groove 64 of the second moving element 61, which groove 64 engages the first projection 55 of the pivot arm 51, forcing the pivot arm to change position via the first moving element 57, and moving the valve piston 38 between the first and the second valve position.
[0093] In FIG. 6, the pivot point 54 is arranged on the second moving element 61. The pivot arm 51 pivots around a pivot point 54, and at the second arm end part 53 the pivot arm 51 is connected to the valve piston 38. The control unit 20 further comprises the first moving element 57. The first moving element 57 has a second end part 65b connected to the first arm end part 52 of the pivot arm 51, and a first end part 65 of the first moving element 57 engages a groove 64 in the second moving element 61. The second moving element 61 is configured to move the first moving element 57, forcing the pivot arm 51 to pivot, resulting in a change of valve position. A spring 66 is connected to the first end part 65 of the first moving element 57 and connected to the second arm end part 53 of the pivot arm 51. The second moving element 61 is connected with the second piston 29 and follows the back-and-forth movement of the second piston 29, thus moving the groove 64 and the first moving element 57, resulting in the valve piston 38 changing position between the first and the second valve positions.
[0094] As shown in FIG. 7, the downhole positive displacement pump 1 further comprises a discharge control unit 60 for discharging fluid in the packer 80 in order to deflate the packer 80. The packer 80 is shown in its deflated position. The discharge control unit 60 may be a flow-operated discharge control unit 90. In another embodiment, the discharge control unit 60 comprises an electrically operated valve which is operated through an electrical conductor passing through the housing 3 to open a discharge outlet 91 of fluid in the packer 80 out into the well 2 in order to deflate the packer 80. The downhole positive displacement pump 1 is mounted as part of a downhole patch setting tool for setting a patch 81 within a well tubular metal structure by means of at least one inflatable packer 80 arrangeable within the metal patch 81 for expanding the metal patch 81 in the well tubular metal structure 102. The packer 80 having an expandable bladder 83 is arranged around a base pipe 84, as shown in FIGS. 9 and 10. The expandable bladder 83 is expanded via openings 85 in the base pipe 84. The expandable bladder 83 is made of a deflatable material, such as rubber, elastomer, etc., and/or it may be made of a reinforced material. The patch is expanded for sealing off an opening/leak 86, shown in FIG. 7, in the well tubular metal structure. The expandable bladder 83 is connected to a base pipe 84 by connecting sleeves 87.
[0095] In FIG. 8, the downhole positive displacement pump 1 comprises two packers 80 mounted with a tool part having openings 85 between them so that a zone in the well 2 is isolated as shown in FIG. 8 in order to pressurise a confined space 88 between two packers 80 in order to fracture the formation. In FIG. 9, the downhole positive displacement pump 1 comprises two packers 80 mounted with a tool part having an opening between them, and a patch 81 is arranged in an overlapping manner with the packers 80 forming a confined space 88, which is pressurised together with the packers 80 to expand the patch by letting fluid out through the openings 85. The downhole positive displacement pump 1 is thus also used to inflate the packers 80 before presurising the confined space. In FIG. 10, the downhole positive displacement pump 1 comprises two packers 80 mounted with a tool part having at least one opening between them so that a zone in the well tubular metal structure is isolated in order to expand an expandable metal sleeve 98 of an annular barrier 89 through an opening 99 in the well tubular metal structure. The opening 99 may be arranged opposite a valve block of the annular barrier 89 arranged at one end of the annular barrier 89.
[0096] 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 open hole, 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. Tool fluid is clean fluid and not well fluid.
[0097] By “annular barrier” is meant an annular barrier comprising a tubular metal part mounted as part of the well tubular metal structure and an expandable metal sleeve surrounding and connected to the tubular part defining an annular barrier space.
[0098] By “casing” or “well tubular metal structure” is meant any kind of pipe, tubing, tubular, liner, string, etc., used downhole in relation to oil or natural gas production.
[0099] In the event that the tool is not submersible 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 112 may have projectable arms 110 having wheels 111 that 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®.
[0100] Although the invention has been described above in connection with preferred embodiments of the invention, it will be evident to a person skilled in the art that several modifications are conceivable without departing from the invention as defined by the following claims:
