Delivering Pressurised Fluid

Abstract

A pressure intensifier and method of increasing fluid pressure at a desired location in a well bore. A central mandrel having a bore therethrough is affixed in a string. Surrounding the mandrel is a cylindrical body having stacked pistons. At a predetermined fluid pressure through the bore, the pistons release and are moved downwards, to integrate pressure across the pistons and act on a chamber pre-filled with application fluid. The application fluid is forced through delivery conduits at a higher pressure than the predetermined fluid pressure and may be used to morph a tubular. In an embodiment, the predetermined fluid pressure is field adjustable.

Claims

1. A pressure intensifier, the pressure intensifier comprising: an elongate mandrel defining an inner bore into which fluid is delivered, the mandrel being co-axially located within an elongate hollow outer cylindrical body; at least one annular piston extending inwardly from the cylindrical body across the annular bore to the mandrel and shaped such that a discreet fluid receiving void is created between an active surface of the piston and the elongate mandrel; at least one input port to enable fluid communication between the inner bore and the fluid receiving void and thereby move the piston; at least one stop located on an outer surface of the mandrel to limit travel of each piston when fluid enters the void, the at least one stop being static; morph fluid located in a chamber of the annular bore between an opposing surface of a first piston and a first stop; wherein at least one delivery port exits the chamber to deliver the morph fluid at a greater pressure than the pressure of fluid delivered through the inner bore.

2. A pressure intensifier according to claim 1 wherein there is a plurality of pistons arranged along the cylindrical body.

3. A pressure intensifier according to claim 1 wherein the plurality of pistons and the outer cylindrical body are secured together and form a pressure development mechanism which can move relative to the mandrel.

4. A pressure intensifier according to claim 1 wherein the at least one delivery port exiting the chamber forms delivery conduits having an inner diameter less than the inner diameter of the annular bore between each adjacent piston and stop.

5. A pressure intensifier according to claim 3 wherein the intensifier includes a pressure releasable locking mechanism, the locking mechanism being pressure adjustable and the locking mechanism being arranged to hold the pressure development mechanism in a first position until a morph is required.

6. A pressure intensifier according to claim 5 wherein the locking mechanism is at least one shear pin which secures the pressure development mechanism in a predetermined position.

7. A pressure intensifier according to claim 5 wherein the locking mechanism is accessible from an outer surface of the tool to adjust the pressure for release.

8. A pressure intensifier according to claim 1 wherein a hydraulic fluid delivery tool is provided at an output end of the pressure intensifier, the hydraulic fluid delivery tool being operable to receive morph fluid from the pressure intensifier and deliver it to a location where a high pressure fluid is required.

9. A method of intensifying pressure of fluid for delivery to a location, comprising the steps: (a) providing a pressure intensifier comprising: an elongate mandrel defining an inner bore into which fluid is delivered, the mandrel being co-axially located within an elongate hollow outer cylindrical body; at least one annular piston extending inwardly from the cylindrical body across the annular bore to the mandrel and shaped such that a discreet fluid receiving void is created between an active surface of the piston and the elongate mandrel; at least one input port to enable fluid communication between the inner bore and the fluid receiving void and thereby move the piston; at least one stop located on an outer surface of the mandrel to limit travel of each piston when fluid enters the void, the at least one stop being static; morph fluid located in a chamber of the annular bore between an opposing surface of a first piston and a first stop; wherein at least one delivery port exits the chamber to deliver the morph fluid at a greater pressure than the pressure of fluid delivered through the inner bore. (b) positioning the pressure intensifier such that pressurised fluid will be output at a location in the tubular; (c) flowing fluids through the inner bore of the pressure intensifier; (d) passing fluid through the input port(s) into the fluid receiving void(s) to apply a pressure upon the active surface(s) of the piston(s); (e) forcing the outer cylindrical body and the piston(s) to move along the fixed mandrel until each piston reaches a stop; (f) driving morph fluid out of the delivery conduit(s) at a desired morph pressure by movement of the first piston towards the first stop; and (g) delivering morph fluid to the desired location.

10. The method according to claim 9 including the step of selecting a number of pistons dependent upon the morph pressure required.

11. The method according to claim 9 including the step of setting a release pressure of the intensifier via a pressure releasable locking mechanism accessible from an outer surface of the intensifier.

12. The method according to claim 11 including the steps of: a) setting the release pressure on the pressure releasable locking mechanism at surface; b) causing release of the outer cylindrical body and piston arrangement by applying fluid pressure in the inner bore at the release pressure to cause the release of the piston arrangement from the outer cylindrical body; and c) operating the pressure intensifier on fluid pressure in the inner bore.

13. The method according to claim 9 including the step of retaining the outer cylindrical body and piston arrangement in a first position while running a further string through the inner bore.

Description

[0045] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0046] FIG. 1 is a cross-section of a pressure intensifier in a first state according to an embodiment of the present invention; and

[0047] FIG. 2 is a cross-section of the pressure intensifier of FIG. 1 in a second state according to an embodiment of the present invention;

[0048] Referring initially to FIG. 1 there is shown a longitudinal cross-section of a pressure intensifier, generally indicated by reference numeral 10, for use in providing pressurised fluid to a predetermined location within a wellbore.

[0049] The pressure intensifier 10 comprises a cylindrical body 12 provided with a first end 14, a second end 16 with a central length 17 therebetween formed by an outer cylindrical wall 18.

[0050] Cylindrical body 12 is of metal construction and is a substantially hollow tubular having a cylindrical wall 18 with an inner surface 19 defining a bore 20 therethrough. Within bore 20 is arranged co-axially a cylindrical mandrel 22, also of metal construction, having an outer surface 23 and an inner surface 24 that defines an inner bore 26. Mandrel 22 is further provided with a first end 30 and a second end 32, the ends 30, 32 are provided with suitable fittings as are known in the art for connecting the tool 10 into a string not shown for running the tool 10 into a wellbore. Suitable strings may be coiled, tubing, drill pipe, liner and the like. The mandrel 22 is thus fixed on a string. The second end 32 can be attached to a hydraulic fluid delivery tool.

[0051] Arranged within bore 20 at first end 14 of the cylindrical body 12 is a locking mechanism 34 which in this case comprises shear pins that extend through openings 33 in the cylindrical wall 18 and are received in recesses 35 formed in the first end 30 of mandrel 22. The shear pins 34 secure the cylindrical body 18 and mandrel 22 relative to one another. The shear pins can be removable inserted into the recesses 35 through openings 33 such that the pins 34 used can be provided at different strengths so that a suitable pin is used depending on the environment in which the tool is deployed and the level of fluid pressure which will pass through the bore 26 in general operation as well as the level of fluid pressure required to actuate the pressure intensifier 10.

[0052] A pressure development mechanism 34 is formed from the first end 14 along the central length 17 of the cylindrical body 12 with pistons 40 provided at intervals along the central length 17. A pressure application mechanism 36 is formed at the second end 32 of the mandrel 22.

[0053] In the pressure development mechanism 34, the central mandrel 22 continues co-axially through cylindrical body 12. The cylindrical body 12 is provided along its central portion 17 with actuating pistons 40. In the embodiment show, the mechanism 34 is provided with two actuating pistons 40a, b and a high pressure piston 40c with each piston 40a, b, c associated with a segment of mandrel 22a-c respectively. The pistons 40a, b, c are spaced apart along, and project perpendicularly inwards from the cylindrical wall 18. Each piston 40a, b, c is substantially annular and extends across bore 20 such that a movable seal is formed between internal piston surface 42 and recessed portion 25 of outer surface 23 of mandrel 22.

[0054] The pressure development mechanism 34 further includes annular stop mechanisms 44 which are spaced equidistantly apart and project from the outer surface 23 of mandrel 22. In the embodiment shown, two annular stop mechanisms 44a, b are provided projecting from the from the outer surface 23 of mandrel portions 22a and 22b respectively such that a movable seal is formed between inner surface 19 of the cylindrical body 12 and the projected surfaces 45a, 45b of the mandrel stops 44a, 44b. The third annular stop mechanism 44c is formed by the active surface 45c of the pressure application mechanism 36. Each annular stop mechanism 44 is static and fixed relative to the end 30. Thus the stop mechanisms 44 and mandrel 22 does not move within the string.

[0055] The mandrel 22 is further provided with ports 46 spaced apart along the length of the mandrel. In this case, three ports 46a, 46b and 46c are provided. The ports 46a,b,c enable fluid communication between the mandrel bore 26 and voids 48a, 48b, 48c defined between an active surface 49 of pistons 40, a void defining surface 50 and recess surface 25 of outer surface 23 of the mandrel 22.

[0056] Between the leading face 43a, b, c of the pistons 40a, b, c, stop mechanisms 44a, b, c, recessed outer surface 25 of mandrel 22 and inner surface 19 of cylindrical body 22, there are further defined annular voids 20a, 20b, 20c. Each of annular voids 20a, 20b is provided with a port 27 which extends through wall 18 of body 12.

[0057] In the pressure application mechanism 36 the mandrel 22 is provided with a segment 22d having a cylindrical wall 21d that overlaps cylindrical wall 21c of segment 22c in a manner which causes it to extend annularly across bore section 20c such that a movable seal is formed between surface 23d and 19d. The thickness of the mandrel wall 23 where segments 22c and 22d overlap provides additional resilience to pressure created by the intensifier tool. A delivery conduit 52 is defined longitudinally through cylindrical wall 21d of pressure application mechanism 36 such that it is parallel to bore 26. A delivery port 54 allows fluid communication between void 20c and delivery conduit 52. The delivery conduit 52 is operable then to provide fluid communication between annular void 20c and a desired location (not shown). The diameter of the fluid delivery conduit 52 is less than the diameter or annular void 20c which, in turn, is less than the diameter of annular voids 20a and 20b. The annular void 20c is provided with application fluid 56, which may be any suitable fluid including, for example, clean water.

[0058] The pressure intensifier 10 is operable to have two states. In the first state, the components of the intensifier are arranged in a first position as is shown in the embodiment illustrated in FIG. 1. The intensifier 10 is in a first state prior to actuation of the mechanism 36 to apply pressure to a tool (not shown).

[0059] In the first state, the first end 14 of the body 12 is arranged such that it extends longitudinally away from first end 30 of mandrel 22 and is secured in position by retaining mechanism 34. End 30 is attached to a sting providing a continuous central bore 26 through the pressure intensifier 10. The pressure application mechanism 36 extends longitudinally beyond the second end 16 of cylindrical body 12.

[0060] The inner surface 19, outer surface 24, actuating piston 40a and mandrel void defining surface 50a co-operate in the first state so as to form a chamber 48a. The first actuating piston 40a is arranged so that it is spaced remotely along the bore 20 from stop 44a. The actuating piston 40a, inner surface 19, outer surface 25 and stop 44a co-operate in the first state to form a chamber 20a.

[0061] Similarly, the actuating piston 40b is arranged spaced remotely along the bore 20 from stop 44b. The actuating piston 40b, void defining surface 50b, outer surface 25 and stop 44a co-operate in the first state to form a chamber 48b. The actuating piston 40b, inner surface 19, outer surface 25 and stop 44b co-operate in the first state to form a chamber 20b.

[0062] High pressure piston 40c is arranged mounted projecting inwardly from cylinder 12 such that in a first state it is closely adjacent to stop 44b and defines chamber 48c. The high pressure piston 40c, outer surface 25, void defining surface 50c and fluid facing face 54 of bore stop 44c co-operate in the first state to form a sealed chamber 20c which is filled with morph fluid 56.

[0063] Each co-operating mandrel and cylindrical body or piston surface is provided with a resilient seal ring 60 such as a rubber or elastomeric o-ring or similar, that provides a resilient seal between the adjacent surfaces. The seal rings 60 allow lateral movement between the mandrel surfaces and the inner wall and piston surfaces whilst preventing the passage of fluid therebetween.

[0064] Each piston 40 may be integrally formed with mandrel 22 or is attached to the cylindrical body segments by a screw mechanism such that the pistons 40 act as joining mechanisms between adjacent cylindrical body segments. This enables the cylindrical body and piston arrangement to be constructed, and built up from the bottom of, a mandrel secured in position.

[0065] Upon actuation, the moveable components of intensifier 10, namely, the components of the cylindrical body 12 and piston arrangement, through the process of receiving and applying fluid under pressure, move to a second state. The arrangement of the components in the second state is shown in FIG. 2.

[0066] In use, the pressure intensifier is connected on a string at end 30 and a hydraulic fluid delivery tool is connected at end 36 of the mandrel 22. A determination is made as to the maximum fluid pressure which is likely to be applied through the string when the tool 10 is in the wellbore and activation is not required. The shear pins 34 are then selected to shear at a greater pressure than the maximum fluid pressure calculated. The shear pins 34 can then be arranged in the locking mechanism. If a maximum pressure is not expected then a nominal pressure rating of shear pin can be used. The selection of the shear pin rating can be done in the field.

[0067] The tool 10 is then run in the wellbore whereupon fluid in the bore 26 enters ports 46 to fill the chambers 48. Additional fluid outside the string will fill the chambers 20. The tool 10 will not activate and no components will move until the pressure of fluid entering the ports 46 is sufficient to shear the pins 34. The hydraulic fluid pressure entering the ports 46 acts on the active surface 50 of the pistons 40 and when this is greater than the shear pressure on the pins 34, these will shear releasing the cylindrical body 12 and piston arrangement 40. Consequently the voids 48 will increase in size as the pistons 40 move longitudinally downwards over the mandrel 22.

[0068] As the pistons 40 move downwards, chambers 20 will reduce in size as the volume of each void decreases. Fluid in the chambers 20 will be forced out of the tool 10 through ports 27. Chamber 20c does not include a port 27 and instead, the exit of fluid is through the delivery conduit 52. The fluid is the morph fluid sealed in the chamber 20c before activation. High pressure piston 44c thus acts upon the morph fluid 56 and forces the fluid 56 into the delivery conduit 52 for use in the hydraulic fluid delivery tool mounted below.

[0069] In FIG. 2, the arrangement of the components of intensifier 10 are shown in a second state, subsequent to activation according to an embodiment of the invention. In this embodiment, outer cylindrical body 12 has been driven forward as has pistons 40a,b such that they now abut against stops 44a,b respectively and high pressure piston 44c has been driven forward to abut against wall end stop 54. The force created by hydraulic pressure acting upon pistons 40a,c cumulatively acts upon application piston 44c such that the fluid 56 is driven through delivery conduit 52 with such a force that it is capable of performing a tubular morphing operation with a single actuation of the mechanism.

[0070] The cumulative pressure against pistons 40a,b creates a total force applied to fluid 56 by the movement of piston 44c which is the sum of force from all the pistons 40a,b. The increased thickness of overlapped walls 22c, d 18c enables the force of pressure applied to the conduit 52 to be directed to a desired location without damaging or causing deformation of the pressure intensifier 10.

[0071] The number of pressure development segments used in the pressure intensifier 10 can be varied depending upon the level of pressure required for a particular use of the intensifier; the more pressure development segments in the form of pistons 40, outer cylindrical segments 12 and stops 48 included in the intensifier 10, the more pressure will can be applied from the mechanism 10. Fewer segments and pistons will result in a lower pressure being applied by the mechanism 10.

[0072] The principle advantage of the present invention is that it provides a pressure intensifier which uses a force created downhole to generate pressure which can be applied to a downhole location as desired.

[0073] A further advantage of the present invention is that by mounting the movable components of the outer cylinder and pistons on a fixed mandrel, the intensifier mechanism can be constructed from the first end 14, or top down.

[0074] A further advantage of the present invention is that by providing locking mechanisms that are easily accessible and simple to swap out for different strength components, the intensifier mechanism can easily be adapted for different applications in the field.

[0075] It will be appreciated by those skilled in the art that modifications may be made to the invention herein described without departing from the scope thereof. For example, the ports 44 are shown in the above embodiments as small round holes through the mandrel 20. However, the instead of a single hole, each port may comprise a plurality of holes, or the port may be shaped as a slit, a slot or a plurality of slots formed around the circumference of the mandrel 20. The pistons and stops may also have different shapes and configurations.