WO2015153306A1

WO2015153306A1 - Supplementary closure device for use in controlling flow

Info

Publication number: WO2015153306A1
Application number: PCT/US2015/022875
Authority: WO
Inventors: Robert Thomas Brooks
Original assignee: Shell Internationale Research Maatschappij BV; Shell Oil Co
Current assignee: Shell Internationale Research Maatschappij BV; Shell USA Inc
Priority date: 2014-04-04
Filing date: 2015-03-27
Publication date: 2015-10-08
Anticipated expiration: 2016-10-04

Abstract

A supplementary closure device comprising: a housing and one or more flapper fingers disposed on the housing.

Description

SUPPLEMENTARY CLOSURE DEVICE FOR USE IN CONTROLLING FLOW

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 61/975,292, filed April 4, 2014, which is incorporated herein by reference.

BACKGROUND

[0002] The present disclosure relates generally to supplementary closure devices. More specifically, in certain embodiments, the present disclosure relates to supplementary closure devices capable of being activated above a collapsible insert device and associated methods and systems.

[0003] During the drilling or production of well bores, a well may experience an uncontrolled release of hydrocarbon. One method of controlling this uncontrolled release is to use a collapsible insert device (CID). Examples of CIDs are discussed in U.S Patent Application Publication No. 2013/0214183, the entirety of which is hereby incorporated by reference. Briefly, collapsible insert devices are well bore inserts that may comprise a housing that surrounds a collapsible insert. The collapsible insert devices may be installed within a tubular. When that tubular experiences an uncontrolled release of hydrocarbon, the CID may be activated allowing the collapsible inset to deform thus sealing the well bore.

[0004] One problem with collapsible insert devices is that they may not fully seal a well bore. Furthermore, if a collapsible insert device does not obtain a closure of at least 96% then it may not effectively control the flow of hydrocarbons from the wellbore. In some instances, if flow continues through the sleeve for a finite period when the sleeve does not have a consistent closure of at least 96%, flow erosion may breach a wall of the collapsed CID sleeve. Other problems may include the complete failure of the CID to close. Still other problems may be caused by the nature of the various types of steels and metals that are used for the collapsible sleeve, resulting in uneven closure of the CID. Uneven closure can result in higher fluid velocity rates through the sleeve, lack of pressure drop, and high erosion rates.

[0005] It is desirable to develop a supplementary closure device which could be activated above the CID to further restrict a blowout flow up the wellbore in the event the CID does not fully close. SUMMARY

[0006] The present disclosure relates generally to supplementary closure devices. More specifically, in certain embodiments, the present disclosure relates to supplementary closure devices capable of being activated above a collapsible insert device and associated methods and systems.

[0007] In one embodiment, the present disclosure provides a supplementary closure device comprising: a housing and a one or more flapper fingers disposed on the housing.

[0008] In another embodiment, the present disclosure provides a supplementary closure device system comprising: a tubular and a supplementary closure device disposed in the tubular, wherein the supplementary closure device comprises a housing and one or more flapper fingers disposed on the housing.

[0009] In another embodiment, the present disclosure provides a method comprising: providing a supplementary closure device system comprising a supplementary closure device and a tubular and activating the supplementary closure device to seal the tubular.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A more complete and thorough understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings.

[0011] Figure 1 is an illustration of a supplementary closure device in an open position in accordance with certain embodiments of the present disclosure.

[0012] Figure 2 is an illustration of a supplementary closure device in a closed position in accordance with certain embodiments of the present disclosure.

[0013] Figure 3 is an illustration of a supplementary closure device system in accordance with certain embodiments of the present disclosure.

[0014] The features and advantages of the present disclosure will be readily apparent to those skilled in the art. While numerous changes may be made by those skilled in the art, such changes are within the spirit of the disclosure. DETAILED DESCRIPTION

[0015] The description that follows includes exemplary apparatuses, methods, techniques, and/or instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.

[0016] The present disclosure relates generally to supplementary closure devices. More specifically, in certain embodiments, the present disclosure relates to supplementary closure devices capable of being activated above a collapsible insert device and associated methods and systems.

[0017] In certain embodiments, the present disclosure provides a device that forms an additional closure in an open wellbore to stop, or substantially reduce, an uncontrolled release of hydrocarbons. In certain embodiments, this device may be used in conjunction with a collapsible insert device. In certain embodiments, this device may enable an operator to regain control of a well experiencing an uncontrolled flow. In certain embodiments, once the device has been used to regain control of a well experiencing an uncontrolled flow, an operator may be able to use heavyweight muds or cement that can be pumped through the tool to plug off the wellbore, manually open the tool, or drill through the tool to further service the well.

[0018] Referring now to Figure 1 , Figure 1 illustrates supplementary closure device 100 in accordance with certain embodiments of the present disclosure. As can be seen in Figure 1, in certain embodiments, supplementary closure device 100 may comprise housing 110 and one or more flapper fingers 120.

[0019] In certain embodiments, housing 110 may be constructed of any conventional downhole material suitable for use as a tubular. In certain embodiments, housing 110 may be constructed out of steel, cast iron, cast steel, and/or stainless steel. In certain embodiments, housing 110 may have a cylindrical shape with a hollow center. In certain embodiments, housing 110 may comprise outside surface 111, inside surface 112, top surface 113, and bottom surface 114. In certain embodiments, housing 110 may further comprise groove 115. In certain embodiments, O-ring 118 may be disposed in groove 115.

[0020] In certain embodiments, housing 110 may be from 2 to 10 inches in length.

In certain embodiments, housing 110 may have an outer diameter of from 5 to 15 inches, an inner diameter of from 4 to 14 inches, and/or a thickness of 0.25 to 1 inches. In certain embodiments, housing 110 may have an outer diameter of 9.73 inches, an inner diameter of 8.75 inches, and/or a thickness of 0.49 inches.

[0021] In certain embodiments, top surface 113 of housing 110 may have several indented portions comprising indented surfaces 116 and side surfaces 117a and 117b. In certain embodiments, side surfaces 117a and 117b may each define a cavity.

[0022] In certain embodiments, flapper fingers 120 may be constructed out of any conventional downhole material suitable for use as a tubular. In certain embodiments, flapper fingers 120 may be constructed out of steel, cast iron, cast steel, stainless steel, Incalloy/Inconel, and/or titanium. In certain embodiments, flapper fingers 120 may be arrow shaped and/or comprise base portion 121, side sealing faces 122, back sealing face 123, bottom surface 124, and top surface 125. In certain embodiments, base portion 121 may define one or more cavities.

[0023] In certain embodiments, the one or more flapper fingers 120 may be disposed on the top surface 113 of housing 110. In certain embodiments, supplementary closure device 100 may comprise 6, 7, 8, 9, or 10 flapper fingers 120 disposed and equispaced on top surface 113 of housing 110. In certain embodiments, the base portion 121 of flapper fingers 120 may be in contact with the side surface 117 and 117b of housing 110. In certain embodiments, base portion 121 of flapper fingers 120 may be disposed within the indented portions of top surface 113 of housing 110.

[0024] In certain embodiments, flapper fingers 120 may be attached to housing 110 through the use of pivot pin 130 and torsion spring 131. In certain embodiments, pivot pin 130 may be disposed in the cavities defined by side surfaces 117a and 117b and base portion 121. In certain embodiments, torsion spring 131 may be disposed around pivot pin 130. In certain embodiments, torsion spring 131 may be capable of keeping supplementary closure device in a closed position, as further described below.

[0025] In certain embodiments, as shown in Figure 1, supplementary closure device 100 may be in an open position. In such embodiments, flapper fingers 120 are arranged such that they do not restrict flow through supplementary closure device 100. In such embodiments, flapper fingers 120 may be vertically disposed on housing 110. In certain embodiments, the top surfaces of flapper fingers 120 may be in vertical alignment with the outside surface 111 of housing 110.

[0026] Referring now to Figure 2, Figure 2 illustrates a supplementary closure device 200 in accordance with certain embodiments of the present disclosure. In certain embodiments, supplementary closure device 200 may share any combination of characteristics discussed above with respect to supplementary closure device 100. In certain embodiments, supplementary closure device 200 may comprise housing 210 comprising outside surface 211, an inside surface (not illustrated in Figure 2), top surface 213, bottom surface 214, groove 215, O-ring 218, indented surfaces 216, and side surfaces 217a and 217b. In certain embodiments, supplementary closure device 200 may comprise one or more flapper fingers 220 comprising base portion 221, side sealing faces (not illustrated in Figure 2), back sealing faces 223 (not illustrated in Figure 2), bottom surface 224 (not illustrated in Figure 2), and top surface 225. In certain embodiments, supplementary closure device 200 may comprise one or more torsion springs 231 and pivot pins 230 (not illustrated in Figure 2) connecting the one or more flapper fingers 220 to housing 210.

[0027] In certain embodiments, as shown in Figure 2, supplementary closure device 200 may be in a closed position. In such embodiments, flapper fingers 220 are arranged such that they restrict flow through supplementary closure device 200. In certain embodiments, the restriction may be a complete restriction or a partial restriction. In certain embodiments, flapper fingers 220 may be arranged such that they restrict 97% to 100% of the flow when in the closed position. In other embodiments, flapper fingers 220 may restrict all flow through supplementary closure device 200 when in the closed position.

[0028] In certain embodiments, supplementary closure device 200 may be capable of providing a pressure containment up to 5000 psi when in the closed position. In certain embodiments, supplementary closure device 200 may be capable of providing a pressure containment in excess of 5000 psi when in the closed position. In certain embodiments, the selection of materials used for the flapper fingers 220 and housing 210 may govern the amount of pressure containment supplementary closure device 200 may withstand.

[0029] In certain embodiments, when in the closed position, the side sealing faces of each of each flapper fingers 220 may be in sealing contact with the side sealing faces of the adjacent flapper fingers 220. In such embodiments, flapper fingers 220 may create a self-supporting bridge effectively sealing the supplementary closure device.

[0030] Referring now to Figure 3, Figure 3 illustrates a supplementary closure device system 300. In certain embodiments, supplementary closure device system 300 may comprise supplementary closure device 310, outer housing 320, stop sleeve 322, inner sleeve assembly 330, coil spring 332, shear pins 331, piston 340, explosive material 350, and tubular 360. In certain embodiments, supplementary closure device 300 may further comprises a collapsible insert device (not illustrated). Examples of such collapsible insert devices (CID) are described in U.S Patent Application Publication No. 2013/0214183.

[0031] In certain embodiments, supplementary disclosure device 310 may comprise any combination of features discussed above with respect to supplementary closure devices 100 and/or 200. In certain embodiments, supplementary closure device 310 may be located above a collapsible insert device.

[0032] In certain embodiments, supplementary closure device 310 may be disposed within outer housing 320 within tubular 360. In certain embodiments, tubular 360 may be a casing string. In certain embodiments, outer housing 320 may match or exceed the physical and chemical ratings of the casing string. In certain embodiments, outer housing 320 may comprises top, middle, and bottom cylindrical components that are threadedly connected to each other by metal-to-metal premium sealing threads. In certain embodiments, stop sleeve 321 may be an integral part of outer housing 320. In other embodiments, stop sleeve 321 may be disposed within outer housing 320. In certain embodiments, when supplementary closure device 310 is in the closed position, the bottom surfaces of the flapper fingers of supplementary closure device 310 may be in contact with the outer housing.

[0033] In certain embodiments, inner sleeve assembly 330 may be disposed within outer housing 320. In certain embodiments, inner sleeve assembly 330 may comprise inner sleeve 333 and/or spacer sleeve 334. In certain embodiments, inner sleeve assembly may be held in a down position by one or more shear pins 331. In such embodiments, the one or more flapper fingers of supplementary closure device 310 may be held in the open position and the torsion springs of supplementary closure device 310 may be torsionally loaded. In such embodiments, coil spring 332 may be held in tension by shear pin 331. In such embodiments, once shear pin 331 is sheared, coil spring 332 may move inner sleeve 333 upward allowing for the one or more flapper fingers to rotate upward and bring supplementary closure device 310 into the closed position. In certain embodiments, coil spring 332 may be rectangular, square, or round wire shape construction.

[0034] In certain embodiments, piston 340 may be capable of shearing shear pins

331. In certain embodiments, activation of explosive material 350 may move piston 340 to shear shear pin 331. In certain embodiments, explosive material 350 may be a solid propellant. In certain embodiments, explosive 350 may initiate a gas pressure surge to move piston in response to an activation signal. In certain embodiments, explosive material 350 may be disposed within an annulus formed by outer housing 320 and piston 340. In certain embodiments, explosive material 350 may comprise any solid gas propellant. Examples of suitable solid gas propellants include solid gas propels that comprises potassium perchlorate. In certain embodiments, the solid gas propellant may comprise potassium perchlorate mixed with a resin. In certain embodiments a Lead Azide may be used as a primer for the solid gas propellant.

[0035] In operation, supplementary closure device 310 may be activated by activating explosive material 350. Explosive material 350 may be activated by a signal that is sent to a downhole receiver which in turn activates/switches on a battery pack which sends an electrical charge to the detonator package which ignites the primer and solid propellant to create the gas pressure. Once activated, propellant gas generated from explosive material 350 may be applied to piston 340 which then shears the one or more shear pins 331. Once the one or more shear pins 331 have been sheared, coil spring 332 may then move inner sleeve 333 upwards until it contacts an inner shoulder of spacer sleeve 334. This contact then allows torsion springs to urge the flapper fingers to rotate around the pivot pins in the housing and move into the closed position where they sealing meet and mate together, thus restricting or cutting off fluid/gas/entrained particle flow that may be flowing up from the wellbore.

[0036] In certain embodiments, the present disclosure provides a method comprising: providing a supplementary closure device system comprising a supplementary closure device and a tubular and activating the supplementary closure device to seal the tubular. In certain embodiments, the supplementary closure device system may comprise any supplementary closure device system discussed above. In certain embodiments, the supplementary closure device may comprise any supplementary closure device discussed above. In certain embodiments, the tubular may comprise any tubular discussed above.

[0037] In certain embodiments, activating the supplementary closure device may comprise activating an explosive material. In certain embodiments, the explosive material may be activated by a signal sent to a downhole receiver. In certain embodiments, once the explosive material has been activated, propellant gas may be generated from the explosive material. In certain embodiments, the propellant gas may be applied to a piston of the supplementary closure device system. In certain embodiments, once the propellant gas is applied to the piston, the piston may move shearing the shear pins of the supplementary closure device system. In certain embodiments, once the shear pins have been sheared, a coil spring may move an inner sleeve of the supplementary closure device so that it contacts an inner shoulder of a spacer sleeve. In certain embodiments, once the inner sleeve is in contact with the inner shoulder of the spacer sleeve, the torsion springs may urge the flapper fingers to rotate around the pivot pins and move into the closed position.

[0038] While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.

[0039] Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.

Claims

C L A I M S

1. A supplementary closure device comprising: a housing and one or more flapper fingers disposed on the housing.

2. The supplementary closure device of claim 1, wherein the supplementary closure device comprises 6 flapper fingers.

3. The supplementary closure device of claim 1 or 2, wherein the flapper fingers are attached to the housing through the use of pivot pins and torsion springs.

4. The supplementary closure device of any one of claims 1-3, wherein the flapper fingers each comprise a base portion, a side sealing face, a back sealing face, a bottom surface, and a top surface.

5. The supplementary closure device of any one of claims 1-4, wherein the housing comprises an outside surface, an inside surface, a top surface, and a bottom surface.

6. The supplementary closure device of any one of claims 1-5, wherein the supplementary closure device is capable of transitioning from an open position to a closed position.

7. The supplementary closure device of any one of claims 1-6, wherein the supplementary closure device is capable of providing a pressure containment up to 5000 psi when in a closed position.

8. The supplementary closure device of any one of claims 1-7, wherein the supplementary closure device is capable of restricting 97% to 100% of fluid flow through the supplementary closure device when in a closed position.

9. The supplementary closure device of any one of claims 1-8, wherein the one or more flapper fingers create a self-supporting bridge effectively sealing the supplementary closure device when in a closed position.

10. A supplementary closure device system comprising: a tubular and a supplementary closure device disposed in the tubular, wherein the supplementary closure device comprises a housing and a plurality of flapper fingers disposed on the housing.

11. The supplementary closure device system of claim 10, wherein the supplementary closure device comprises the supplementary closure device of any one of claims 1-9.

12. The supplementary closure device system of claim 10 or 11, wherein the tubular comprises a casing string.

13. The supplementary closure device system of any one of claims 10-12, further comprising one or more shear pins, a piston, and an explosive material.

14. The supplementary closure device system of any one of claims 10-13, further comprising an outer housing, a stop sleeve, an inner sleeve assembly, and a coil spring,

15. The supplementary closure device system of any one of claim 14, wherein the inner sleeve assembly comprises an inner sleeve and a spacer sleeve.

16. The supplementary closure device system of claim 14 or 15, further comprising a collapsible insert device.

17. The supplementary closure device system of any one of claims 14-16, wherein the inner sleeve assembly is held in a down position by the one or more shear pins.

18. The supplementary closure device system of any one of claims 14-17, wherein the supplementary closure device is in an open position.

19. The supplementary closure device system of any one of claims 14-16, wherein the supplementary closure device is in a closed position.

20. A method comprising: providing a supplementary closure device system comprising a supplementary closure device and a tubular and activating the supplementary closure device to seal the tubular.