WO2023239576A1 - Pressure control device and method - Google Patents

Abstract

A pressure control device includes a housing having an annular through bore. A removable insert is mounted within the housing through bore. The insert has an annular through bore configured for passage of a tubular therethrough such that the tubular traverse through the housing ends. The insert includes at least one seal to restrict fluid passage along the housing through bore when the insert is disposed within the housing through bore. A method for operating a pressure control device.

Description

PRESSURE CONTROL DEVICE AND METHOD

Background

[0001] This disclosure relates to methods and apparatus for pressure management and control for fluid conveyance via tubulars.

[0002] Coiled tubing is a conventional technique for performing a variety of oil and gas well operations, including drilling, setting casing, setting packers, perforation, fluid distribution, and other operations. Coiled tubing systems use a flexible continuous tubing that can be run into the wellbore from a large spool or reel. The tubing is typically run into and pulled out of the wellbore utilizing an injector mechanism. Wireline operations are also well known in the oil and gas industry. In wireline operations, tools are positioned on the lower end of a wireline, which is typically a steel cable, and lowered into the wellbore to perform various operations downhole.

[0003] Coiled tubing and wireline operations also entail the use of specialized apparatus to control well pressure during operations. In such operations, well pressure control may be performed by annular or ram-type apparatus, known as “blowout preventers” (BOPS), examples of which are described in U.S. Pat. Nos. 5,590,867 and 6,843,463. Conventional BOPs are designed to accommodate tools of varying dimensions and external diameters, which is not ideal for coiled tubing or wireline operations wherein the tubing or cable has a uniform external diameter. This results in poor control of well pressure.

[0004] A need remains for improved techniques to control and manage fluid pressure along conduits such as wellbores, particularly in applications entailing uniform diameter tubulars.

Summary

[0005] A pressure control device according to an aspect of the disclosure includes a housing having an annular through bore running from a first end to a second end thereof. An insert is configured for insertion within and removal from the housing through bore. The insert has an annular through bore configured for passage of a tubular therethrough such that the tubular can traverse through the first end and the second end of the housing when the insert is disposed within the housing through bore. The insert is configured with at least one seal to restrict fluid passage along the housing through bore when the insert is disposed within the housing through bore.

[0006] A method for operating a pressure control device comprising a housing having an annular through bore running from a first end to a second end thereof according to another aspect includes disposing an insert within the housing through bore, the insert having an annular through bore coaxially aligned with the housing through bore. The insert is configured with at least one seal to restrict fluid passage along the housing through bore. A tubular is passed through the insert through bore such that the tubular traverses through the first end and the second end of the housing.

[0007] A pressure control device according to another aspect of the disclosure includes a housing having a through bore running from a first end to a second end thereof. An insert is configured for insertion within and removal from the housing through bore. The insert has a through bore configured for passage of a tubular therethrough. The insert is configured with a plurality of seals to restrict fluid passage along the housing through bore when the insert is disposed within the housing through bore. At least one seal of the plurality of seals is configured for energization. A controller is linked to the device to selectively activate energization of the at least one seal configured for energization.

[0008] A method for operating a pressure control device comprising a housing having an annular through bore running from a first end to a second end thereof according to another aspect of the disclosure includes disposing an insert within the housing through bore, the insert being configured with an annular through bore formed therein and coaxially aligned with the housing through bore. A tubular is inserted within the insert through bore such that the tubular traverses through the first end and the second end of the housing. A plurality of seals disposed on the insert are selectively energized to restrict fluid passage along the housing through bore.

Brief Description of the Drawings

[0009] The following figures form part of the present specification and are included to further demonstrate certain aspects of the present disclosure and should not be used to limit or define the claimed subject matter. The claimed subject matter may be better understood by reference to one or more of these drawings in combination with the description of embodiments disclosed herein. Consequently, a more complete understanding of the present embodiments and further features and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numerals may identify like elements. [00010] FTG. 1 shows a cross section schematic of a pressure control device according to an example embodiment of the present disclosure.

[00011] FIG. 2 shows a detail of the pressure control device section marked A in FIG. 1.

[00012] FIG. 2A shows a detail of the pressure control device section marked B in FIG. 2.

[00013] FIG. 2B shows a detail of the pressure control device section marked C in FIG. 2.

[00014] FIG. 3 shows a cross section schematic of another pressure control device according to an example embodiment of the present disclosure.

[00015] FIG. 4 shows a cross section schematic of another pressure control device according to an example embodiment of the present disclosure.

[00016] FIG. 5 shows a cross section schematic of another pressure control device according to an example embodiment of the present disclosure.

[00017] FIG. 6 shows a perspective view of another pressure control device according to an example embodiment of the present disclosure.

[00018] FIG. 7 shows a top view of a pressure control device according to an example embodiment of the present disclosure.

[00019] FIG. 8 shows a schematic of a pressure control device coupled into a typical stack in an oil and gas well operation.

Detailed Description

[00020] The foregoing description of the figures is provided for the convenience of the reader. It should be understood, however, that the embodiments are not limited to the precise arrangements and configurations shown in the figures. Also, the figures are not necessarily drawn to scale, and certain features may be shown exaggerated in scale or in generalized or schematic form, in the interest of clarity and conciseness. Figures of the disclosed embodiments may not show all the interconnections (e.g., tubing, electrical wiring) between the components for clarity of illustration. Nevertheless, it will be understood by those skilled in the art how the components are linked together to operate as disclosed herein.

[00021] In the development of any disclosed embodiment, numerous implementation- specific decisions may need to be made to achieve the design-specific goals, which may vary from one implementation to another. It will be appreciated that such a development effort, while possibly complex and time-consuming, would nevertheless be a routine undertaking for persons of ordinary skill in the art having the benefit of this disclosure. The following detailed description of exemplary embodiments, read in conjunction with the accompanying drawings, is merely illustrative and is not to be taken as limiting the scope of the invention.

[00022] FIG. 1 shows a cross section of an embodiment of a pressure control device 10 according to this disclosure. The device 10 includes an elongated housing 12 having an annular through bore 14 running along a longitudinal axis from a first end 16 to a second end 18 of the housing. The housing 12 is configured to accept a removable insert 20 within the annular through bore 14. The insert 20 is also an elongated member with an annular through bore 22 running along a longitudinal axis. The longitudinal axes of the housing 12 and the insert 20 are coaxial when the insert is mounted within housing. As shown in FIG. 1, the insert 20 is configured to receive and allow passage of a tubular 24 via the through bore 22. As used herein for purposes of this disclosure, the word “tubular” is not to be limited to any particular type of pipe or conduit; it is meant to encompass any tubular means, including wireline and coiled tubing as used in the oil and gas industry. Tubular embodiments 24 also encompass pipes or conduits configured for fluid transmission therethrough (e.g., coiled tubing for wellbore fluid conveyance). Additionally, fluids are meant to encompass liquids, gases, and/or mixtures thereof.

[00023] The housing 12 and the insert 20 may be formed of any suitable materials depending on the application. Metals such as steel are preferable for applications in the oil and gas industry. However, other embodiments may be implemented with the housing 12 and/or insert 20 formed of synthetic or composite materials as known in the art. The insert 20 may also be formed as a unitary component or as a multi-piece structure of individual sections joined together (e.g., via welding).

[00024] Once the insert 20 is mounted within the housing 12 through bore 14, a locking mechanism may be activated to lock the insert in place. In some embodiments, the locking mechanism may consist of a pair of locking dogs 26A, 26B mounted near the first end 16 of the housing 12. As shown in FIG. 1, a first locking dog 26A may be mounted on the housing 12 across from a second locking dog 26B mounted on the housing. The locking dogs 26A, 26B may be implemented for actuation by various means as known in the art (e.g., hydraulically, pneumatically, electrically). The insert 20 is configured with a pair of receptacles 28A, 28B formed near one end to receive the respective locking dogs 26A, 26B when the dogs are actuated to extend outward to engage and hold the insert in place within the housing 12. [00025] The first and second ends 16, 18 of the housing 12 may be configured to couple the housing into any fluid conveyance line or system using any suitable mating means as known in the art (e.g., bolt-on flange, direct weld, pin-cup threads, etc.). When coupled into a tool string on a well (see FIG. 8), the pressure control device 10 may be used to run a tubular 24 (e.g., coiled tubing, wireline) into the well to perform the typical operations as known in the industry. In one application, the housing 12 may be coupled onto the desired line or system via the first and second ends 16, 18. The tubular 24 may be inserted into the insert 20 through bore 22, traversing through the insert via one end and out the other. Depending on the application, any desired tools, instruments, or apparatus may then be linked to the tubular 24 end extending out from the insert 20 through bore 22 (e.g., from the bottom end of the insert 20 as shown in FIG. 1). For example, a bottom hole assembly (not shown) may be linked to the tubular 24 as well known in the oilfield industry. The insert 20 can then be mounted into the housing 12 through bore 14. As shown in FIG. 1, the housing 12 through bore 14 may be configured with a conical taper 30 formed near the second end 18. The insert 20 may also be formed with a complementary conical taper 32 formed at one end to abut against the housing 12 conical taper 30 when the insert is fully engaged within the housing through bore 14. Once the insert 20 is fully engaged as such, the locking dogs 26A, 26B may be actuated to lock the insert in place.

[00026] As shown in FIG. 1, the insert 20 is configured with a plurality of seals to restrict fluid passage along the housing 12 through bore 14 when the insert is mounted in the housing. The insert 20 is implemented with a plurality of annular radial seals 34. The seals 34 comprise an annular ring structure disposed within recesses or channels 36 formed on the interior surface of the insert 20 through bore 14. Each channel 36 is formed along the entire circumference of the through bore 14 surface to house the annular seal 34. The seals 34 restrict fluid passage along the external surface of the tubular 24 when the tubular is disposed within the insert through bore 22. The seals 34 may be conventional annular seals as known in the art for use with tubulars.

[00027] In some embodiments, some or all the radial seals 34 may be configured for energization (i.e., pressure activation) to provide greater sealing engagement between a sealing surface on the seal and the exterior surface of the tubular 24. FIG. 1 shows an embodiment configured with a pair of energizable seals 34'.

[00028] Turning to FIG. 2, a blown-up view is shown of the section marked A in FIG. 1. In this embodiment, the housing 12 includes separate sealed cylindrical chambers 38A, 38B formed thereon along the longitudinal axis of the housing wall. Each chamber 38A, 38B is respectively in fluid communication with the seal 34' channels 36 through ports 40A, 40B. Each chamber 38A, 38B includes an end cap 42A, 42B (e.g., a threaded cap or plug) with an injection nozzle 44A, 44B to receive a fluid (e.g., hydraulic fluid, oil, nitrogen, grease mixture) into the respective chamber from an external source. Each chamber 38 A, 38B respectively contains a floating piston 46A, 46B. Use of the pistons 46A, 46B allows for preloading of the chambers 38A, 38B with a selected fluid or compound. The pistons 46A, 46B also function as shut-off valves to prevent any fluids escaping from the housing 12 through bore 22 or the insert 20 through bore 22 from reaching the injection nozzles 44A, 44B.

[00029] FIG. 2 A shows a blown-up view of the section marked B in FIG. 2. In FIG. 2 A, a cross section of an energizable seal 34' embodiment is shown in a passive or de-energized mode. In this embodiment, the seal 34' is configured with a sealing surface 48 having raised portions 50 formed thereon. At the opposite or back end, the seal 34' is configured with sloping surfaces that extend outward slightly to form wings 52. In the passive mode, the seal 34' resides in the channel 36 such that the sealing surface 48 is not in direct contact with the external surface of the tubular 24, as shown in FIG. 2A.

[00030] FIG. 2B shows a blown-up view of the section marked C in FIG. 2. FIG. 2B shows a seal 34' in an energized mode. Once fluid is injected under pressure via the injection nozzle 44A, pressure (shown by arrow 54) is applied to the space in the channel 36 behind the seal 34' through port 40A. The seal 34' then moves outward from the channel 36 to engage the sealing surface 48 against the external surface of the tubular 24. The higher the fluid pressure 54, the greater the sealing force applied to the seal 34'.

[00031] Returning to FIG. 1, in this embodiment the insert 20 is also configured with another plurality of seals to restrict fluid passage along the housing 12 through bore 14 when the insert is mounted in the housing. The insert 20 is implemented with a plurality of annular ring seals 56 disposed within recesses or channels 58 formed on the exterior surface of the insert 20. Each channel 58 is formed along the entire circumference of the insert 20 surface to house a seal 56. The seals 56 restrict fluid passage along the external surface of the insert 20 when the insert is disposed within the housing 12 through bore 14.

[00032] It will be appreciated by those skilled in the art that the seals 34, 34', 56 according to this disclosure may be formed from conventional materials suitable for the desired application as known in the art (c.g., resilient materials, elastomers, rubber compounds, synthetic elastomeric materials, composites, POLYPAK® seals, etc.). Other seal 34, 34', 56 configurations that may be implemented with embodiments of this disclosure are further described in Inti. Pat. App. Nos. WO 2021/14199 Al and WO 2021/142004 Al, both assigned to the present assignee, and both entirely incorporated herein by reference.

[00033] FIG. 3 shows another embodiment of a pressure control device 10 according to this disclosure. The sealing integrity of the annular seals 34, 34' on the insert 20 can be tested by injecting grease (e.g., high viscosity grease, thixotropic fluid, other semi-solid compound as known in the art) in between the external surface of the tubular 24 and the surface of the insert 20 through bore 22 with the tubular disposed within the insert. Grease injectors 60A, 60B can be mounted on the housing 12 body with respective fluid communication ports 62A, 62B leading to the insert 20 through bore 22. The sealing integrity of the annular seals 34, 34' can be tested as desired by activating the respective grease injector 60A, 60B to inject grease in between two seals to be tested. For example, the integrity of seals BB and CC in FIG. 3 can be tested by actuating injector 60A to inject grease via port 62A into the annulus gap in between the insert 20 through bore 22 surface and the external surface of the tubular 24. Seals BB and CC should restrain the injected grease to the annulus gap in between the seals. However, if either or both seals BB, CC have lost sealing integrity (e.g., due to wear) the injected grease will flow past the failing seal(s). Grease for the injector 60A can be introduced under pressure from an external source via an injector nozzle 64A on a cap 66. In the event of total seal BB, CC failure, the injector 60A is configured with a spring-activated shuttling piston 68 that functions as a shut-off valve to prevent any fluids from returning to the injector 60A via port 62A. Although FIG. 3 shows a housing 12 equipped with only two grease injectors 60A, 60B, it will be appreciated that other embodiments may be implemented with multiple injectors to test every seal 34, 34' disposed on the insert 20.

[00034] FIG. 4 shows another embodiment of a pressure control device 10 according to this disclosure. Upon injection of grease by the injectors 60A, 60B as described with respect to FIG. 3, the grease pressure in the annulus gap between the seals 34, 34' under test can be monitored for greater testing reliability. For example, after grease has been injected via injector 60A and port 62A, grease will fill the insert-tubular annulus gap between seals BB and CC, resulting in a grease pressure increase in the annulus gap. A port 70 extending through the insert 20 and the housing 12 body provides fluid communication between the insert-tubular annulus gap and a pressure detector 71A with a piston 72 in a chamber 74 formed in the housing 12 body. The piston 72 is in fluid communication with a pressure transducer 76 coupled to the chamber via additional porting. The piston 72 also functions as a shut-off valve to prevent any fluids escaping from the housing 12 through bore 14 or the insert 20 through bore 22 from reaching the transducer 76.

[00035] With the detector 71 A, the grease pressure in the annulus gap between seals BB and CC can be monitored. A drop in pressure would indicate a potential leak due to seal failure. Although FIG. 4 shows a housing equipped with only two pressure detectors 71 A, 7 IB, it will be appreciated that other embodiments may be implemented with multiple detectors to monitor every seal 34, 34' disposed on the insert 20.

[00036] Embodiments of the pressure control device 10 of this disclosure can also be implemented without grease injectors 60A, 60B (see FIG. 3). In such embodiments, the housing 12 may be implemented with one or more pressure detectors 71 A, 7 IB to monitor seal 34, 34' integrity. For example, with an embodiment implemented with energizable seals 34' (see FIG. 2), a pressure detector 71 A, 7 IB located on the housing 12 to monitor the annulus gap between the seals can be used to detect a pressure increase via the transducer, indicating seal failure.

[00037] FIG. 5 shows another embodiment of a pressure control device 10 according to this disclosure. Upon disposal of the insert 20 within the housing 12, the annular ring seals 56 on the insert can be tested for sealing integrity. As shown in the embodiment of FIG. 5, the housing 12 includes a test circuit 80A consisting of a lateral port 82 extending from the exterior of the housing body to the surface of the housing through bore 14. The port 82 is located on the housing 12 such that when the insert 20 is mounted therein, the port opening on the interior surface of the housing through bore 14 is between a pair of annular ring seals 56. A removable plug 84 (e.g., threaded plug) is disposed on the exterior surface of the housing 12 to cap off the port 82. To test the annular ring seals 56, the plug 84 in between the seals to be tested is removed and a fluid under pressure (e.g., hydraulic fluid) is introduced via the port 82. In this manner, the sealing integrity of the annular ring seals 56 can be tested to identify a failing seal. Although FIG. 5 shows a housing equipped with only two test circuits 80A, 80B, it will be appreciated that other embodiments may be implemented with multiple test circuits to test every seal 56 disposed on the insert 20.

[00038] FIG. 6 shows another embodiment of a pressure control device 10 according to this disclosure. The housing 12 is shown with bolt-on flange type first 16 and second 18 ends. Embodiments may also be implemented with a controller 90 and quick connect panel 92. The quick connect panel 92 may be configured with fluid quick connects 94 (e.g., hydraulic fluid connects, grease injection connects, pressurized gas connects). The quick connect panel 92 may be linked to the injection nozzles (see FIG. 2, 44A, 44B) via tubing 96 to provide the pressurizing fluid to energize the energizable seals 34', to actuate the locking mechanism dogs 26A, 26B, and to the grease injectors (see FIG. 3, 60A, 60B) as disclosed herein. Fluids and grease for operation of the device 10 can be supplied to the quick connects 94 via external supply lines or from local reservoirs (not shown). The quick connect panel 92 may also be implemented with an electric power connector 98 to provide power to components requiring electricity for operation. Some embodiments may also be configured with a replaceable/rechargeable battery disposed in the controller 90 housing. The transducers 76 on the pressure detectors (see FIG. 4, 71A, 71B) are also linked to the controller via wiring 99.

[00039] Returning to FIGS. 3 and 4, embodiments may be implemented with a controller 90 (FIG. 6) linked to the pressure detectors 71 A, 7 IB and programmed to perform autonomous seal 34, 34' monitoring, testing, and energization. For example, with a pressure control device 10 embodiment wherein the insert 20 seals AA - EE are all configured for energization (see FIG. 2), the insert may be mounted within the housing 12 with all seals in the passive or de-activated mode (see FIG. 2B). The controller 90 may be programmed to autonomously actuate energization (see FIG. 2C) of seals BB and CC, injection of grease (via grease injector 60A) in the annulus gap between seals BB and CC, and monitoring of the pressure in the annulus gap between the seal via pressure detector 71 A. If a leak is detected, the controller 90 can automatically send a signal to an operator (e.g., to a mobile phone, remote display, etc.), actuate energization of seal DD, stop grease injection between seals BB and CC, actuate grease injection between seals CC and DD, and continue monitoring all the seals for a pressure differential signaling a possible seal failure. With this embodiment, the controller 90 may be programmed to autonomously energize the seals AA - FF in a selective and sequential manner to ensure effective and constant control of annular pressure across the device 10. It is understood that this example scenario may be conducted with an insert 20 and housing 12 configured with multiple injectors and detectors to perform the disclosed operations.

[00040] FIG. 7 shows an overhead view of a pressure control device 10 according to this disclosure. Looking down the first end 16 of the device 10, the tubular 24 is shown inserted within the insert 20 through bore 22. The locking mechanism locking dogs 26A, 26B are extended and engaged with the receptacles 28A, 28B on the insert 20. The locking dogs 26A, 26B and receptacles 28A, 28B are configured to ensure proper timing of the porting channels to ensure the ports in the insert 20 align with the ports in the housing 12 to permit fluid/grease communication as disclosed herein. FIG. 8 shows a schematic of a pressure control device 10 linked into a typical stack 100 mounted on a wellhead 102 in an oil and gas operation.

[00041] The disclosed pressure control device 10 configurations provide for limited seal 34, 34' movement, which provides effective and efficient control of annular pressure, particularly in applications entailing uniform diameter tubulars 24. Another advantage of the disclosed devices 10 is greater reliability provided by increased redundancy using multiple seals 34, 34', 56. In certain industries, it is common to encounter what is known as “sour gas.” Such gases typically contain Hydrogen Sulfide (H2S), which is an extremely hazardous gas that is colorless and flammable. H2S occurs naturally as crude petroleum and natural gas. For such applications, the seals 34, 34', 56 according to this disclosure may be formed from materials that have H2S resistant properties.

[00042] In light of the principles and example embodiments described and illustrated herein, it will be recognized that the embodiments can be modified in arrangement and detail without departing from such principles. It will be appreciated by those skilled in the art that conventional hardware, electronics, processors, memory, software, controllers, and components may be used to implement the embodiments according to this disclosure. It will also be appreciated that the injectors, controls, and components of disclosed embodiments may be configured for remote operation (e.g., via wireless signal communication). Embodiments of this disclosure may also be implemented for use at surface and in underwater applications and operations, in the oil and gas industry, and in other fields of endeavor. What is claimed as the invention, therefore, are all implementations that come within the scope of the following claims, and all equivalents to such implementations .

Claims

Claims A pressure control device, comprising: a housing having an annular through bore running from a first end to a second end thereof; an insert configured for insertion within and removal from the housing through bore; the insert having an annular through bore configured for passage of a tubular therethrough such that the tubular- can traverse through the first end and the second end of the housing when the insert is disposed within the housing through bore; and the insert configured with at least one seal to restrict fluid passage along the housing through bore when the insert is disposed within the housing through bore. The device of claim 1 wherein the housing consists of an elongated member having a longitudinal axis and the insert consists of an elongated member having a longitudinal axis, wherein the housing through bore and the insert through bore are coaxial when the insert is disposed within the housing. The device of claim 1 wherein the housing is configured with a first coupler at the first end and a second coupler at the second end to link the housing to a fluid conveyance system. The device of claim 1 wherein the insert comprises a plurality of seals to restrict fluid passage along the housing through bore, the seals consisting of a plurality of seals configured to restrict fluid passage along an external surface of the insert when the insert is disposed within the housing through bore. The device of claim 1 wherein the insert comprises a plurality of seals to restrict fluid passage along the housing through bore, the seals consisting of a plurality of seals configured to restrict fluid passage along an external surface of the tubular when the tubular is disposed within the insert through bore. The device of claim 5 wherein at least one seal of the plurality of seals is configured for energization. The device of claim 1 further comprising at least one injector to inject grease in between an external surface of the tubular and a surface of the insert through bore when the tubular is disposed within the insert through bore. The device of claim 1 wherein the tubular is configured for fluid passage therethrough. The device of claim 1 further comprising a slip ram disposed on the housing to selectively restrain the tubular when the tubular is disposed within the insert through bore. A method for operating a pressure control device, the device comprising a housing having an annular through bore running from a first end to a second end thereof, comprising: disposing an insert within the housing through bore, the insert having an annular through bore coaxially aligned with the housing through bore; wherein the insert is configured with at least one seal to restrict fluid passage along the housing through bore; and passing a tubular through the insert through bore such that the tubular traverses through the first end and the second end of the housing. The method of claim 10 further comprising coupling the housing to a fluid conveyance system. The method of claim 10 wherein the insert comprises a plurality of seals to restrict fluid passage along the housing through bore, the seals consisting of a plurality of seals configured to restrict fluid passage along an external surface of the insert. The method of claim 10 wherein the insert comprises a plurality of seals to restrict fluid passage along the housing through bore, the seals consisting of a plurality of seals configured to restrict fluid passage along an external surface of the tubular. The method of claim 13 wherein at least one seal of the plurality of seals is configured for energization. The method of claim 10 wherein the housing comprises at least one detector to detect a pressure change in between an external surface of the tubular and a surface of the insert through bore.