CROSS REFERENCE TO RELATED APPLICATIONS This application is a divisional of application Ser. No. 10/345,229 filed Apr. 18, 2003 entitled Slip Spring with Heel Notch, which is hereby incorporated by reference, which in turn claims the benefit of provisional applications Ser. No. 60/373,309 filed Apr. 18, 2002, entitled Patriot Retrievable Production Packer which is hereby incorporated by reference, and Provisional Application No. 60/373,308 filed Apr. 18, 2002, also hereby incorporated by reference.
BACKGROUND OF THE INVENTION A. Field of the Invention
The present invention relates to a retrievable production packer for zone isolation, injection, pumping and production.
B. Description of the Prior Art
Wireline set packer tools are well known and have been used in the industry for many years. See for instance U.S. Pat. No. 5,197,547 issued Mar. 30, 1993 to Allen B. Morgan which is incorporated herein by reference. In Morgan, a combination of shear pins, spring tools, and J slots are used to control insertion, setting, and retrieval of the tools. Through sequential release of the shear pins and springs, a top slip body and a lower drag body are moved in contact with a packer body thereby expanding the packers to seal a zone in a well bore. The complexity of the parts and their manufacture has continued to increase to provide complex movements to set and release the parts of the tool.
The present invention provides a tool capable of being set and released without requiring the complexity of former tools. A novel arrangement of a push sleeve in the spring body eliminates the need for several shear pins while an internal j slot formed directly on the mandrel significantly reduces the size of the lower drag body and thus the length of the tool. These and other improvements to the packer tool result in a significantly simplified tool capable of meeting the full requirements of a production packer.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION Accordingly, it is a principal object of the invention to provide a retrievable production packer tool having a novel arrangement of parts capable of isolating zones in a well bore.
It is a further object of the invention to provide a packer tool having an internal J slot on the mandrel to reduce the overall length of the packer tool.
Still another object of the invention is to provide a packer tool having a molded seal in the rubber mandrel to selectively seal the packer tool when the tool is set.
It is a further object of the invention to provide a packer tool having a lower cone collet for setting the lower slips and allowing retrieval of the lower drag body during removal of the tool.
It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a side plan view of the production packer tool according to a preferred embodiment of the present invention.
FIG. 2 is a side elevation view of the collet according to the preferred embodiment of the invention.
FIG. 3 is a diagrammatic view of the J tool slot according to a preferred embodiment of the present invention.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) The present invention relates to aretrievable packer tool100. Illustratively, a production packer tool is shown which has as its main purpose to be installed in a wellbore to seal the zone above the packer from the zone below the packer. Since conditions around the well bore can change, the packers may have to be moved, removed, or reinserted. Since the tools are positioned a great distance below the earth and the size of the wellbore is extremely small, it is impractical to send a man to retrieve the tools. The distances also make it a major undertaking to send any tool in to manipulate the tool. The size and distance between the operator and the tool and the limited room to manipulate the tool inside the wellbore leave only a few kinds of motion that can be used to act on the tool to change the orientation or operation of the tool. Among these ranges of actions available are pushing downward on the tool, lifting upward on the tool, clockwise or counterclockwise rotation of the tool and a combination of these movements.
The limited movements have necessitated that the tools have complex actions built into them so that when a certain sequence of the above actions are taken, the tool will perform one of its several intended functions such as setting, running, or releasing. The current invention represents a simplification of the manufacture and arrangement of the tool, while still allowing the tool to be selectively run into a hole, set at the desired location and released using only the limited range of control movements from the operator. Prior art devices have relied on a number of shear pins arranged to fail as the downward forces on the tool increased to shear the pins in a predetermined sequence to initiate different reactions by the tool. Elimination of complex parts and the rearrangement of parts according to the present invention represent a substantial savings in the cost of manufacture as well as the size and reliability of the tool.
As shown inFIG. 1, the tool is divided into several major parts, the tubing110, theupper slip body120, the lower drag block body130 (which is also the “lower slip body”), and the rubber mandrel assembly (“packer body”)140. Though these demarcations are only for illustrative purposes as the parts overlap somewhat by necessity as will be hereinunder explained.
The tubing includes atop sub1 connected to an inner mandrel4 upon which all of the other components, including therubber mandrel body140, are mounted. The center of the tool is therubber mandrel body140 which includes preferably twopacker elements13, though more or less elements could be used depending on the location and requirements. The packer elements are made of extremely durable rubber or similar compositions and are expanded outwardly to engage the inner wall of the well bore when therubber mandrel body140 is compressed (“packed off”).
At either end of the rubber mandrel assembly is theupper cone11 andlower cone20. The purpose of the cones is to expand theslips8,27 outwardly to lock the upper andlower slip bodies120,130 into position about the rubber mandrel assembly as will be explained further below.
Between the upper andlower cones11,20 is located thepacker elements13. The packer elements are held securely between tworetaining rings15,16 and are separated by a cylindrical or ring-shaped spacer14. Preferably the retaining rings and the spacer are each made of steel or similar material so that during compression of the rubber mandrel assembly, only the packer elements compress to maximize the outward expansion of the elements. When thepacker elements13 are forced outwardly they seal against the internal surface of the well bore to provide a seal between portions (“zones”) of the wellbore above the packer elements and below the elements until the packer elements are released from the compressive forces thereon.
Thepacker elements13 are positioned radially outward from a steel rubber mandrel12 which locates therubber packer elements13 between theretaining rings15 andspacer14 and ensures that the packer elements can only expand outwardly during setting. The rubber mandrel12 is preferably also made of steel to resist any inward force of thepacker elements13.
The rubber mandrel12 has an overall length less than the cavity inside the upper andlower cones11,20 when the cones are un-compacted. Thus normally the rubber mandrel is unexpanded when the cones are in their “relaxed” state. As shown inFIG. 1, as the rubber mandrel assembly is compressed, thecones11,20 can compress towards each other until theinternal shoulder144 of thelower cone20 contacts the lower end of the rubber mandrel12. This distance controls the amount of compression (“pack off”) of the rubber elements. However, when the rubber mandrel assembly is not in compression or when the compression is released, thepacker elements13 will return to their original shape forcing the cones apart from each other and withdrawing thepacker elements13 from the wall of the wellbore unsealing the zones above the packer elements from those below the packer elements.
In order to compress the packers, which is the main function of the other parts of the tool, an upper andlower slip body120,130 are provided at either end of the rubber mandrel body. The lower slip body, also called thelower drag body130, is slidingly secured to atubular extension146 of therubber mandrel assembly140. A release collet148 (FIG. 2) provided at the end of the tubular extension allows the tubular extension146 (FIG. 1) to be interference fit with thelower drag body130.
As shown inFIG. 2, thecollet148 at the termination of thetubular extension144 is formed by a number of axially slots around the circumference of the tubular extension to form separate fingers of the collet. The axially slots allow the tubular extension to be compressed during insertion into thelower drag body130. Eachfinger150 ends in an outwardly turnedneck portion152 which acts as a lock in conjunction with aninternal shoulder154 of thelower drag body130. When the mandrel (“tubing”)4 is inserted through therubber mandrel assembly140 and though thelower drag body130, theneck152 of the collet thus cannot pass by the shoulder of the lower drag body without compressing inwardly. However, the collet cannot compress inwardly because of the close fit between the mandrel4 and thetubular extension146. This locks the lower mandrel on the rubber mandrel to ensure that drag body is retrieved with the rubber mandrel assembly, but allows the lower drag body to slide along the tubular extension between the neck of the collet on the tubular extension and the lower cone of therubber mandrel assembly140.
The lower drag body is so called because it contains thedrag body21. Drag bodies are well know in the art and as shown inFIG. 1 includes aninternal spring22 urging thedrag block21 outwardly. The spring strength is chosen such that the drag block provides a moderate amount of friction between the drag body and the inner wall of the well bore while allowing the tool to be tripped down the wellbore (“inserted”). The purpose of the drag blocks, as is well know, is that it allows the drag block to be manipulated by turning or otherwise acting on the drag block when thepacker tool100 reaches the proper depth in the wellbore.
Thedrag block body130 also includeslower slips27 and aJ pin25. The slips are well known as shown aselements27 and57 in the Morgan patent which has been incorporated herein by reference. The slips of the present invention are mounted in thedrag body130 by inserting the head of the slip into an opening in the drag body sized to receive theslip27 as shown in parent application Ser. No. 10/345,229, filed Apr. 18, 2003. The tail end of the slip extends beyond the upper end of thelower drag body130 such that onerib156 of thedrag body130 is trapped in a pocket of the slip body. Intermediate the slip and the rib of the drag body is a spring for urging the slip away from the rib and inwardly away from the wellbore. This spring acts to retract the slip into the position shown inFIG. 1 when the tool is being run in (“inserted”) into the well bore to reduce the force necessary to insert the packer tool into the wellbore.
When thelower drag body130 is caused to slide along thetubular extension146 towards thelower cone20 of therubber mandrel assembly140, the slips are brought into contact with thelower cone20. An inner edge of theslips27 is tapered inwardly to form a cone in conjunction with the other slips of nearly mating shape to thelower cone20. As the lower drag body further approaches the rubber mandrel assembly, the interaction of the slips with thelower cone20 causes the slips to expand outwardly compressing the slip spring between the slip and the lowerdrag body rib156.
The slips continue to extend outwardly as it rides up the lower cone of the rubber mandrel assembly until it is brought into contact with the inner surface of the well bore. Teeth along the tail of the slip help lock the slip into position with the well bore to trap thedrag body130 into set position along the well bore. Likewise a mirror image set ofupper slips8 are installed in a like manner in theupper slip body120 and operate in a like manner.
TheJ pin25 provided in the lower drag body which controls the relative motion between thelower drag body130 and therubber mandrel assembly140 and likewise the travel of the lower drag body along thetubular extension146 of the rubber mandrel assembly. As best shown diagrammatically inFIG. 3, aJ slot160 is provided on an outer surface of the mandrel4 radially inward from thedrag body130.
The J pin is selected to be of sufficient length to ride within the J slot of the mandrel to control the motion of the drag body between several positions. Afirst position162 is provided for run in (“insertion”) of the tool where the pin is in a position in the slot furthest from the rubber mandrel assembly. Thelower drag body130 is run in while separated from the lower cone of the rubber mandrel to prevent the lower slips27 from extending and impeding progress of the packer tool's insertion into the well bore. However, the drag blocks will still be in contact with the well bore to allow the tool to be manipulated as it is inserted.
The J pin has asecond position164 at the topmost portion of the J slot closest to the packer. This is the maximum compression (of the mandrel) resulting from placing the most downward compression on the tubing during setting. When the J pin is in this position, the rubber mandrel assembly and the lower drag body are in close contact with both thepacker elements13 expanded and theslips27 expanded in contact with the well bore. However, it is not necessary to be in this extreme position to fully seal the bore. Because of the split axis of the J slot, releasing the tension or even putting the tubing in tension (i.e., pulling on the tubing) will cause the J pin to move to athird position166 where the tubing is in tension, but the rubber mandrel assembly is still in compression (“packed off”) and thepacker tool100 cannot be accidentally released solely by upward tension on the tubing. All along the J slot between thetension position166 and thecompression position164 the tubing can be manipulated while the packers remain packed off.
Only when the J pin is between afourth crossover position168 and arelease position170 can the packing elements be released or set as will be described further below in the “operation” section. This provides the packer tool to be locked in its set position with the tubing in either tension, compression or a neutral position between the two.
Theupper slip body120 has a number ofupper slips8 arranged about its lower periphery which have the same configuration and operation as the lower slips27 and interact with theupper cone11 in the same way that the lower slips interact with thelower cone20. However, no drag block or J pin need be provided, as will be described below.
Theupper slip body120 contains aspring cage3 andspring6. The spring is located between thetop sub1 and apush sleeve5. The push sleeve includes a wall172 to absorb the force of the top sub directly when the pressure of the top sub on theupper slip body120 exceeds the force of thespring6 to protect the spring and to allow more force to be applied directly to the packer tool from the tubing.
Operation of the Packer Tool
In operation of thepacker tool100, the tool is assembled above ground for run in into the well bore. Thelower drag body130 is inserted over thecollet148 andtubular extension146 of therubber mandrel assembly140. The rubber mandrel and lower drag body are inserted onto the mandrel4. TheJ pin25 is inserted into theJ slot160. The J pin is moved along the slot until it is position in the run inposition162. Theupper slip body120 is then inserted over the mandrel4.Top sub1 is then threaded onto the mandrel securing the upper slip body in place.
The top sub is then affixed to the rest of the tubing on the tubing string for insertion into the well bore. With thepacker elements13 retracted and the upper andlower slips8,27 retracted, thetool100 is inserted into the wellbore with only the drag blocks contacting the outer wall. It should be noted that as the tool is run in, the weight of the upper slip body will tend to force theslips8 downwardly ontocone11 forcing the slips out against the wall of the wellbore which could result in premature setting of the slips. However,spring6 will allow the slips to withdraw away from the cones before any significant friction develops between the slips and the wall. As soon as theslips8 catch on the wellbore, the upward force of the wall on the slip will causespring8 to compress againsttop sub1 allowing the slips to withdraw upwardly from thecone11 thereby retracting the slips from the wellbore before significantly impacting the run in of the tool. The tool can thus be run in to the well bore until it reaches the desired depth where the packer seals are to be deployed to seal the zone below the tool from the zone above the tool.
When the proper depth is reached, it is necessary to set thepacker elements13. To set the packer elements, the upper and lower slips must be deployed to put the rubber mandrel assembly into compression to compress thepacker elements13 outwardly.
The transition from run in to setting (and to retrieval) is the function of thelower drag body130 by moving upwardly into therubber mandrel assembly140. However, this relative motion is prevented by theJ pin25 locking the lower drag body in place along the mandrel while the packer is prevented from moving towards the rubber mandrel assembly by the interaction of retainingring19 against shoulder174.
TheJ pin25 must be moved from the run inposition162 to thecrossover position168 to allow the lower drag body to slide along the rubber mandrelassembly tubular extension146 so that the slips can contact thelower cone20 to deploy the slips against the wall of the well bore. To achieve this, an initial tension is placed on the tubing by “picking up” on the tubing after the wellbore has been positioned at the proper depth. After halting the progress of the tool in the well bore, quick pressure on thetool100 through the tubing will cause the mandrel4 to move upwardly relative to lower drag body which is inhibited from moving freely by drag blocks21. Since the J pin is installed in the lower drag body, the J pin likewise will move downwardly relative to the mandrel4.
The drag blocks21 will slow the progress of the tool in the well bore sufficiently to allow this relative motion between the drag body and the mandrel by frictionally “dragging” the drag blocks against the well bore wall while the mandrel is under no such friction. With the pin thus moving downwardly in theslot160 of the mandrel to its bottom dead position, the tubing can be rotated to free the pin from the run in position. Without this initial “pick up” the pin would be prevented from rotating relative to the slot by the shoulder165 thereby preventing the tool from prematurely setting.
During this initial rotation the tubing is preferably rotated about one quarter turn to the right (moving the pin one quarter turn left relative to the slot). By setting down which will put the tubing in compression, the pin will be caused to travel upwardly relative to the slot as the mandrel is lowered. With thelower drag body130 free to travel relative to the mandrel, therubber mandrel assembly140 will travel downwardly with the mandrel causing thelower cone20 to slide behind the lower slips27 forcing the slips outward into contact with the well bore as described above. As best shown inFIG. 3, the right hand pressure on the tubing110 should be released to allow the mandrel to rotate back to the left as the tubing is continued to be compressed (“pushed downwardly”). TheJ pin25 will follow along the wall of theJ slot160 causing the mandrel to move leftward as the J pin moves from thecrossover position168 into the upper slot between thetension position166 andcompression position164.
The compressive (“downward”) force on the tubing will cause the top sub to travel downwardly compressing thespring6 until the top sub touches the push sleeve wall172. At the same time theupper slip body120 will travel downwardly until contacting therubber mandrel assembly140. Because the rubber mandrel assembly will provide relatively little resistance to the upper slip body, the rubber mandrel assembly will move downwardly before the slips can fully deploy as they contact theupper cone11. As more pressure is placed on the tubing the rubber mandrel assembly will continue to travel towards thelower drag body130 further extending the slips into the wellbore fixing the lower drag body in position. Teeth may be provided along the tail of theslips27 to further lock the slips against sliding along the wellbore wall.
As the J pin travels past the cross over position, the rubber mandrel assembly will continue to compress against the lower drag body which is now fixed in position and cannot travel further downwardly with the slips locked against the wall. When the rubber mandrel assembly is locked against the lower drag body, pressure of the tubing on theupper slip body120 will cause the upper slip body to contact theupper cone11 of the rubber mandrel assembly. The pressure of the tubing will compress thespring6 until the top sub compresses the spring entirely within the push sleeve wall172 so that thebottom shoulder180 contacts the wall172 of thepush sleeve5. This will allow for a full transfer of the force onto theupper slips8 to push them into theupper cone8 and will at the same time force the further compression of the rubber mandrel against the lower slips and lower drag body.
The rubber mandrel177 inside the rubber mandrel assembly (“inner mandrel sleeve”) will move under compression towards theinner shoulder144 of thelower cone20 as the rubber mandrel assembly is compressed (“packed off”). This will cause therubber packer elements13 to be compressed as theupper cage ring16 on theupper cone11 moves towards thespacer14 and lower cage retaining ring (“rubber retainer”)15. The packer elements will expand outwardly (“pack off”) as they are compressed radially until they contact the wellbore wall.
The rubber mandrel assembly will be prevented from re-expanding as the upper slips lock into the wall of the wellbore (as described above) locking the mandrel in compression between theupper slip body120 and thelower drag body130. Further, the lost motion provided by thespring6 in the upper slip body will allow the upper slip body to reduce the pressure on the slips whenever some of the pressure is released from the top sub or if the pressure on the top sub was not sufficient to fully compress the spring during the run in.
This will seal the zone above the packer elements from the zone below the packer elements on the outside of the packer tool. The sealing of the inside of the packer tool is accomplished by the molded seal17.
During run in, it is desirable to maintain equal pressure across the packer tool to prevent pressure build up from retarding the insertion or removal of the packer tool in the well bore. Apressure equalizing channel176 is provided by the spacing between the mandrel4 and the inner mandrel sleeve12. A seal17 selectively closes the channel when the packer tool is set and opens the channel when the tool is being run in. Ashoulder178 located along the mandrel is dimensioned to contact the seal as the mandrel moves downwardly relative to the rubber mandrel assembly. During run in, gravity causes therubber mandrel assembly140 to move downward relative to the mandrel until the retainingring19 rests against mandrel shoulder174. This allows thechannel176 to remain open allowing pressure equalization across therubber mandrel assembly140. When the J pin moves inslot160 as explained above into the cross overposition168 and the set position between166 and164, the mandrel will have moved downwardly relative to the rubber mandrel assembly as the rubber mandrel assembly contacts and is stopped by the lower drag body. The movement of the mandrel will forceshoulder178 against seal17. Preferably the should178 is sloped and more preferably is sloped at an angle of 20 degrees to cause the seal17 to compress to increase the sealing force of the seal against the shoulder. Preferably the seal is part metal and part rubber to withstand the forces on the seal and to maintain the integrity of the seal. And preferably the seal has a pair of o-rings18 formed about its periphery to aid in sealing. The seal may also be bonded to the inside of the rubber mandrel12 to securely locate the seal. The use of the pressure equalization channel interior to the tool eliminates the need for providing a section of the mandrel body to accomplish the same task thereby reducing the overall length of the tool and lowering production and installation costs.
This interaction will complete the internal sealing of the zone above the rubber mandrel assembly with the zone below. Since thepacker elements13 have packed off during the same downward mandrel movement, a complete seal of the zones around the packer elements and rubber mandrel assembly will exist.
At this point the tubing is in compression as the tubing is pressed down to compress the rubber mandrel assembly. The J pin should be at or near the topmost position164 or the “compression position.” Lifting the tubing will cause the pin to travel downward to the “tension position”. The J slot will prevent the mandrel from being released enough to free the lower slips and pressure provided byspring6 will ensure that the upper slips stay locked into the wellbore allowing thecones11 to be pulled into the upper slips locking them more securely against the wellbore wall. Thus thepacker elements13 and therubber mandrel assembly140 will be locked in compression between theupper slip body120 and thelower drag body130. At any point with the J pin locked between compression andtension positions166,164, including the neutral point, the packer tool will remain packed off.
To add more compressive force to the rubber mandrel assembly, the above process can be repeated to further lock (“land”) the rubber mandrel assembly in compression between the upper andlower slips8,27 by “snugging” the slips closer to the cones in successive application of tension and compression on the tubing.Spring6 will provide a force on the upper slips to prevent their total release as long as J pin is prevented from returning past thecrossover position168.
Removal (“Tripping Out”)
To release the tool and to rejoin the zones above and below the packer tool, the J pin must be manipulated in the slot to allow the parts to move relative to each other. As shown inFIGS. 1 and 3, theJ pin25 must be moved to the left to allow the J pin to return past thecrossover position168 down to therelease position170. Therefore a light compressive force (preferably about 100 pounds) is applied to the tubing while the tubing is turned one quarter turn to the right to align theJ pin25 with the elongated axial slot of the J slot. The tubing is then lifted causing the mandrel to move upward relative to the J pin, thereby causing the J pin to follow the J slot downwardly.
This upward motion of the mandrel relative to the upper slip body, the rubber mandrel assembly and the drag body will first cause a sequential release of the tool as will now be described. Thepressure equalization channel176 will be opened as theshoulder178 is withdrawn upwardly from the seal17 opening the lower mouth of the channel.
Spring6 will also expand as thetop sub1 is pulled upward. Thelower shoulder180 of thetop sub1 will pull the top part (“spring cage cap”)2 of the spring cage upward releasing the slips from theupper cone11 and from the well bore wall allowing the slips to withdraw into theupper slip body120. A releasing slip9 may be used to aid in the release of the slips as is well known and described in U.S. Pat. No. 4,530,398 issued Jul. 23, 1985 to Greenlee et al. and which is incorporated herein by reference.
With the top of therubber mandrel assembly140 free, the rubber mandrel assembly can expand releasing thepacker elements13 as the mandrel inner sleeve12 moves away from thewall144 and the packer element returns to its unexpanded position.
As therubber mandrel assembly140 moves out of contact with the lower drag body as the mandrel urges the mandrel upward, the lower slips will release from the well bore wall. Thelower neck152 of the collet will then contact the internal shoulder of the lower drag body pulling thelower drag body130 upward with the rest of the tool releasing the tool from the wellbore where it can be tripped out of the hole for reuse at a later time.
As a further safety device, should theJ pin25 andJ slot160 become inoperable, the J pin is preferably formed as a shear pin which will separate under a predetermined force to allow the tool to be released in the method described above without moving the J pin within particular course of the slot. It should be noted that prior art devices have used J tools (see for instance the Morgan U.S. Pat. No. 5,197,547), but the relocation of the J tool from the lower drag body to the mandrel location results in significant reduction in the overall length of the tool saving tooling costs, transportation costs and installation costs, etc. while increasing the reliability of the tool.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.