USRE36723E - Spoolable coiled tubing completion system - Google Patents

Abstract

A coiled tubing completion system is provided with a plurality of completion apparatus, all of which is designed flush with the diameter of the coiled tubing outside diameter for avoiding upsets and are flexible, spoolable on a coiled tubing reel and having through bores large enough to pass wireline tools for performing other operations. The spoolable coiled tubing system may use standard coiled tubing well control equipment and can be used in live wells. The flush, flexible, spoolable and through bore completion equipment may include a tubing retrievable safety valve, an annular control valve, concentric gas lift valves, a zone packer, a landing nipple, a sliding sleeve, and may include at the end a non-flexible but flush and open bore production packer and pump out plug. The completion system may be retrieved through a retrieval system.

Description

BACKGROUND OF THE INVENTION

The present invention is directed to a method and apparatus for completion or recompletion of oil and/or gas wells with spoolable, flexible coiled tubing and retrieving the same.

In place of conventional drilling rigs or workover rigs, completions or recompletions of conventional oil and gas wells by coiled tubing have been disclosed in U.S. Pat. No. 4,844,166. However, the various completion equipment utilized, such as safety valves, gas lift mandrels and packers are rigid tools placed in the coiled tubing while the coiled tubing is being inserted into the well. In addition, the various completion equipment components are of a larger diameter than the coiled tubing (called upset). Since the completion equipment is rigid and has a larger outside diameter than the coiled tubing, these characteristics prevent the completion equipment from being run through a coiled tubing injector head. Therefore, equipment including windows must be provided to couple and splice this type of completion equipment in the coiled tubing string under the injector head. Furthermore, various specialized well control equipment, such as pack-offs and BOP stacks, were required because of the external upsets in the installation. Such installations were much more complicated to operate and required additional equipment when used with live wells which need to be pressure balanced.

The present invention is directed to a coiled tubing completion system which utilizes a continuous flush outside diameter length of coiled tubing and various completion components. The coiled tubing and the components are flexible and may be spooled onto a reel into lengths as long as 25,000 feet. The spool of coiled tubing and components is transported to the well site by a motorized vehicle and may be continuously injected into the well bore. As injection is occurring, a seal of well bore pressure may be more easily maintained around the circumference of the coiled tubing and components allowing the entire length to be placed in the well bore without a killing operation, eliminating the need for expensive kill fluids or damaging the formation. Included in the coiled tubing are various completion equipment, such as safety valves, annular control valves, concentric gas lift valves, packers, landing nipples, and sliding sleeves which are provided with an outside diameter flush with the coiled tubing outside diameter and which are flexible, spoolable, and with through bores large enough to pass wireline tools for various well completion operations. In addition, some of this equipment, such as safety valves and annular control valves are hydraulically operated through a hydraulic control conduit which must not be upset to the outside diameter of the coiled tubing or interfere with the through bore of the coiled tubing. The coiled tubing completion system is simplified and cost is reduced since well control equipment that is normally required for handling external upsets in a production tubing is not required.

SUMMARY

The present invention is directed to a spoolable, flexible coiled tubing completion system which includes a flexible coiled tubing having an outer wall and a bore therethrough in which the outer wall has a continuous outer diameter without upsets and the bore is adapted to pass wireline tools. The system may include one or more of the following completion components: a longitudinally flexible safety valve, a longitudinally flexible annular control valve positioned in the coiled tubing, one or more longitudinally flexible gas lift valves positioned in the coiled tubing, a longitudinally flexible isolation packer positioned in the coiled tubing, a longitudinally flexible landing nipple positioned in the coiled tubing, a longitudinally flexible sliding sleeve positioned in the coiled tubing, a production packer and a pump out plug. All of the above include a bore therein for passage of wireline tools and have an outside diameter flushed with the outside diameter of the coiled tubing. The safety valve and annular control valve each have a hydraulic control line extending upwardly within the outer wall of the coiled tubing but adjacent the outer wall for avoiding interference with the passage of wireline tools through the coiled tubing bore.

A still further object of the present invention is the provision of a coiled tubing hanger supporting the coiled tubing, a control line housing positioned above the coiled tubing hanger for receiving the upper end of the coiled tubing and for connection to the hydraulic control lines, and an internal connector gripping means having an outside diameter no greater than the coiled tubing for longitudinal movement into the interior of the top of the coiled tubing. In one embodiment, a hydraulic control line cutting means is positioned in the control line housing for cutting any hydraulic control line. In addition, holding means may be provided in the control line hanger for holding the hydraulic control line in tension whereby any cut lines will retract in the coiled tubing and out of the way of the internal connector.

Yet a further object of the present invention is the provision of movable centralizing means in the control line housing for engaging and aligning the top of the coiled tubing for engagement by the internal connector.

Still a further object of the present invention is the provision of a coiled tubing safety valve having a housing secured to the coiled tubing, a valve closure means in the passageway moving between open and closed position for controlling the fluid flow through the passageway, a flow tube telescopically moving in the housing for controlling the movement of the valve closure member, hydraulic piston and cylinder fluid actuating means positioned above and connected to the flow tube with a biasing spring means positioned about the flow tube and connected thereto for moving the valve to a closed position. The spring means and the flow tube are longitudinally flexible for allowing bending about the longitudinal axis of the valve for allowing the valve to be spooled on a coiled tubing reel. Preferably, the hydraulic actuating means is connected to the flow tube by a flexible connection. Preferably, a downstop is connected to the inside of the coiled tubing for limiting the movement of the flow tube. In one embodiment, the coiled tubing includes a wall and a hydraulic control line is connected to the hydraulic piston and cylinder actuating means and is positioned in the wall of the coiled tubing. The longitudinally flexible valve is provided longitudinal flexibility by having a housing which includes first and second separated parts secured to the inside of the coiled tubing, and includes a plurality of separated longitudinally extending ribs.

Yet a further object of the present invention is the provision of a hydraulically controlled annular control valve having a housing with an expandable flexible cup seal having a sealing lip and positioned around the housing for sealing between the housing and a well conduit, hydraulic piston and cylinder means for retracting the cup seal, expandable slip means positioned around the housing for gripping the interior of the well conduit and a second hydraulic piston and cylinder means for expanding the slip means. The flexible cup and the slip means are initially retracted to an outer dimension substantially equal to the outside diameter of the coiled tubing and the control valve for passing through an injector and wellhead. The control valve is longitudinally flexible for allowing bending about its longitudinal axis for allowing the valve to be spooled on a coiled tubing reel. Preferably, the annular control valve includes a longitudinally movable protector sleeve initially covering and protecting the seal lip, spring means biasing the cup seal into a fail safe expanded sealing relationship, movable wedge means for expanding the cup seal, a second spring means for biasing the cup seal toward a retracted position, and a breakable protective covering initially positioned about the cup seal and the slips.

Still a further object of the present invention is the provision of a spoolable, flexible hydraulically set, straight pull release well packer positioned in the coiled tubing and including a mandrel having a bore therethrough for the passage of wireline tools, an expandable packer seal positioned about the mandrel, expandable slip means positioned about the mandrel in which the packer seal and slip means are initially retracted to an outer dimension substantially equal to the outside diameter of the coiled tubing. Hydraulic piston and cylinder actuating means are positioned outside the mandrel and between the packer seal and the slip means for setting the slip means in the packer seal. The well packer is longitudinally flexible for allowing bending about its longitudinal axis for allowing the packer to be spooled on a coiled tubing reel. Preferably, the piston and cylinder actuating means is longitudinally flexible and a breakable protective coating is initially positioned around the packer and the slip means.

Still a further object of the present invention is the provision of a spoolable, flexible landing nipple positioned in a coiled tubing for receiving well tools which includes first and second separate spaced tubular members in which the members each have a bore extending therethrough for the passage of wireline tools. Each of the members is secured to the inside of the coiled tubing and a flexible boot is positioned between each of the members and the inside of the coiled tubing. Preferably, one of the members include a no-go shoulder and a locking recess and the other of the members includes a polished bore.

Yet a still further object of the present invention is the provision of a spoolable, flexible sliding sleeve positioned in a coiled tubing for controlling communication between the inside and the outside of the coiled tubing. The sleeve includes a tubular housing having a bore therein for the passage of wireline tools and has first and second ends connected in a coiled tubing. The housing includes at least one port for communicating between the outside and inside of the housing. A sliding tubular member telescopically moves in the housing for opening and closing the ports. An upper and lower guide is positioned on opposite sides of the member and secured to the inside of the coiled tubing, and a flexible boot is positioned between each of the guides and the inside of the coiled tubing wherein the sliding sleeve is longitudinally flexible for allowing the sliding sleeve to be spooled on a coiled tubing reel.

A still further object of the present invention is the provision of a retrievable system for retrieving a coiled tubing system having a continuous sized outside diameter which includes a coiled tubing hanger supporting and sealing the outside of the upper end of the coiled tubing with a wellhead, a blowout preventer and an injector head successively positioned above the coiled tubing hanger, and a second coiled tubing positioned on a reel and having a first end with a longitudinally actuated internal gripping connector attached thereto for insertion through the injector, blowout preventer and wellhead and into the upper end of the first coiled tubing for gripping and removal the tubing from the well.

Yet a further object is the provision of a control line housing positioned above the coiled tubing hanger for receiving the upper end of the first coiled tubing and for connection to any hydraulic lines in the first coiled tubing. Preferably, a hydraulic control line cutting means is positioned in the control line housing for cutting any control lines for preventing the control lines from interfering with the internal gripping connector. Preferably holding means are provided in the control line hanger for holding the hydraulic control lines in tension whereby a cut line will retract in the first coiled tubing housing and out of the way of the internal connector. Preferably centralizing means are provided in the control line housing for engaging and aligning the top of the first coiled tubing for engagement by the internal connector. Preferably the centralizing means is transversely movable in relation to the longitudinal axis of the control line housing. Preferably the centralizing means includes a guide for guiding the internal connector into the top of the first coiled tubing.

Other and further objects, features and advantages will be apparent from the following description of presently preferred embodiments of the invention, given for the purpose of disclosure, and taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H, 1I, 1J, 1K, 1L, 1M, 1N, 1O, 1P, 1Q, 1R, 1S, 1T, and 1U are fragmentary elevational views, partly in cross section, and together form a spoolable coiled tubing completion system of the present invention,

FIG. 2 is a cross-sectional view taken along the line 2--2 of FIG. 1D,

FIG. 3 is a cross-sectional view taken along theline 3--3 of FIG. 1F,

FIG. 4 is a cross-sectional view taken along the line 4--4 of FIG. 1A,

FIG. 5 is a schematic elevational view, partly in cross section, of another embodiment of a control line hanger,

FIGS. 6A and 6B are elevational views, in cross section, illustrating the flexible hydraulically controlled safety valve of the present invention in a spooled and closed position,

FIGS. 7A, 7B and 7C is an elevational view, in quarter section of the hydraulic control annular control valve of the present invention in the retracted and spooled position,

FIGS. 8A, 8B, 8C, 8D and 8E are continuations of each other and form an elevational view, in cross section, of the annular control valve of the present invention in position in a well conduit in a closed position,

FIGS. 9A, 9B, 9C and 9D are continuations of each other and form an elevational view in quarter section of the isolation packer of the present invention in a retracted and spooled position,

FIGS. 10A, 10B and 10C are continuations of each other and form and elevational view, in cross section of the production packer of the present invention in the retracted position,

FIG. 11 is an elevational view, in cross section, of the landing nipple of the present invention shown in the spooled position,

FIG. 12 is an elevational view, in cross section, of the sliding sleeve of the present invention shown in the spooled position,

FIG. 13 is a cross-sectional view taken along theline 13--13 of FIG. 8A,

FIG. 14 is a cross-sectional view taken along the line 14--14 of FIG. 8B,

FIG. 15 is an elevational view of a retrieval system connected to the spoolable coiled tubing completion system of the present invention, and

FIGS. 16A and 16B are continuations of each other and illustrate a suitable internal connector for retrieving the coiled tubing completion system of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

While the spoolable coiled tubing completion system of the present invention will be described, for purposes of illustration only as including a tubing retrievable safety valve, an annular safety valve, one or more concentric gas lift valves, an isolation packer, a landing nipple, a sliding sleeve, a production packer and a pump out plug, many completion systems may utilize only some of this equipment depending upon the particular application.

Referring now to FIGS. 1A-1U, the spoolable coiled tubing completion system of the present invention is best seen and is referred to by thereference numeral 10 and is installed and retrieved though a retrieval system generally indicated by the reference numeral 12 (FIG. 15). Thecompletion system 10 is installed and retrieved by theretrieval system 12 which generally includes a mobile truck and power unit 14 having a conventionalcoiled tubing reel 16 which inserts and removes thecompletion system 10 through a guide arch 18, an injector head 20, a blowout preventer 22, a wellhead orvalve 24, acontrol line housing 26, acoiled tubing hanger 28, a tubing hanger 30, and a casing hanger 32.

As will be more fully discussed hereinafter, acompletion system 10 is longitudinally flexible and can be spooled on thereel 16. All of the components have a flush diameter substantially equal to the outside diameter of the coiled tubing, but yet have a bore with a passageway therethrough for passage of wireline tools. Thus, thecompletion system 10 is highly advantageous as it may be inserted into and retrieved with theretrieval system 12 without requiring a window to insert or splice equipment into the coiled tubing and allows the use of standard well control equipment such as the injector head 20, the BOP 22 and any packoffs therein to control annular pressure because of the externally flushed design of thesystem 10. Thus, the installation of the present invention is simplified and cost reduced since well control equipment for external upsets is not required.

Referring now to FIGS. 1A, 1B and 4, a flexible coiledtubing 34 has an outer wall and abore 36 therethrough in which the outer wall has a continuous outer diameter without upsets and the bore is adapted to pass wireline tools. The coiledtubing 34 is supported in the coiled tubing hanger 28 (FIG. 1B) and the top 37 of the coiledtubing 34 extends up into thecontrol line hanger 26 for providing one or more hydraulic control line exits for any hydraulic control lines which are utilized in thecompletion system 10 such as a safety valve and annular control valve, which will be more fully discussed hereinafter. The preferred embodiment is to provide twohydraulic control lines 38 and 40 within and inside the wall of the coiledtubing 34 as more fully described in patent application Ser. No. 08/142,637, filed Oct. 25, 1993, entitled "Coiled Tubing With Control Conduit And Manufacture Thereof" which is hereby incorporated by reference. Thecontrol line hanger 26 is positioned in acontrol line housing 27 which may include a conventionalpressure test plug 29. Additionally, movable centralizing means, such asguides 42, are provided in thecontrol line housing 27 for being transversely movable to the axis of the coiledtubing 34 for supporting theupper end 37 of the coiledtubing 34 during the retrieval process as will be more fully discussed hereinafter. Preferably, theguides 42 include inclined surfaces 44.

Referring now to FIGS. 1C, 1D and 2, a surface control sub-surface spoolable hydraulic control longitudinally flexible safety valve is generally indicated by thereference numeral 46 having a housing which includes first 48 and second 50 separated parts each of which is secured to the inside of the coiledtubing 34 and which forms part of the housing of thesafety valve 46 and thus presents a flush exterior with the remainder of the coiledtubing 34 without requiring any upsets. Thevalve 46 generally includes abore 52 therethrough for the passage of wireline tools, anannular valve seat 54, a valve closure element orflapper valve 56 connected to the housing bypivot pin 58, aflow tube 60 is telescopically movable in the housing through thevalve seat 54 to move theflapper 56 to the open position as best seen in FIG. 1D. When theflow tube 60 is moved upwardly, theflapper 56 is allowed to move upwardly onto theseat 54. Hydraulic piston and cylinder actuating means such as one ormore pistons 62 andcylinders 64 in communication withhydraulic conduit 38 are positioned above and connected to theflow tube 60 by aflexible connection 66, such as a loose tongue and groove connection, for moving theflow tube 60 downwardly and opening thevalve 46. A biasingspring 67 is positioned about theflow tube 60 and connected thereto for moving theflow tube 60 upwardly and into a fail safe closed position. Thespring 67 and theflow tube 60 are longitudinally flexible for allowing bending about the longitudinal axis of the valve for allowing the valve to be spooled onto a coiled tubing reel. Preferably, theflow tube 60 includes a plurality of separated longitudinally extendingribs 68 for providing longitudinal flexibility. In addition, thevalve 46 includes adown stop 70 positioned to engage a stop on theflow tube 60 for preventing excessive column loading in thesafety valve 46. Referring now to FIGS. 6A and 6B, thesafety valve 46 is shown in the closed and spooled condition.

Referring now to FIGS. 1E, 1F, 1G, 1H and 1I, a surface control subsurface annular control safety valve which is longitudinally flexible, spoolable and hydraulically controlled is positioned in the coiledtubing 34 and has abore 74 therein for passage of wireline tools. Thevalve 72 includes ahousing 76 having an outside diameter substantially equal to the outside diameter of the coiledtubing 34. Thevalve 72 includes an expandable,flexible cup seal 78 having a sealinglip 80 and is positioned around thehousing 76 for sealing between thehousing 76 and awell conduit 79 which may be production tubing or well casing. Thevalve 72 also includesslips 82 outside of thehousing 76.

As best seen in FIGS. 7A, 7B and 7C, theannular control valve 72 is longitudinally flexible and theexpandable cup seal 78 and theslips 82 are initially in a retracted position whereby the outside diameter of thevalve 72 is substantially the same as the outside diameter of the coiledtubing 34 whereby thevalve 72 may be inserted through theretrieval system 12. Preferably, the outside of thecup seal 78 is sealed with a thin breakable protective cover such as aheat shrinkable plastic 77, such as sold under the trademark "Teflon" and theslips 82 are initially sealed with a thin breakable protective covering such as room temperature vulcanizedrubber 83. The protective covers on theseal 78 and theslips 82 are for protecting these elements from components in thesystem 12 and also protecting any seals in thesystem 12 from thevalve 72. However, after installation in the well, the protective covers, which are breakable, are broken on expansion of theseal 78 and slips 82. Additionally, a longitudinally movableprotective sleeve 81 initially covers and protects the sealinglip 80 as it is passed downwardly through thesystem 12 and into the well.

Referring again to FIGS. 1E and 1F, hydraulic piston and cylinder means, such as one ormore pistons 84, are movable incylinders 86 and in communication withhydraulic control conduit 40. The hydraulic control means are connected by asleeve 88 to a plurality of wedges 90 (FIGS. 1F and 3). Spring biasing means 92 normally biases the piston and cylinder assembly upwardly moving thesleeve 88 and thewedges 90 upwardly to expand thelip seal 80 against the interior of thewell conduit 94, as best seen in FIGS. 8A-8E (after setting the slips). Actuation of the hydraulic piston andcylinder assemblies 84 and 86 moves thewedges 90 downwardly and allows the flexible cup seal, which may be rubber, to retract by the action ofsprings 93 embedded in theflexible cup seal 78. As best seen in FIG. 1F, with thecup seal 78 in the retracted position, lift gas may be injected down the annulus between theannular control valve 72 and the inside of thewell conduit 79 to downhole gas lift valves which will be more fully discussed hereinafter. And the annulus provides a much greater gas flow area than conventional annular control valves. However, actuation of theflexible cup 78 to the expanded position (FIG. 8B) packs off and seals the annulus between thevalve 72 and the inside of thewell conduit 79. And thelip 80 is pressed into an increasing sealing relationship with the inside of thewell conduit 79 as the annulus pressure therebelow increases.

Prior to expanding thecup seal 78, theslips 82 are expanded and set. Referring now to FIGS. 1F, 1G and 1H, hydraulic pressure is exerted through thebore 74 of the control valve 72 (as will be more fully explained hereinafter through a pump out plug) and hydraulic fluid is exerted through ports 94 (FIG. 1G) between seals 96 (1G) and 98 (1F) to moveelement 100 downwardly which (1) moves theprotective sleeve 81 downwardly away from thelip 80 of thecup seal 78 and wedges theslips 82 outwardly against the inside wall of thewell conduit 79. This sets theslips 82 which are then held in a set position byratchet 102 on themember 100 acting againstratchet teeth 104 on thehousing 76.

Theannular control valve 72 includes mechanically actuated releasing means for releasing thecontrol valve 72 from the inside of thewell conduit 74. Referring to FIGS. 1H and 1I, theinterior housing 76 of thevalve 72 is connected throughdogs 106 to the coiledtubing 34. Asleeve 108 which holds thedogs 106 in place is connected to the coiledtubing 34 by shear pins 110. Thesleeve 108 includes an upwardly facingshoulder 112 which, when jarred by a suitable tool, shears thepins 110, moves thesleeve 108 downwardly, and releases the dogs for allowing thecontrol valve 78 to be lifted and theslips 82 retracted.

Referring now to FIGS. 1J, a longitudinally flexiblegas lift valve 120 is shown connected in the coiledtubing 34. In thecompletion system 10, normally a plurality of such gas lift valves may be provided. Thegas lift valve 120 is more fully disclosed in patent application Ser. No. 08/115623, filed Sep. 3, 1993, entitled "Coiled Tubing Concentric Gas Lift Assembly", and such disclosure is incorporated herein by reference. Thegas lift valve 120 has an outside diameter equal to the outside diameter of the coiledtubing 34, and includes abore 122 for passage of wireline tools and is longitudinally flexible. Generally, thegas lift valve 120 includes ahousing 124 which includes one ormore ports 126 for the admission of gas in the annulus outside of thehousing 12 which is injected into thebore 122 for lifting fluids therein. Thevalve 120 is normally biased to a closed position by a gas chargedcompartment 128 acting on one ormore bellows 130 and 132. Thegas compartment 128 is charged through adill valve 134. Amovable ball 136 and aseat 138 are provided in thehousing 124 in communication with theport 126. The gas chargedcompartment 128 acts to seat theball 136 on theseat 138 by being connected to avalve element extension 140. For opening thevalve 120, lifting gas is injected into theport 126, lifts theball element 136 and allows the gas to pass into thebore 122.

Referring now to FIGS. 1K, 1L, 1M, 1N and 1O, a zone orisolation packer 150 is shown. Thepacker 150 is shown in the set position in FIGS. 1K-1O. Thepacker 150 is shown in its spooled and retracted position in FIGS. 9A-9D. Thepacker 150 includes ahousing 152 connected to the inside of the coiledtubing 34 in which the coiled tubing forms part of the housing for thepacker 150. As best seen in FIGS. 9A-9D, thepacker 150 in its retracted position has an outside diameter equal to the outside diameter of the coiledtubing 34 and thus does not create any upsets. Thepacker 150 also includes abore 154 where passage of wireline tools. Thepacker 150 includes conventional seal means 156 which may be a conventional wire mesh and resilient seal and also includes slip means 158. The seal means 156 and slip means 158 are adapted to expand and engage against the inside of thewell conduit 79. Preferably, the seal means 156 includes a thin breakableprotective coating 157 such as a heat shrinkable plastic such as one sold under the trademark "Teflon". And theslips 158 include a thin breakableprotective coating 159 such as room temperature vulcanized rubber. Thecoatings 157 and 159 are to protect theseal 156 and theslips 158 as they are moved into the well and also protect any seals in thesystem 12. Thereafter, theprotective coatings 157 and 159 will be broken when the seal means 156 and the slip means 158 are expanded into a set position.

Thepacker 150 is a hydraulic set straight pull release packer. Thepacker 150 is set by pressuring up hydraulic fluid in thebore 154 and applying this pressurizing fluid throughports 160 in FIG. 1N which act between piston seals 162 (FIG. 1O) and seal 164 (FIG. 1M). This causes movement of thewedges 166 for extending theslips 158 into engagement with thewell conduit 79 and thereafter compressing the seal means 156 into the set position of FIG. 1L. The seal means 156 and the slip means 158 are held in the set position by aratchet 166 coacting withratchet teeth 168. As shown in FIGS. 9A-9D, thepacker 150 is longitudinally flexible for allowing bending about the longitudinal axis of thewell packer 150 for allowing thepacker 150 to be spooled on a coiled tubing reel. The piston seals 162 and 164 form pistons movable in their respective cylinders between the seal means 156 and the slip means 158 and are longitudinally flexible for assisting in bending of thepacker 150. Thepacker 150 includes shear pins 170 (FIG. 1K) for releasing the seal means 156 and the slip means 158 on an upward pull of the coiledtubing 34 when it is desired to pull thecompletion system 10 from thewell conduit 79.

Referring now to FIG. 1P, thereference numeral 180 refers to a longitudinally flexible landing nipple positioned in the coiledtubing 34 and having abore 182 therein for the passage of wireline tools. The landingnipple 180 is shown in a spoolable position in FIG. 11 for storage on a coiled tubing reel. The landingnipple 180 includes first 184 and second 186 separate and spaced tubular members each having a bore extending therethrough for the passage of the wireline tools. Themembers 184 and 186 are secured to the inside of the coiledtubing 34, such as by welding, and therefore themembers 184 and 186 along with a section of the coiledtubing 34 form a housing for thenipple 180. Therefore, the exterior of thelanding nipple 180 is flush with the coiledtubing 34. Thepart 184 may include a no-go shoulder 187 and alocking recess 188 and thesecond part 186 may include apolished bore 190. Thus, the interior of thelanding nipple 180 is similar to that of a conventional D nipple of Camco International Inc. However, by providingseparate members 184 and 186 thelanding nipple 180 may be made longitudinally flexible and in addition themembers 184 and 186 may be separated from each other by variable lengths to accommodate various types of other well tools. In addition, aflexible boot 192 is positioned between each of themembers 184 and 186 and the inside of the coiledtubing 34 for providing flexibility and provide barriers at each end of themembers 184 and 186 for preventing wireline tool hangups.

Referring now to FIG. 1Q, a spoolable longitudinally flexible slidingsleeve 200 is best seen positioned in the coiledtubing 34 and having abore 202 therein for the passage of wireline tools. The slidingsleeve 200 has a housing including a portion of the coiledtubing 34, afirst end 204, and asecond end 206 connected to the coiledtubing 34. The housing includes one ormore ports 208 for communicating fluid between the outside and the inside of the housing. The slidingsleeve 200 is shown in the spooled and flexed position in FIG. 12.

A slidingtubular member 210 is telescopically movable in the housing for opening and closing theports 208. The ends 204 and 206 are positioned on opposite ends of thetubular member 210. Aflexible boot 212 and 214 is positioned between each of theends 204 and 206, respectively, and the inside of the coiledtubing 34 whereby the slidingsleeve 200 is longitudinally flexible for allowing the slidingsleeve 200 to be spooled on a coiled tubing reel.

Referring now to FIGS. 1R, 1S and 1T, aproduction packer 220 is illustrated in the set position and is shown in the set position in FIGS. 10A, 10B and 10C. Theproduction packer 220 includes abore 222 therethrough for the passage of wireline tools and the packer, in the retracted position, as best seen in FIGS. 10A, 10C includes an outside diameter flush with the outside diameter of the coiledtubing 34. While thepacker 220 is positioned in the coiledtubing 34, it is connected adjacent the lower end of thecompletion system 10 and therefore is not required to be longitudinally flexible when thecompletion system 10 is rolled upon a coiled tubing reel. However, it is important that thepacker 220 have a flush OD for passing through the injector head, packoff and blowout preventer and yet have a bore size for passage of other wireline tools. Thepacker 220 is similar in structure and operation to theisolation packer 150 previously described and is hydraulically set and mechanically released with a straight pull. Thus, thepacker 220 includes packing sealing means 224 and slips 226. Thepacker 220 is set by pressuring up fluid in thebore 222 and applying it through aport 228 to act acrossseals 230 and 232 to actuate the slip means 226 and the seal means 224. Thepacker 220 is then held in the set position by the action of aratchet 234 acting againstteeth 236. A thin breakableprotective coating 238, such as a heat shrinkable plastic, such as sold under the trademark "Teflon", is applied around theseal 224. And a thin breakableprotective coating 240, such as a room temperature vulcanized rubber, is applied around the slip means 226.

Referring now to FIG. 1U, a pump outplug 250 is connected to the lower end of the coiledtubing 34 and includes abore 252 therethrough for the passage of wireline tools. The pump outplug 250 includes an outside diameter substantially equal to the outside diameter of the coiledtubing 34, but the pump outplug 250 is used to pressurize the bore of thetubing completion system 10 by dropping aball 254 onto aremovable seat 256. In addition, the pump outplug 250 may include a no-go shoulder 258 and alocking recess 260 for landing additional well tools therein.

Referring now to FIG. 5, another embodiment of a control line hanger and control line housing is shown as a variation of the embodiment illustrated in FIG. 1A. Like parts to that shown in FIG. 1A are similarly numbered with the addition of the Suffix "a". In FIG. 1A, thehydraulic control conduits 38 and 40 were illustrated as being within the walls of the coiledtubing 34. However, in some installations the control conduit or conduits may be positioned on the inside of the coiledtubing 34a. Such an internal type hydraulic control conduit would interfere with the operation of theretrieval system 12 which will be more fully discussed hereinafter which grips the inside of the top 37a of the coiledtubing 34a. Thus, acontrol line hanger 26a is positioned in a controlline hanger housing 27a in which one or more hydraulic control conduits, here shown as a singlehydraulic conduit 38a extends down the interior of the coiledtubing 34a. Thecontrol line hanger 26a holds thecontrol line 38a in tension, such as an inverted U configuration, and thecontrol conduit 38a is shown exiting thehousing 27a. Thehanger 26a includes a cutting means 39 which, when actuated, such as hydraulically cuts thecontrol conduit 38a which is under tension, and thusconduit 38a springs back into the interior of the coiledtubing 34a and below the top 37a. This clears the inside of the top of the coiledtubing 34a for retrieval operations. Additionally, thecontrol line housing 27a includes movable centralizingguides 42a having guide surfaces 44a for moving inwardly against the outside of the top 37a of the coiledtubing 34a for centralizing thecoiled tubing 34a for insertion of theretrieval system 12.

Referring now to FIGS. 15, 16A and 16B, a system for retrieving thespoolable completion system 10 of the present invention is best seen. Because thetubing completion system 10 has a flush and constant outside diameter without any upsets and is flexible and spoolable, theretrieval system 12 is able to retrieve thetubing system 10 through the injector 20, the blowout preventer 22 and thewellhead 24 and any other packoffs even if the well is live without needing to pressure balance the well as thecompletion system 10 is removed. Theretrieval system 12 includes thereel 16, and a secondcoiled tubing 34b positioned on thereel 16 having at its end a longitudinally actuated internalgripping connector 300 which is longitudinally flexible and has an outside diameter equal to the outside diameter of the coiled tubing so that it may be inserted through the injector 20, the blowout preventer 22 and thewellhead 24 and into theupper end 37 or 37a of the coiledtubing 34 or 34a for gripping and removing thecompletion system 10 from the well. Theinternal connector 300 may be of the type disclosed in patent application Ser. No. 08/013,385, filed Feb. 4, 1993, entitled "Method And Apparatus For Internally Connecting To Coiled Tubing", now U.S. Pat. No. 5,306,050, which is incorporated herein by reference. Generally, theconnector 300, as shown in FIGS. 16A and 16B, is initially positioned, but unset, in the inside of one end of the coiledtubing 34b and 34, shown in dotted outline. Theconnector 300 includes ametal body 316 having afirst end 318 and asecond end 320 and abore 322 therethrough for the passage of fluids. Thebody 316 has an outside diameter 324 of a size no greater than the outside diameter of the coiledtubing 34b and 34. Therefore, thebody 316 does not upset or protrude past the outside diameter of the coiledtubing 34b and 34 and thus passes freely through coiled tubing injector chains, round goosenecks, and on to thecoiled tubing reel 16. Thefirst end 318 of thebody 316 and thesecond end 320 of thebody 316 have an outside diameter substantially equal to the inside diameter of the first and secondcoiled tubing 34b and 34, respectively.

Seal means, such as O-ring seals 326 and 328 are provided on thefirst end 318 of thebody 316 and also on thesecond end 320 of thebody 316, respectively, for sealing between thefirst end 318 and the inside of the firstcoiled tubing 34b and for sealing between thesecond end 320 of thebody 316 and the inside of the second coiledtubing 34, respectively.

In the preferred embodiment, the outside diameter of the metal part of thebody 316 is substantially equal to the inside diameter of the coiledtubing 34b and 34 which allows thebody 316 to be thin and flexible and spoolable. A plastic coating 324, such as sold under the trademark "Halar 200" is bonded to the exterior of thebody 316. The coating 324 has an outside diameter substantially equal to the outside diameter of the coiledtubing 34b and 34.

Afirst mandrel 330 has afirst end 332 and asecond end 334 and is provided with abore 336 therethrough in communication with thebore 322. Thefirst end 332 of thefirst mandrel 330 includes a plurality ofcollet fingers 333 and coacting ratchet means on the fingers and the inside of thefirst end 318 of thebody 316. Thus, thecollet fingers 333 include a plurality ofratchet teeth 335 which coact withratchet teeth 337 on the inside of thebody 316. Thus, themandrel 330 may ratchet into thebore 322 of thebody 316 but cannot longitudinally move out of thebody 316. Asecond mandrel 340 includes afirst end 342 and asecond end 344 with abore 346 therebetween in communication with thebore 322. Thefirst end 342 of themandrel 340 includes a plurality ofcollet fingers 343. Coacting ratchet means are provided on the outside of thefingers 343 and on the inside of thesecond end 320 of thebody 316. Thus, ratchetteeth 345 are provided on the exterior of thecollet fingers 343 andteeth 347 on the inside of thebody 316. Preferably, theteeth 345 and 347 are coacting threads. Therefore, themandrels 330 and 340 may longitudinally move towards thebody 316, but are prevented from moving away from thebody 316 by the coacting ratchet teeth.

First slip means 350 abuts thefirst end 318 of thebody 316 and is engagable with the outside of thefirst mandrel 330. The slip means 350 includes a plurality of outwardly directedteeth 352 which are preferably directed towards thefirst end 318 of thebody 312 and towards the end of the fist coiledtubing 312. A second slip means 360 is provided abutting thesecond end 320 of thebody 316 and is engagable with the outside of thesecond mandrel 340. The slip means 360 includes a plurality of outwardly directedteeth 362 directed towards theend 320 of thebody 316 and towards the end of the coiledtubing 314. Thus, it is noted that when theslips 350 and 352 are inserted into thecoiled tubings 312 and 314, respectively, the slip means 350 and 352 travels into the ends of the coiledtubings 312 and 314, but not out of the ends of the coiledtubing 312 and 314.

Coacting wedge surfaces are provided on the inside of the first slip means 350 and on the outside of thefirst mandrel 330 such aswedge surface 354 on the slip means 350 andwedge surface 356 on the outside of themandrel 330. The wedge surfaces 354 and 356 wedge the first slip means 350 into the inside of the firstcoiled tubing 312 when thebody 316 is longitudinally pulled out of the end of the coiledtubing 312 thereby pulling themandrel 330 by the coacting engaging ratchetteeth 335 and 337. Similarly, second coacting wedge surfaces are provided on the inside of the second slip means 360 and the outside of thesecond mandrel 340 such aswedge surface 364 on the inside of slip means 360 andwedge surface 366 on the outside ofmandrel 340 for wedging the second slip means 360 into the inside of the secondcoiled tubing 314 when the body is longitudinally pulled out of the secondcoiled tubing 314.

In use, theconnector 300 is made up as best seen in FIGS. 16A and 16B. A longitudinal pull is exerted on thecoiled tubing 34b in a direction to withdraw thebody 300 from the ends of the coiledtubing 34b and 34. The longitudinal force is alternated to provide a compressive force to allow theconnector 300 to longitudinally ratchet together to securely grip the insides of the coiledtubings 34b and 34. After securing theconnector 300 to the coiled tubings, thespoolable completion system 10 may be removed (after thepackers 150 and 220 are unseated) and withdrawn from the well.

The present invention, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned as well as others inherent therein. While a presently preferred embodiment of the invention has been given for the purpose of disclosure, numerous changes in the details of construction, will be readily apparent to those skilled in the art and which are encompassed within the spirit of the invention and the scope of the appended claims.

Claims (31)

What is claimed is:

1. A spoolable flexible coiled tubing completion system comprising,

a flexible coiled tubing having an outer wall and a bore therethrough, said outer wall having a continuous outer diameter without upsets, and said bore adapted for passage of wireline tools,

one or more longitudinally flexible gas lift valves positioned in the coiled tubing and having a bore therein for passage of wireline tools,

a longitudinally flexible packer positioned in the coiled tubing and having a bore therein for passage of wireline tools,

a longitudinally flexible landing nipple positioned in the coiled tubing and having a bore therein for the passage of wireline tools,

a pump out plug connected to the coiled tubing, said plug having a bore therein for passage of wireline tools, and

said gas lift valves, flexible packer, landing nipple, and pump out plug, each having an outside diameter continuous with the outside diameter of the coiled tubing.

2. The completion system of claim 1 including,

a coiled tubing hanger connected to and supporting the coiled tubing,

a control line housing positioned above the coiled tubing hanger for receiving the upper end of the coiled tubing and for connection to any hydraulic control lines, and

internal connector gripping means having an outside diameter no greater than the coiled tubing for longitudinal movement into the interior of the top of the coiled tubing for gripping and retrieving the coiled tubing.

3. The completion system of claim 2 including hydraulic control line cutting means positioned in the control line housing for cutting any hydraulic control line for preventing the control lines from interfering with gripping the coiled tubing.

4. The completion system of claim 3 including,

holding means in a control line hanger for holding the hydraulic control line in tension whereby the cut lines will retract into the coiled tubing and out of the way of the internal connector gripping means.

5. The completion system of claim 2 including,

movable centralizing means in the control line housing for engaging and aligning the top of the coiled tubing for engagement by the internal connector gripping means.

6. The completion system of claim 1 including,

a spoolable hydraulically controlled longitudinally flexible safety valve positioned in the coiled tubing and having a bore therein for passage of wireline tools.

7. The completion system of claim 1 wherein the safety valve includes:

a housing secured to the inside of the coiled tubing, said housing having a passageway extending therethrough for the passage of wireline tools when the valve is open,

a valve closure member in the passageway moving between open and closed positions for controlling fluid flow through the passageway,

a flow tube telescopically moving in the housing for controlling the movement of the valve closure member,

hydraulic piston and cylinder fluid actuating means positioned above and connected to the flow tube,

biasing spring means positioned about the flow tube and connected thereto for moving the valve to a closed position, and

said spring means and said flow tube are longitudinally flexible for allowing bending about the longitudinal axis of the valve for allowing the valve to be spooled on a coiled tubing reel.

8. The completion system of claim 7 wherein the valve includes:

a down stop connected to the inside of the coiled tubing for limiting the movement of the flow tube.

9. The completion system of claim 7 wherein the coiled tubing includes a wall and wherein the safety valve includes:

a hydraulic control line connected to the hydraulic piston and cylinder actuating means and positioned in the wall of the coiled tubing.

10. The completion system of claim 7 wherein the valve housing includes first and second separated parts each secured to the inside of the coiled tubing.

11. The completion system of claim 7 wherein the safety valve flow tube includes a plurality of separated longitudinally extending ribs for providing longitudinal flexibility.

12. The completion system of claim 7 wherein the valve includes hydraulic actuating means connected to the flow tube by a flexible connector.

13. The completion system of claim 1 including,

a longitudinally flexible spoolable hydraulically controlled annular control valve positioned in the coiled tubing and having a bore therein for passage of wireline tools.

14. The completion system of claim 1 wherein the hydraulically controlled annular control valve includes:

a housing having a bore extending therethrough for the passage of wireline tools,

an expandable flexible cup seal having a sealing lip and positioned around the housing for sealing between the housing and a well conduit,

hydraulic piston and cylinder means for retracting the cup seal,

expandable slip means positioned around the housing for gripping the interior of the well conduit,

second hydraulic piston and cylinder means for expanding the slip means,

said flexible cup seal and said slip means being initially retracted to an outer dimension substantially equal to the outside diameter of the coiled tubing, and

said control valve being longitudinally flexible for allowing bending about the longitudinal axis of the control valve for allowing the valve to be spooled on a coiled tubing reel.

15. The completion system of claim 14 wherein the control valve includes:

a longitudinally movable protector sleeve initially covering and protecting the sealing lip.

16. The completion system of claim 14 wherein the control valve includes:

spring means biasing the cup seal into a fail safe expanded sealing relationship.

17. The completion system of claim 14 wherein the control valve includes:

movable wedge means for expanding the cup seal.

18. The completion system of claim 14 wherein the control valve includes:

second spring means for biasing the cup seal toward a retracted position.

19. The completion system of claim 14 wherein the control valve includes:

a breakable protective coating initially positioned around the cup seal and the slip means.

20. The completion system of claim 14 wherein the control valve includes:

mechanically actuated releasing means for releasing the control valve for pulling.

21. The completion system of claim 1 wherein the flexible well packer includes:

a mandrel having a bore therethrough for the passage of wireline tools,

an expandable packer seal positioned about the mandrel,

expandable slip means positioned about the mandrel,

said packer seal and said slip means being initially retracted to an outer dimension substantially equal to the outside diameter of the coiled tubing,

hydraulic piston and cylinder actuating means positioned outside the mandrel and between the packer seal and the slip means for setting the slip means and the packer seal,

said well packer being longitudinally flexible for allowing bending about the longitudinal axis of the well packer for allowing the packer to be spooled on a coiled tubing reel.

22. The completion system of claim 21 wherein the packer piston and cylinder actuating means is longitudinally flexible.

23. The completion system of claim 21 wherein the well packer includes:

a breakable protective coating initially positioned around the packer seal and the slip means.

24. The completion system of claim 1 wherein the landing nipple includes:

first and second separate and spaced tubular members, said members each having a bore extending therethrough for the passage of wireline tools,

said members each secured to the inside of the coiled tubing, and

a flexible boot positioned between each of the members and the inside of the coiled tubing allowing the nipple to be spooled on a coiled tubing reel.

25. The completion system of claim 24 wherein one of the members of the landing nipple includes a no-go shoulder and a locking recess, and the other of the members includes a polished bore.

26. The completion system of claim 1 including,

a spoolable longitudinally flexible sliding sleeve positioned in the coiled tubing and having a bore therein for the passage of wireline tools.

27. The completion system of claim 26 wherein the sliding sleeve includes:

a tubular housing having a bore therein for the passage of wireline tools and connected in a coiled tubing, said housing having at least one port for communicating between the outside and the inside of the housing,

a sliding tubular member telescopically moving in the housing for opening and closing the ports,

said housing having an upper and a lower end positioned on opposite sides of the tubular member and secured to the inside of the coiled tubing,

a flexible boot between each of the guides and the inside of the coiled tubing whereby the sliding sleeve is longitudinally flexible for allowing the sliding sleeve to be spooled on a coiled tubing reel. .Iadd.

28. A spoolable flexible coiled tubing completion system comprising,

a flexible coiled tubing having an outer wall and a bore therethrough, said outer wall having a continuous outer diameter, and

one or more gas lift valves positioned in a longitudinally flexible tubular member attached to said coiled tubing,

said longitudinally flexible tubular member having an outer diameter substantially equal to the outer diameter of said flexible coiled tubing outer wall. .Iaddend..Iadd.29. A spoolable flexible coiled tubing completion system according to claim 28 further comprising,

at least one packer positioned in the coiled tubing and having a bore therein. .Iaddend..Iadd.30. A spoolable flexible coiled tubing completion system according to claim 29, wherein said packer has an outside diameter substantially equal to the outer diameter of said flexible coiled tubing outer wall. .Iaddend..Iadd.31. A spoolable flexible coiled tubing completion system according to claim 28 further comprising,

at least one landing nipple positioned in the coiled tubing and having a bore therein. .Iaddend..Iadd.32. A spoolable flexible coiled tubing completion system according to claim 31, wherein said landing nipple has an outside diameter substantially equal to the outer diameter of said flexible coiled tubing outer wall. .Iaddend..Iadd.33. A spoolable flexible coiled tubing completion system according to claim 28 further comprising,

at least one pump out plug connected to the coiled tubing, said plug having a bore therein. .Iaddend..Iadd.34. A spoolable flexible coiled tubing completion system according to claim 33, wherein said pump out plug has an outside diameter substantially equal to the outer diameter of said

flexible coiled tubing outer wall. .Iaddend..Iadd.35. A spoolable flexible coiled tubing completion system according to claim 28 further comprising,

at least one safety valve connected to said coiled tubing, said safety valve having a bore therein. .Iaddend..Iadd.36. A spoolable flexible coiled tubing completion system according to claim 35, said safety valve comprising,

a longitudinally flexible tubular member having a passageway extending therethrough,

a valve closure member positioned in the passageway,

a flow tube positioned in the passageway,

a flow tube actuator connected to the flow tube,

and a biasing element connected to said flow tube,

wherein said longitudinally flexible tubular member has an outside diameter substantially equal to the outer diameter of said flexible coiled tubing outer wall. .Iaddend..Iadd.37. A spoolable flexible coiled tubing completion system according to claim 28 further comprising,

at least one annular control valve connected to said coiled tubing, said annular control valve having a bore therein. .Iaddend..Iadd.38. A spoolable flexible coiled tubing completion system according to claim 37, said annular control valve comprising,

a longitudinally flexible tubular member having a bore extending therethrough,

a seal positioned around said tubular member,

a seal actuator attached to said seal, and

a slip attached to said tubular member,

wherein said seal and said slip are retractable to an outer dimension no greater than the outside diameter of said flexible coiled tubing outer

wall. .Iaddend..Iadd.39. A spoolable flexible coiled tubing completion system according to claim 28 further comprising,

at least one sliding sleeve connected to said coiled tubing, said sliding

sleeve having a bore therein. .Iaddend..Iadd.40. A spoolable flexible coiled tubing completion system according to claim 39, said sliding sleeve comprising,

a longitudinally flexible tubular member having a bore therein, and at least one lateral port communicating between the inside interior and exterior of said tubular member, and

a sliding tubular member adapted to move through said longitudinally flexible tubular member, .Iaddend.

wherein the outside diameter of said longitudinally flexible tubular member is substantially equal to the outside diameter of said flexible coiled tubing outer wall.

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