Sacrificial protector sleeve

A method of protecting a nipple profile of a downhole tool that forms a portion of a tubing string and that is exposed to through-tubing completion operations includes securing a single-trip protective sleeve to the tool so that the sleeve covers the nipple profile of the tool during the completion operations and dissolving the single-trip protective sleeve so that it breaks away from the nipple profile to expose the nipple profile for use.

PRIORITY

The present application is a U.S. National Stage patent application of International Patent Application No. PCT/US2016/021191, filed on Mar. 7, 2016, the benefit of which is claimed and the disclosure of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to well completion operations and, more specifically, to a sacrificial protector sleeve used to protect interior geometries of a downhole tool during completion operations.

BACKGROUND

After a well is drilled and a target reservoir has been encountered, a completion operation may be performed, which may include gravel packing or hydraulic fracturing. Often, through-tubing hydraulic fracturing or gravel packing may be performed through a tubing string that includes a tool, such as a tubing retrievable safety valve, that has a nipple profile. The injection of fluids during through-tubing completion operations (hydraulic fracturing fluid in the case of through-tubing hydraulic fracturing and a slurry in the case of gravel packing) can cause erosion damage to the nipple profile of the tool. As such, nipple protectors are often placed downhole and secured relative to the tool to fluidically isolate or partially isolate the nipple profile from the injected fluids. These nipple protectors are generally run downhole and set using wireline or coiled tubing. After the injection of fluids is completed, the wireline or coiled tubing will be run downhole again to retrieve the nipple protectors from the nipple profiles.

However, the nipple protectors often do not fluidically isolate the nipple profile from the injected fluids and proppant from the slurry may enter an annulus formed between the nipple protector and the tool. This may result in the nipple protector becoming jammed in the tool and thus prevent successful retrieval of the tool.

DETAILED DESCRIPTION

The foregoing disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” “uphole,” “downhole,” “upstream,” “downstream,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the apparatus in use or operation in addition to the orientation depicted in the figures. For example, if the apparatus in the figures is turned over, elements described as being “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” may encompass both an orientation of above and below. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

FIG. 1is a schematic illustration of an offshore oil and gas platform generally designated10, operably coupled by way of example to a sacrificial protective sleeve according to the present disclosure. Such an assembly could alternatively be coupled to a semi-sub or a drill ship as well. Also, even thoughFIG. 1depicts an offshore operation, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in onshore operations. By way of convention in the following discussion, thoughFIG. 1depicts a vertical wellbore, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in wellbores having other orientations including horizontal wellbores, slanted wellbores, multilateral wellbores or the like.

Referring still to the offshore oil and gas platform example ofFIG. 1, a semi-submersible platform15may be positioned over a submerged oil and gas formation20located below a sea floor25. A subsea conduit30may extend from a deck35of the platform15to a subsea wellhead installation40, including blowout preventers45. The platform15may have a hoisting apparatus50, a derrick55, a travel block60, a hook65, and a swivel70for raising and lowering pipe strings, such as a substantially tubular, axially extending tubing string75.

As in the present example embodiment ofFIG. 1, a wellbore80extends through the various earth strata including the formation20, with a portion of the wellbore80having a casing string85cemented therein. Disposed in the wellbore80is a completion assembly90.

Generally, the assembly90may be any one or more completion assemblies, such as for example a hydraulic fracturing assembly, a gravel packing assembly, etc. The assembly90may be coupled to the tubing string75which includes a downhole tool95having a sacrificial protector sleeve100disposed therein (shown in greater detail inFIG. 2).

FIG. 2illustrates the sleeve100secured, or locked, to the tool95. The sleeve100forms a longitudinally extending fluid passageway105. The sleeve100has an exterior surface110and an interior surface115that defines the passageway105. Annular grooves120and125may be formed within the exterior surface110. The grooves120and125may accommodate sealing elements130and135, respectively. The sealing elements130and135may be o-rings or any other similar device. In one or more exemplary embodiment, one or both of the sealing elements130and135are elastomeric seals. The exterior surface may also form a protrusion or a plurality of protrusions140located axially between the grooves120and125. The annular protrusions140generally correspond with at least a portion of a nipple profile95aformed in the tool95. However, the annular protrusions140may form a portion of a “rest on no-go”, “snap in”, “drop off”, and “lock in” type configurations for securing or locking the sleeve100to any portion of the tool95.

The sleeve100may be composed of a first material that reacts upon exposure to a first liquid. In an exemplary embodiment, the first material is, such as for example, a metal including aluminum, magnesium, zinc, iron, alloys of these metals and the like; a plastic including a polymer; or any combination thereof. In one or more examples, the first liquid may be a completion fluid, production hydrocarbons, a slurry, etc. In one or more exemplary embodiments, the first liquid may be, such as for example, any one of an acid, a carboxylic acid, a sulfonic acid, an organic acid, a sulfuric acid, a hydrochloric acid, a nitric acid, an inorganic acid, an ammonium, a Lewis acid, a base, a hydroxide, a potassium hydroxide, a sodium hydroxide, a strong base, an acetone, a Lewis base, a gasoline, a hydrocarbon, an alcohol, water, and a chloride.

The sealing elements130and135may be composed of the first material or a second material that is different than the first material. In an exemplary embodiment, the sealing elements130and135are dissolvable elastomer o-rings.

The tool95may be a safety valve, such as a tubing retrievable safety valve (“TRSV”), or any other type of tool that has a nipple profile, or other interior geometry, that may be damaged during completion operations or any other type of downhole operations or well intervention activities. Generally, the tool95is composed of a material that is different from the first material of the sleeve100and the second material of the sealing elements130and135.

In operation, the sleeve100is run downhole through an interior passageway of the tubing string75and locked, or secured relative to the tool95using the plurality of protrusions140prior to the fracturing, gravel packing, or other activity. The sleeve100may be locked, or secured relative to the tool95when at least one of the plurality of protrusions140is accommodated or “set” within a corresponding interior geometry of the tool95, such as for example, the nipple profile95aof the tool95. When locked relative to the tool95, the sleeve100isolates and protects an interior geometry of the tool95, such as for example the nipple profile95a, a seal bore95b, etc. Once the sleeve100is locked relative to the tool95, completion operations may begin, such as for example, the slurry may be injected downhole and through an interior passageway of the tubing string75and the passageway105. During completion operations, the interior geometry of the tool95will be isolated or at least shielded from the injected slurry by the sleeve100. The sealing elements130and135prevents or at least discourages the injected slurry from entering an annulus formed between the tool95and the sleeve100, where the annulus is at least partially defined by the interior geometry of the tool95and the sleeve100. After a certain period of time after exposure to the first fluid, the sleeve100is dissolved and/or weakened such that the sleeve100unlocks and breaks away from the tool95. Thus, the sleeve100dissolves into a plurality of pieces that are flushed down the interior passage of the tubing string75to reveal the previously-protected interior geometry of the tool95. In the event that the injected slurry enters into the annulus formed between the tool95and the sleeve100, the injected slurry may be washed away from the tool95by production fluid to allow for full operation of the tool95.

In one or more exemplary embodiments, the sleeve100begins to dissolve and weaken when exposed to the first fluid within the wellbore80, which may be present in the wellbore80prior to the sleeve100locking to the tool95, may be introduced prior to start of completion operations, may be introduced during completion operations, may be introduced after the completion operations, or may be introduced anytime in-between. Regardless, upon the injection of the first fluid through the sleeve100, the sleeve100begins to dissolve and weaken. The first fluid dissolves the sleeve100at a rate such that the sleeve100unlocks at a predetermined time or time range soon after the completion operation is completed. Additionally, the sealing elements130and135may dissolve and weaken to unlock in a similar manner to the sleeve100, although it may occur independently of the type of fluid injected in the wellbore80. In an exemplary embodiment, the dissolution rate of the sleeve100is dependent upon the first fluid and the temperature of the first fluid within the wellbore80. In an exemplary embodiment, the temperature of the first fluid within the wellbore80is between about 80° F. and 300° F.

Thus, the sleeve100protects the internal geometry of the tool95from erosion damage or other types of damage when the injected fluids pass through the tool95at high flow rates that are often associated with completion operations. The sleeve100is a sacrificial sleeve that protects components of the tool95from erosion damage and then dissolves within a predetermined amount of time when exposed to the first fluid. In an exemplary embodiment, the sleeve100does not require retrieval after it is locked relative to the tool95. As such, the sleeve100avoids time spent and costs associated with a nipple protector retrieval. Additionally, the sleeve100avoids costly intervention operations associated with retrieving a protector sleeve that is jammed, or stuck to, the tool95. Accordingly, costs and time spent to retrieve a jammed sleeve100are avoided. Thus, the sleeve100is a single-trip protective sleeve used to protect interior-facing tool components from slurries injected at high flow rates. In an exemplary embodiment and due to the sleeve100dissolving to expose the internal geometry of the tool95, the sleeve100has a tool-less release mechanism or is a self-removing sleeve. As such, mechanical release mechanisms found in conventional protectors are not necessary, which simplifies the design and manufacture (and thus the cost) of the sleeve100.

Exemplary embodiments of the present disclosure can be altered in a variety of ways. In some embodiments, the annular protrusions140generally correspond to a lock profile and/or a no-go shoulder formed within an interior surface of the tool95that is spaced from the nipple profile95aof the tool95. In this exemplary embodiment, the lock profile and/or no-go shoulder may be uphole relative to the nipple profile95aof the tool95. However, the length of the sleeve100extends over the nipple profile95aof the tool95such that the annular groove125and sealing element135extend below, or downhole, from the nipple profile95aof the tool95when the plurality of protrusions140are locked to the lock profile and/or the no-go shoulder of the tool95. Thus, the engagement of the plurality of protrusions140with the nipple profile95ais not required for the sleeve100to protect the nipple profile95a. Additionally, the axial length of the sleeve100may be sized to isolate other tool components, such as for example, a flow tube and flapper, etc.

In an exemplary embodiment, the tool95is a TRSV and the completion operation is through-TRSV cementing. Thus, sleeve100minimizes contact between injected cement and the internal geometry of the TRSV. However, the sleeve100may protect the interior geometry of the tool95from any injected fluid, whether the injected fluid be the slurry as described above in relation toFIG. 2, the cement, a hydraulic fracturing fluid, or other injected fluid whether injected at a high flow rate or otherwise.

In an exemplary embodiment, the interior geometry of the tool95, such as for example, the nipple profile95aand or the seal95b, are interior-facing tool components, which also may include flow tubes, flappers, etc.

In an exemplary embodiment, the sacrificial sleeve100is locked or set in place at the surface of the well. Therefore, the sleeve100is locked to the tool95at the surface of the well and is run downhole with the tool95.

In several exemplary embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In several exemplary embodiments, the steps, processes and/or procedures may be merged into one or more steps, processes and/or procedures. In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.

Thus, a method has been described. Embodiments of the method may generally extending a sacrificial sleeve within an interior passageway of a tool; securing the sacrificial sleeve to the tool such that an interior-facing tool component of the tool is covered by the sacrificial sleeve; passing a first fluid through an interior passageway of the sacrificial sleeve; and dissolving the sacrificial sleeve using the first fluid to uncover the interior-facing tool component. For any of the foregoing embodiments, the completion assembly may include any one of the following elements, alone or in combination with each other:The tool forms a portion of a tubing string that extends within a wellbore; the method further includes injecting a second fluid through a fluid passageway of the tubing string and towards a completion assembly that is coupled to the tubing string; and the interior-facing tool component is shielded from the second fluid when covered by the sacrificial sleeve.The tool is a tubing retrieval safety valve and the interior-facing tool component is at least one of a nipple profile and a seal bore.Securing the sacrificial sleeve to the tool such that the interior-facing tool component of the tool is covered by the sacrificial sleeve includes setting a protrusion formed on an exterior surface of the sacrificial sleeve within a nipple profile that is the interior-facing tool component.The first fluid includes at least one of an acid, an ammonium, a base, an hydroxide, an acetone, a gasoline, a hydrocarbon, an alcohol, water, and a chloride.Sealingly engaging an annular seal with an exterior surface of the sacrificial sleeve and an interior surface of the tool to at least resist fluid flow into an annulus formed between the tool and the sacrificial sleeve.Dissolving the annular seal using the first fluid.The interior-facing geometry is at least one of a nipple profile or a seal bore.The sacrificial sleeve is a single-trip protective sleeve.The first fluid comprises at least one of a completion fluid, a production hydrocarbon, and a slurry.

Thus, a method of protecting a nipple profile of a tool, the tool forming a portion of a tubing string has been described. Embodiments of the method may generally include concentrically disposing a single-trip protective sleeve within an interior passageway at least partially formed by the nipple profile of the tool such that the sleeve covers the nipple profile of the tool; accommodating an external protrusion on the sleeve within the nipple profile of the tool to secure the sleeve to the tool; injecting a first fluid through the interior passageway, wherein the nipple profile is protected from the first fluid by the sleeve; and at least one of: continuing to inject the first fluid through the interior passageway to dissolve the sleeve so that the nipple profile is not covered by the sleeve; and injecting a second fluid through the interior passageway to dissolve the sleeve so that the nipple profile is not covered by the sleeve. For any of the foregoing embodiments, the method may include any one of the following, alone or in combination with each other:The second fluid includes at least one of an acid, an ammonium, a base, an hydroxide, an acetone, a gasoline, a hydrocarbon, an alcohol, water, and a chloride.Sealingly engaging an annular seal with an exterior surface of the sleeve and an interior surface of the tool to at least resist flow of the first fluid into an annulus formed between the tool and the sleeve.Dissolving the annular seal using at least one of the first fluid and the second fluid.The first fluid includes at least one of an acid an acid, an ammonium, a base, an hydroxide, an acetone, a gasoline, a hydrocarbon, an alcohol, water, and a chloride.The first fluid includes at least one of a completion fluid, a production hydrocarbon, and a slurry.

Thus, a single-trip, sacrificial protector sleeve has been described. Embodiments of the apparatus may generally include single-trip, sacrificial protector sleeve for concentric disposal within an interior passageway of a tool having an internal geometry, wherein the sleeve has an external protrusion that corresponds with the internal geometry of the tool to secure the sleeve within the tool such that the sleeve extends over the internal geometry when the sleeve is concentrically disposed within the interior passageway of the tool; and wherein the sleeve is adapted to dissolve within a predetermined amount of time to expose the internal geometry after exposure to a first fluid. For any of the foregoing embodiments, the method may include any one of the following, alone or in combination with each other:A first and second annular groove formed on the exterior surface of the single-trip, sacrificial protector sleeve; a first annular seal disposed in the first groove that sealing engages the single-trip, sacrificial protector sleeve and the tool when the sleeve is concentrically disposed within the interior passageway of the tool; and a second annular seal disposed in the second groove that sealing engages the single-trip, sacrificial protector sleeve and the tool when the sleeve is concentrically disposed within the interior passageway of the tool.The tool is a tubing-retrievable safety valve and the internal geometry is a nipple profile.The internal geometry is at least one of a nipple and a bore seal.

The foregoing description and figures are not drawn to scale, but rather are illustrated to describe various embodiments of the present disclosure in simplistic form. Although various embodiments and methods have been shown and described, the disclosure is not limited to such embodiments and methods and will be understood to include all modifications and variations as would be apparent to one skilled in the art. Therefore, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Accordingly, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.