# Patent

## Title
Cup tool, cup tool cup and method of using the cup tool

## Abstract

A cup tool includes a cup tool tube having a threaded upper end for connection to a high-pressure mandrel, an outer surface over which an elastomeric cup is slidably mounted for reciprocal movement from an unset position for entry into a wellbore to a set position in which an annular gap is obstructed to contain fluid pressure below the elastomeric cup. The outer surface of the cup tool tube has a lower portion of a first diameter and an upper portion with a second, larger diameter and a tapered region between the upper portion and the lower portion. The elastomeric cup includes a lip seal that rides against the outer surface of the cup tool tube, and seals against the tapered region of the cup tool tube to provide a high pressure seal between the cup tool tube and the elastomeric cup in the set position.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This is the first application filed for the present invention.
MICROFICHE APPENDIX
Not applicable.
FIELD OF THE INVENTION
This invention generally relates to wellhead isolation equipment and, in particular, to a cup tool for use with wellhead isolation equipment.
BACKGROUND OF THE INVENTION
Most oil and gas wells require stimulation to enhance hydrocarbon flow to make or keep them economically viable. The servicing of oil and gas wells to stimulate production requires the pumping of fluids into the well under high pressure. The fluids are generally corrosive and/or abrasive because they are laden with corrosive acids and/or abrasive proppants, such as sharp sand.
In order to protect components that make up the wellhead, such as the valves, tubing hanger, casing hanger, casing head and blowout preventer equipment, wellhead isolation equipment, such as a wellhead isolation tool, a casing saver or a blowout preventer protector is used during well fracturing and well stimulation procedures. The wellhead isolation equipment generally includes a high pressure mandrel that is inserted through wellhead components to isolate the wellhead components from elevated fluid pressures and from the corrosive/abrasive fluids used in the well treatment to stimulate production. A sealing mechanism, generally referred to as a sealing nipple or a cup tool, connected to a bottom of the high pressure mandrel is used to isolate the wellhead components from high fluid pressures used for well stimulation treatments.
Various sealing mechanisms provided for wellhead isolation equipment are described in prior art patents, such as U.S. Pat. No. 4,023,814, entitled A TREE SAVER PACKER CUP, which issued to Pitts on May 17, 1977; U.S. Pat. No. 4,111,261, entitled A WELLHEAD ISOLATION TOOL, which issued to Oliver on Sep. 5, 1978; U.S. Pat. No. 4,601,494, entitled A NIPPLE INSERT, which issued to McLeod et al. on Jul. 22, 1986; Canadian Patent 1,272,684, entitled A WELLHEAD ISOLATION TOOL NIPPLE, which issued to Sutherland-Wenger on Aug. 14, 1990; U.S. Pat. No. 5,261,487 entitled PACKOFF NIPPLE, which issued to McLeod et al. on Nov. 16, 1993; and Applicant's U.S. Pat. No. 6,261,487 entitled CUP TOOL FOR HIGH PRESSURE MANDREL, published Mar. 25, 2001 which issued Jul. 19, 2005. These sealing mechanisms include an elastomeric cup that radially expands under high fluid pressures to seal against an inside wall of a production tubing or casing.
The elastomeric cups are commonly bonded to a steel ring, sleeve or mandrel. In the most common construction, the elastomeric cup is bonded to a steel ring that sides over a cup tool tube, also referred to as a cup tool mandrel. An O-ring seal carried by the steel ring provides a fluid seal between the elastomeric cup and the cup tool tube.
In spite of all the known cup tools, there still exists a need for an improved cup tool that is simple and inexpensive to manufacture and provides a reliable seal at very high fluid pressures.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a cup tool that is simple and inexpensive to manufacture and provides a reliable seal at very high fluid pressures.
The invention therefore provides a cup tool for providing a high-pressure fluid-tight seal in an annular gap between a high-pressure mandrel and a cased wellbore or a production tubing. The cup tool comprises a cup tool tube having a threaded upper end for connection to the high-pressure mandrel, the cup tool tube having an outer surface over which an elastomeric cup is slidably mounted for reciprocal movement from an unset position for entry of the cup tool into the wellbore to a set position in which the annular gap is obstructed to contain fluid pressure below the elastomeric cup, the outer surface of the cup tool tube having a lower portion of a first diameter and an upper portion with a second, larger diameter and a tapered region between the upper portion and the lower portion. The elastomeric cup includes a lip seal that rides against the outer surface of the cup tool tube, and seals against the tapered region of the cup tool tube to provide a high pressure seal between the cup tool tube and the elastomeric cup when the elastomeric cup is in the set position.
The invention further provides a cup for a cup tool that provides a high-pressure fluid-tight seal in an annular gap between a high-pressure mandrel and one of a cased wellbore and an inner wall of a tubing suspended in the cased wellbore. The cup comprises a hollow, generally tubular elastomeric body having an outer wall and an inner wall, the outer wall extending downwardly past the inner wall and terminating on a bottom end in an annular depending skirt, and the inner wall including a lip seal that rides against an outer surface of a cup tool tube, and seals against a tapered region of the cup tool tube to provide a high pressure seal between the cup tool tube and the elastomeric cup when the elastomeric cup is in a set position in which it seals the annular gap.
The invention further provides a method of sealing an annular gap between a high pressure mandrel and a cased wellbore or a tubing suspended in a wellbore in order to isolate pressure-sensitive wellhead components from high-pressure fracturing or stimulation fluids pumped into a well. The method comprises connecting a cup tool tube to a bottom end of the high-pressure mandrel, the cup tool tube having an outer surface over which an elastomeric cup is slidably mounted for reciprocal movement from an unset position for entry of the cup tool into the wellbore to a set position in which the annular gap is sealed to contain fluid pressure below the elastomeric cup, the outer surface of the cup tool tube having a lower portion of a first diameter and an upper portion with a second, larger diameter and a tapered region between the upper portion and the lower portion. An elastomeric cup is slid over the cup tool tube, the elastomeric cup including a lip seal that rides against the outer surface of the cup tool tube, and seals against the tapered region of the cup tool tube to provide a high pressure seal between the cup tool tube and the elastomeric cup when the elastomeric cup is in the set position. A bullnose is connected to a bottom end of the cup tool tube. The cup tool is then stroked into the wellbore, and high pressure fluids are injected through the high pressure mandrel and into the wellbore to force the elastomeric cup upwardly against a shoulder at a top of the cup tool tube, thereby forcing the lip seal against the tapered portion, while extruding an upper end of the elastomeric cup into the annular gap to provide a high-pressure fluid-tight seal.



BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, in which:
FIG. 1 is a schematic cross-sectional view of a cup tool in accordance with one embodiment of the invention prior to setting an elastomeric cup of the cup tool;
FIG. 2 is a schematic cross-sectional view of the embodiment shown in FIG. 1 subsequent to setting the elastomeric cup;
FIG. 3 is a schematic cross-sectional view of a cup tool in accordance with a second embodiment of the invention prior to setting the elastomeric cup;
FIG. 4 is a schematic cross-sectional view of the embodiment shown in FIG. 3 subsequent to setting the elastomeric cup;
FIG. 5 is a schematic cross-sectional view of a cup tool in accordance with a third embodiment of the invention prior to setting the elastomeric cup;
FIG. 6 is a schematic cross-sectional view of the embodiment shown in FIG. 5 subsequent to setting the elastomeric cup;
FIG. 7 is a schematic cross-sectional view of a cup tool in accordance with a fourth embodiment of the invention prior to setting the elastomeric cup; and
FIG. 8 is a schematic cross-sectional view of the embodiment shown in FIG. 7 subsequent to setting the elastomeric cup.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In general, as will be explained below, the invention provides a cup tool for providing a high-pressure fluid seal in an annular gap between a high-pressure mandrel and a casing or a production tubing in a wellbore. The cup tool includes a cup tool tube having a threaded upper end for connection to the high-pressure mandrel, an elastomeric cup that is slidably received on a cup tool tube. A top end of the elastomeric cup is forced upwardly and over an annular shoulder at the top to the cup tool tube to a set position when the cup is exposed to elevated fluid pressures, thereby extruding into the annular gap to provide the high-pressure fluid seal. In the set position, a lip seal on an internal surface of the cup sealingly engages a tapered external surface of the cup tool tube to provide a high-pressure fluid-tight seal between the elastomeric cup and the cup tool tube. A bullnose, or the like, is threadedly fitted to a bottom of the cup tool tube to protect the cup while guiding the cup tool through a wellhead.
As shown in FIG. 1, a cup tool 300, in accordance with one embodiment of the invention, includes a cup tool tube 302 (also known as a cup tool mandrel). The cup tool tube 302 includes an annular shoulder 304 at a threaded upper end for connection to the high-pressure mandrel (not shown). The cup tool tube also has an external surface with a lower portion 305 of a first diameter, an upper portion 307 of a second, larger diameter and a tapered portion 306 between the first and second regions, the utility of which will be described below. The cup tool further includes an annular abutment 308 with a radius slightly larger than that of the cup tool tube 302.
The cup tool 300 connects to the high-pressure mandrel to form a lower end of a wellhead isolation tool, casing saver or blowout preventer protector for isolating pressure-sensitive wellhead components from the deleterious affects of high-pressure fracturing and stimulation fluids. In order to isolate the pressure-sensitive wellhead components, the cup tool includes an elastomeric cup 310 for sealing off an annular gap 320 between the cup tool 300 and a tubing 330, which may be a casing in a cased wellbore or a production tubing in the wellbore. As shown in this embodiment, the elastomeric cup 310 is slidably received on the cup tool tube 302. The elastomeric cup 310 abuts the annular abutment 308 when the cup is in an unset position for entry into the wellbore. The elastomeric cup 310 has a downwardly depending skirt portion 312 which defines an annular cavity 314 between the skirt portion 312 and the cup tool tube 302.
The elastomeric cup 310 also includes a lip seal 316 that protrudes both downwardly and radially inward and rides against an inner surface of the cup tool tube 302. The lip seal 316 seals against the tapered portion 306 of the cup tool tube 302 when the elastomeric cup 310 is forced upwardly by fluid pressure to a set position shown in FIG. 2.
As shown in FIG. 1, an optional gauge ring 340 is located beneath an annular shoulder 304 at a top end of the cup tool tube 302. The gauge ring 340 can be retained on the cup tool tube by frictional or threaded engagement. The gauge ring 340 can be made of metal and machined to provide one or more right-angled steps engaged by the top end of the As shown in FIG. 1, an optional gauge ring 340 is located beneath an annular shoulder 304 at a top end of the cup tool tube 302. The gauge ring 340 can be retained on the elastomeric cup 310 to inhibit the elastomeric cup from moving to the set position as it is stroked into the wellbore, while facilitating extrusion of the elastomeric cup 310 into the annular gap when the elastomeric cup 310 is exposed to high fluid pressures. The function of the gauge ring 340 is explained in detail in Applicants' U.S. Pat. No. 6,918,441 which issued Jul. 19, 2005, the specification of which is incorporated herein by reference.
A bullnose 350, or the like, is connected, by threads or other suitable connector, to a bottom end of the cup tool tube 302. The bullnose 350 helps to guide the cup tool through the wellhead and also protects the elastomeric cup 310 during insertion of the cup tool through the wellhead.
In one embodiment, the elastomeric cup 310 is made of polyurethane having a Durometer of 80-100. In another embodiment the elastomeric cup 310 has a Durometer of 90-100. The elastomeric cup can be made of any elastomeric material having a durometer of 80-100, including other polymers, nitrile rubber, carbon reinforced rubbers or polymers, etc. During testing, the fluid-tight seal provided by a cup tool having a polyurethane cup has successfully contained fluid pressures of at least 22,500 psi without loss of seal or damage to the elastomeric cup 310. Accordingly, the cup tool is simple and inexpensive to manufacture and provides a reliable high pressure fluid seal for isolating pressure-sensitive wellhead components during well fracturing and stimulation operations. The cup tool also permits well stimulation to be safely conducted at fluid pressures that approach a pressure rating of the well casing.
FIG. 2 illustrates the cup tool with the elastomeric seal in the set position. Fluid pressure 360 in the well causes the elastomeric cup 310 to move both upwardly and radially outwardly (due to pressurization of the annular cavity 314). The skirt portion 312 of the cup presses against the tubing 330 to form a seal therewith. Due to the fluid pressure 360, the cup moves upwardly, extruding over the annular abutment 308, until the lip seal 316 seals against the tapered portion 306 of the cup tool tube 302 and a top portion 318 of the elastomeric cup 310 is forced against the gauge ring 340. Under elevated fluid pressures 360, the top end 318 of the elastomeric cup 310 is extruded into the annular gap 320 between the gauge ring 340 and the tubing 330, thus forming a high-pressure fluid-tight seal between the gauge ring 340 and the tubing 330.
Three other embodiments of the invention are shown in FIGS. 3-8. Most of the components of these three other embodiments are identical to those described above and are not redundantly described below.
FIG. 3 shows a cup tool 300 in accordance with another embodiment of the invention, with the elastomeric cup 310 in the unset position. As is apparent from FIG. 3, the cup tool 300 does not have a gauge ring. The cup tool 300 merely has a cup tool tube 302 with an annular shoulder 304 machined to present a right-angled step to the top of the elastomeric cup 310.
FIG. 4 shows the cup tool shown in FIG. 3 after the elastomeric cup 310 is forced to the set condition. When exposed to fluid pressure 360, the skirt portion 312 of the elastomeric cup 310 expands outwardly into sealing contact with the inner surface of the tubing 330. The elastomeric cup 310 is forced upwardly, extruding first over the annular abutment 308 and then, if the fluid pressure 360 is sufficiently high, over the annular shoulder 304 into the annular gap 320 to form a fluid-tight seal between the cup tool and the tubing. As the elastomeric cup 310 is forced upwardly, the lip seal 316 comes into engagement with the tapered portion 306 of the cup tool tube 302, and forms a high pressure seal therewith. Setting the elastomeric cup 310 seals the annular gap between the cup tool 300 and the tubing 330, thus isolating the pressure-sensitive wellhead components from the affects of high-pressure fracturing and stimulation fluids in the well.
FIG. 5 shows a cup tool 300 in accordance with another embodiment of the invention. The cup tool 300 includes a gauge ring 340 having three right-angled steps. As was explained above, right-angled steps impede setting of the elastomeric cup 310 as is travels down through the wellhead. As shown in FIG. 5, the gauge ring 340 includes a first step 342, a second step 344 and a third step 346 of increasing radius.
FIG. 6 shows the cup tool shown in FIG. 5 after the elastomeric cup 310 is set. If fluid pressure 360 in the well rises above a first threshold pressure, the elastomeric cup 310 extrudes over the first step 342. If the fluid pressure is further elevated beyond a second threshold pressure, the elastomeric cup 310 extrudes over the second step 344. If the fluid pressure is further elevated past a third threshold pressure, the elastomeric cup 310 extrudes over the third step 346.
FIG. 7 shows a cup tool 300 in accordance with yet another embodiment of the invention. The cup tool 300 has a cup tool tube 302 with an annular shoulder 304. Integrally formed with the annular shoulder 304 on the underside thereof is a plurality of square steps 370, which include a first step 372, a second step 374 and a third step 376. The first, second and third steps function in the same way as the gauge rings 340 described above.
FIG. 8 shows the cup tool shown in FIG. 7 after the elastomeric cup 310 is set. If fluid pressure 360 in the well rises above a first threshold pressure, the elastomeric cup 310 extrudes over the first step 372. If the fluid pressure is elevated above a second threshold pressure, the elastomeric cup 310 extrudes over the second step 374. If the fluid pressure is further elevated above a third threshold pressure, the elastomeric cup 310 extrudes over the third step 376.
For certain operations, it may be desirable to install two cup tools 300 in a double cup tool configuration. In a double cup tool configuration, two cup tools are connected end-to-end, with a suitable adapter in between. The lower cup tool typically has a bullnose and acts as the primary seal while the upper cup tool connects to the high-pressure mandrel and acts as a backup seal to prevent fluid leakage if the primary seal fails. A double cup tool is disclosed in Applicant's above-referenced U.S. Pat. No. 6,918,441 entitled CUP TOOL FOR HIGH PRESSURE MANDREL, the entire disclosure of which is hereby incorporated by reference herein.
The invention therefore provides a cup tool with an elastomeric cup that is slidably received on a cup tool tube without the necessity of bonding the cup to metal. Accordingly, the cup tool is simple and inexpensive to manufacture and maintain. Furthermore, the elastomeric cup tool has been successfully tested to fluid pressures exceeding 22,500 psi.
Modifications and improvements to the above-described embodiments of the present invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.

## Claims

1. A cup tool for providing a high-pressure fluid-tight seal in an annular gap between a high-pressure mandrel and a cased wellbore, the cup tool comprising:
a cup tool tube having a threaded upper end for connection to the high-pressure mandrel, the cup tool tube having an outer surface over which an elastomeric cup is slidably mounted for reciprocal movement from an unset position for entry of the cup tool into the wellbore to a set position in which the annular gap is obstructed to contain fluid pressure below the elastomeric cup, the outer surface of the cup tool tube having a lower portion of a first diameter and an upper portion with a second, larger diameter and a tapered region between the upper portion and the lower portion; and
the elastomeric cup including a lip seal that rides against the outer surface of the cup tool tube, and seals against the tapered region of the cup tool tube to provide a high pressure seal between the cup tool tube and the elastomeric cup when the elastomeric cup is in the set position.

2. The cup tool as claimed in claim 1 further comprising a gauge ring located at a top end of the cup tool tube, the gauge ring inhibiting movement of the elastomeric cup to the set position during entry of the cup tool into the well bore.

3. The cup tool as claimed in claim 2 wherein the gauge ring comprises at least two upward annular steps of increasing diameter to facilitate extrusion of the elastomeric cup into the annular gap.

4. The cup tool as claimed in claim 3 wherein the upward annular steps are right angle steps in the gauge ring.

5. The cup tool as claimed in claim 1 further comprising a bullnose connected to a bottom of the cup tool tube for protecting the elastomeric cup and guiding the cup tool through a wellhead.

6. The cup tool as claimed in claim 1 wherein the elastomeric cup is made of polyurethane.

7. The cup tool as claimed in claim 6 wherein the elastomeric cup has a Durometer of 80-100.

8. A cup tool for providing a high-pressure fluid-tight seal in an annular gap between a high-pressure mandrel and a tubing suspended in a wellbore, the cup tool comprising:
a cup tool tube having a threaded upper end for connection to the high-pressure mandrel, the cup tool tube having an outer surface over which an elastomeric cup is slidably mounted for reciprocal movement from an unset position for entry of the cup tool into the wellbore to a set position in which the annular gap is obstructed to contain fluid pressure below the elastomeric cup, the outer surface of the cup tool tube having a lower portion of a first diameter and an upper portion with a second, larger diameter and a tapered region between the upper portion and the lower portion; and
the elastomeric cup including a lip seal that rides against the outer surface of the cup tool tube, and seals against the tapered region of the cup tool tube to provide a high pressure seal between the cup tool tube and the elastomeric cup when the elastomeric cup is in the set position.

9. The cup tool as claimed in claim 8 further comprising a gauge ring located at a top end of the cup tool tube, the gauge ring inhibiting movement of the elastomeric cup to the set position during entry of the cup tool into the well bore.

10. The cup tool as claimed in claim 9 wherein the gauge ring comprises at least two upward annular steps of increasing diameter to facilitate extrusion of the elastomeric cup into the annular gap.

11. The cup tool as claimed in claim 10 wherein the upward annular steps are right angle steps in the gauge ring.

12. The cup tool as claimed in claim 8 further comprising a bullnose connected to a bottom of the cup tool tube for protecting the elastomeric cup and guiding the cup tool through a wellhead.

13. The cup tool as claimed in claim 8 wherein the elastomeric cup is made of polyurethane.

14. The cup tool as claimed in claim 13 wherein the elastomeric cup has a Durometer of 80-100.

15. A method of sealing an annular gap between a high pressure mandrel and a cased wellbore or a tubing suspended in a cased wellbore in order to isolate pressure-sensitive wellhead components from high-pressure fracturing and stimulation operations in a well, the method comprising:
connecting a cup tool tube to a bottom end of the high-pressure mandrel, the cup tool tube having an outer surface over which an elastomeric cup is slidably mounted for reciprocal movement from an unset position for entry of the cup tool into the wellbore to a set position in which the annular gap is obstructed to contain fluid pressure below the elastomeric cup, the outer surface of the cup tool tube having a lower portion of a first diameter and an upper portion with a second, larger diameter and a tapered region between the upper portion and the lower portion;
sliding an elastomeric cup over the cup tool tube, the elastomeric cup including a lip seal that rides against the outer surface of the cup tool tube, and seals against the tapered region of the cup tool tube to provide a high pressure seal between the cup tool tube and the elastomeric cup when the elastomeric cup is in the set position;
connecting a bullnose to a bottom end of the cup tool tube;
inserting the cup tool into the cased wellbore; and
injecting high pressure fluids through the high pressure mandrel and into the wellbore to force the elastomeric cup upwardly against a shoulder at a top of the cup tool tube, thereby forcing the lip seal against the tapered region, while extruding an upper end of the elastomeric cup into the annular gap, thus providing a high-pressure fluid-tight seal.

16. The method as claimed in claim 15 further comprising installing a gauge ring at a top end of the cup tool tube prior to sliding the elastomeric cup over the cup tool tube.

17. The method as claimed in claim 16 further comprising prior to connecting the bullnose, connecting another cup tool tube to a bottom end of the cup tool tube connected to the high pressure mandrel and repeating the step of sliding, followed by the steps of connecting, inserting and injecting.