WELL CEMENTING STAGE TOOL AND METHOD AND DEVICE FOR ALLEVIATING A HYDRAULIC LOCK

Abstract: An hydraulic lock alleviation apparatus (40, 210, 310, 410, 510, 610) alleviates hydraulic lock, for example in a cementing stage tool when a closing plug (107) is employed. The apparatus (40) has a channel (90) for transmitting trapped fluid (which causes a hydraulic lock) from the trapped volume (110) to another volume (113). The channel (90) is blocked by a pressure responsive member (42, 242, 320, 420, 520, 650) which ruptures, moves, breaks, or is punctured to permit trapped fluid to flow from the volume (110) of hydraulic lock. In one embodiment of a stage tool (10) with such an apparatus (40) puncture means (41) is actuable to puncture the pressure responsive member (42). In another embodiment a movable spool (420, 520) is mounted in the channel (490, 590) for actuation to be displaced and thereby to permit the flow of trapped fluid.

Description: This invention relates to an hydraulic lock alleviation device for a well cementing stage tool, such a tool and a method of alleviating an hydraulic lock. A drilled wellbore hole is prepared for oil or gas production by cementing in an annulus round a casing, liners or similar conduit string in the wellbore. Cementing is the process of firstly mixing a composition including cement and water, and secondly pumping the resulting slurry down through the well casing and into the annulus between the casing and the wellbore. Cementing provides protection from the intermixing of the contents of various production zones. Such mixing might otherwise result in undesirable contamination of produced oil or gas or in contamination of the producing strata. In the early days of the oil field industry, the shallower wells allowed cementation to be accomplished by pumping a cement slurry down the well casing, out the casing bottom, and back up the annular space between the bore hole and casing. As wells were drilled deeper, the cementing process was accomplished in two or even three stages. Cementing tools, stage tools, or ported collars equipped with internal valving, were needed for multi-stage cementation. Typically, the internal valving of cementing tools, or stage tools, consists of one or more sliding sleeve valves. These sleeve valves are arranged for the opening and closing of the cement ports before and after a cement slurry has passed through the ports. A variety of plugs are used to aid multi-stage cementing tools to open and to close the correct sleeve valve at the correct time. Problems have been encountered when two sleeve valves are employed to open and close the cement ports. The sleeve valves are shear-pinned in an upper position with the lowermost sleeve sealing the ports closed for running into the wellbore hole. When stage cementing is desired, an opening plug is removed (or dropped and gravitated) to a position in which it seats on the stage tool and seals it off from above. Pressure, which is applied at the wellbore surface, applies enough downward force on the opening plug and seat arrangement to break the shear pins and shift the lower sleeve valve down. This movement opens ports which allow cementing solutions or slurries to flow down the interior of the casing. These solutions then pass through the ports and into the annulus between the exterior of the casing and the interior of the wellbore. Cement is pumped down the casing, through the ports and back up the annulus. As the tail end of the cement slurry is pumped down the casing, a second plug often called a "closing plug" is placed on top of the cement in the casing. This plug moves down to seat and seal off the uppermost sleeve valve until sufficient surface casing pressure is applied to break the shear pins holding the sleeve. The upper sleeve and plug then shift downward to cover and seal off the cementing ports so that no more solution or slurry passes either into the annulus or back from the annulus. An engaging mechanism can be used to lock the closing sleeve in position. A problem has been encountered in this operation due to the creation nf an hydraulic lock when a seal is established across the ports. In particular, when a portion of the solution or slurry ahead of the closing plug is pushed downwardly and the cementing ports close off, this small portion of fluid becomes trapped between the plugs within the stage tool and can flow nowhere. The nearly incompressible nature of the trapped material does not allow the upper sleeve valve to travel sufficiently downward to engage a positive locking mechanism to prevent a reopening of the cementing ports. If the engaging mechanism does not engage on the upper sleeve valve, internal casing pressure must be held until the cement sets. U.S. Patents 3,811,500 and 3,842,905 disclose a device which uses an opening plug to shift a lower sleeve valve open. As the upper sleeve valve slides to cover and seal flow ports, the closing plug, used to shift the upper sleeve valve closed, imposes a downward force on a rod extending through the opening plug which breaks shear pins holding the rod in place and opens a passage through the opening plug for trapped fluid to exit. This configuration is pressure sensitive to excessively high cement pump pressure which can break the shear pins and cause undesirable premature activation; i.e., the rod is pushed out during the cementing operation rather than at its completion. Also, there is no guarantee the mechanism will be aligned correctly upon the seating of the opening plug, due to the loose fitting characteristics of such a plug and the requirement that the plug go down the casing in a properly aligned configuration. If the plug becomes misaligned the device will not work properly. Because of the sensitivity of the shear pin used to hold the rod in place, it is difficult if not impossible to use a hammer means such as a drill pipe joint to jar a stuck plug - since such jarring will cause premature release of the rod or the plug may become damaged. There has long been a need for an effective and efficient cementing stage tool with an hydraulic locking alleviation apparatus and methods for its use. There has long been a need for an apparatus for alleviating hydraulic locking in a wellbore. There has long been a need for a stage tool which does not activate prematurely, which has ports not subject to unwanted plugging, and which does not require complex engaging mechanisms. Also, there has long been a need for such a tool and apparatus which does not damage seals used therein. Embodiments of the present invention recognize, address, and attempt to satisfy these longfelt needs. According to one aspect of the present invention there is provided an hydraulic lock alleviation apparatus for disposition adjacent a first volume in a wellbore in which an hydraulic lock can be created and a second volume into which fluid trapped in the first volume may be communicated by the hydraulic lock alleviation apparatus, the apparatus comprising a body member having an opening therethrough permitting fluid communication between the first and second volumes, said alleviation apparatus being operable to relieve an hydraulic lock when said opening is closed to the flow of fluid therethrough, characterized in that there is provided, in addition to said opening, a channel through the body member in fluid communication with both the first volume and the second volume so that fluid communication is allowed between the two volumes through the channel, a pressure responsive member sealingly disposed in the channel to inhibit the flow of fluid from the first volume into the second volume through the channel thereby trapping fluid in the first volume, the pressure responsive member being actuable to permit flow of the trapped fluid through the channel from the first volume into the second volume thereby alleviating the formation of an hydraulic lock by the trapped fluid in the first volume. Preferably the pressure responsive member is a puncturable disc disposed across and closing off the channel and the apparatus includes a puncture pin disposed in the channel and movable to puncture the puncturable disc thereby permitting fluid to flow from the first volume into the second volume. Advantageously, the puncture pin is configures so that it passes through the puncturable disc once it has been punctured and exists from the channel. Preferably, a seal member is disposed in contact with the pressure responsive member and between the pressure responsive member and the channel to provide a seal between the pressure responsive member and the channel. Advantageously, the pressure responsive member is a rupturable disc disposed across and closing off the channel. Preferably, a gland nut with a bore therethrough is disposed in the channel to hold the rupturable disc in place in the channel, the channel being in communication with the bore of the gland nut so that the fluid is able to flow through the bore in the gland nut and into the second volume upon rupture of the rupturable disc. Advantageously, the pressure responsive member is a breakable plug disposed partially in the channel and partially disposed in the first volume, the breakable plug having an interior bore extending through the part of the plug disposed in the channel and communicating with the channel and extending into the part of the plug disposed in the first volume, the bore not being in communication with the first volume, and the plug breakable so that the bore provides communication between the channel and the first volume. Preferably, the pressure responsive member is a valve spool disposed in and movable in the channel, the valve spool being held immobile in the channel by shear pin means extending from within the body to within the valve spool, the spool being movable upon shearing of the shear pin means to permit the flow of fluid from the first volume through the channel. Advantageously, the spool has a shoulder for preventing it from falling out of the channel into the second volume. Preferably, the spool has a central bore in communication with the first volume and at least one hole in the spool in communication with the bore, the spool being movable in the channel so that the hole(s) may be moved into communication with the channel so that fluid may flow from the first volume into the second volume. Advantageously, the valve spool is configured to be passable through and out of the channel upon shearing of the shear pin means. Preferably, the pressure responsive member comprises a valve spool movably disposed in the channel and closing it off to flow, a movable arm pivotably mounted to the body member above the spool, the arm having a finger extending into a recess on the spool, the spool being movable upon release of the finger from the recess, the arm being inhibited from movement by a break-off member of the arm which abuts the body member thereby inhibiting movement of the arm and is breakable to permit movement of the arm, the member being breakable either in response to the pressure of fluid in the first space or by the force of a member urged against the arm. According to another aspect of the present invention there is provided a stage tool for well cementing operations, the tool disposable between and connectable to lengths of casing in a string of casing within a wellbore, the stage tool comprising a hollow outer case having a top end, a bottom end, and a case bore therethrough for communicating with casing connected to the top end and bottom end of the case, the case having cementing port means therethrough for permitting the flow of cementing fluid from the case bore through the cementing port means to the exterior of the case, a hollow lower sleeve secured in the case and blocking the cementing port means and inhibiting the flow of fluid therethrough, the lower sleeve being movable in response to a predetermined amount of force to unblock the cementing port means, the lower sleeve having disposed therein and therethrough means for alleviating an hydraulic lock between an upper sleeve and the lower sleeve, and the upper sleeve being secured in the case above the lower sleeve, the upper sleeve being movable in response to a predetermined amount of force to contact and move the lower sleeve and to block the cementing port means after cementing fluid has flowed through the port means, characterized in that said alleviating means comprises an hydraulic lock alleviation apparatus in accordance with the invention. Preferably, the puncture pin is disposed so that it can be contacted and moved by a lower portion of the upper sleeve. Advantageously, the puncture pin and channel are disposed at an angle from the longitudinal axis of the stage tool. Preferably the angle is 15° and is inclined toward the body member. Advantageously, the lower sleeve is secured in the case by shear plug means which extends both into a recess in the lower sleeve and into the cementing port means, the shear plug means being shearable upon movement of the lower sleeve to open the cementing port means. Preferably, the sleeves have seat means for receiving plugs for moving the sleeves. Advantageously, seal means are provided on the upper sleeve for sealing between the exterior surface of the upper sleeve and the case bore, and a diffuser groove is formed around the upper sleeve so that when the upper sleeve becomes subjected to the flow of fluid to the cementing port means the diffuser groove diffuses this flow thereby inhibiting damage to the seal means. According to a further aspect of the invention there is provided a method for alleviating an hydraulic lock about a device sealed in a wellbore, the device having a body member having a central bore therethrough permitting fluid communication between a first volume above the device and a second volume apart from the first volume, characterized in that the method comprises the steps of: (a) providing a channel through the body member between the first volume and the second volume; (b) providing a pressure responsive member in contact with trapped fluid in the first volume, the pressure responsive member being sealingly disposed across the channel to close it off; and (c) actuating the pressure responsive member to open the channel so that fluid entrapped in the first volume may flow from the first volume to the second volume. Preferably, the pressure responsive member is a disc which is rupturable in response to a predetermined fluid pressure or puncturable in response to mechanical action. Advantageously, a puncture pin is disposed adjacent the disc and is movable to puncture the disc to permit the flow of trapped fluid. Preferably, a movable member disposed above the puncture pin moves in response to a plug pushing on the movable member, the movable member being movable to contact the puncture pin and push it though the puncturable disc. Advantageously, the pressure responsive member is a spool mounted in the channel and held therein by a shear pin which, when sheared permits the spool to move thereby opening the channel to the flow of entrapped fluid. For a better understanding of the invention reference will now be made, by way of example, to the accompanying drawings in which:- Fig. 1A shows a longitudinal section of one embodiment of a stage tool incorporating an hydraulic lock alleviation apparatus according to the invention; Fig. 1B shows an end view of the stage tool of Fig. 1A; Fig. 1C shows another longitudinal section of the stage tool taken on a plane perpendicular to the plane of Fig.1A; Fig. 1D shows an end view of the stage tool of Fig. 1C; Fig. 1E shows an exploded view of part the stage tool of Fig. 1A; Fig. 2 shows an enlarged view of a portion of the stage tool of Fig. 1A; Fig. 3A shows a simplified view of the stage tool of Fig. 1A in a wellbore; Fig. 3B shows a view of the stage tool of Fig. 1A with an opening plug in it; Fig. 4 shows a view of the stage tool as shown in Fig. 3A with a closing plug; Fig. 5 shows a view of the stage tool shown in Fig. 4 with the plugs in closer proximity; Fig. 6 shows a cross-sectional view of a second embodiment of an hydraulic lock alleviation apparatus according to the invention; Fig. 7A shows a cross-sectional view of a third embodiment of an hydraulic lock alleviation apparatus according to the invention; Fig. 7B is a cross-sectional view of a knock-off plug forming part of the hydraulic lock alleviation apparatus shown in Fig. 7A; Fig. 7C shows the knock-off plug of Fig. 7B in a broken condition; Fig. 8A shows a cross-sectional view of a fourth embodiment of an hydraulic lock alleviation apparatus according to the invention; Fig. 8B is a cross-sectional view of a valve spool forming part of the hydraulic lock alleviation apparatus shown in Fig. 8A; Fig. 9A shows a cross-sectional view of a fifth embodiment of an hydraulic lock alleviation apparatus in accordance with the present invention; Fig. 9B is a cross-sectional view of a valve spool forming part of the hydraulic lock alleviation apparatus shown in Fig. 9A; Fig. 10 shows a cross-sectional view of a sixth embodiment of an apparatus according to the invention. DESCRIPTION OF PREFERRED EMBODIMENTS Reference is now made to Figs. 1A to 1E and 2. A stage tool 10 incorporates an hydraulic lock alleviation apparatus 40. The stage tool 10 has an outer case including an upper case 11 and a lower case 12 which is shown as threadedly connected to the upper case 11, but which may be welded or otherwise secured. Threads 13 are provided on the upper case 11 and threads 14 are provided on the lower case 12 for mating with standard connections on casing or other tubulars (e.g., casing 25, 26 of Fig. 3A below). Preferably the cases 11, 12 are made from a grade of steel compatible with typical casing. Within the cases 11, 12 are disposed an upper seat 30, an upper sleeve 60, and a lower sleeve 80. With appropriate action each of these items can be moved within the upper case 11. A portion of each of the shear plugs 15 is disposed with a tight sliding fit in a respective cementing port 16. These shear plugs 15 prevent the flow of cementing fluid to the exterior of the stage tool 10 until the lower sleeve 80 has been moved downwardly to shear the shearplugs 15 thereby opening the ports (as will be described in detail below). The lower sleeve 80 has a generally circular sleeve body member 81 with recesses 76 for threadedly receiving and holding another portion of the shear plugs 15, which is threaded. The sleeve body member 81 has a central circular opening 82 with an interior cylindrical surface 86. Surface 86 is at the termination of ridges 83 and 84 which extend inwardly from the exterior surface 85 of the sleeve body member 81. An O-ring seal 87 is disposed in a recess 88 in the exterior surface 85 of the body member 81. An O-ring seal 101 is disposed in a recess 79 in the exterior surface 85 of the sleeve body member 81. A stepped channel 90 (Fig. 1C) is provided in and through the sleeve body member 81 and is inclined at an angle of 15° to the longitudinal axis of the lower sleeve 80. A recess 104 is provided on the bottom of the sleeve body member 81. This recess 104 is provided for anti-rotational locking of the sleeve body member 81 on to anti-rotation pins 106 (Fig. 1A , to be described). A groove 100 is provided on the top of the sleeve body member 81 (Fig. 2). Groove 100 is provided for anti-rotational locking with a downwardly extending member 63 (Fig. 1C) of the upper sleeve 60. Conversely, shoulders 78 on the lower sleeve 80 extend into recesses 75 on the upper sleeve 60 to prevent rotation. A recess 17 (Fig. 2) is provided in the interior wall of the case 11. This recess 17 is provided for clearance for the O-ring seal 87 and a seal 64 (to be described) as they move past the cementing ports 16 upon downward movement of the lower sleeve 80 and the upper sleeve 60, respectively. A recess 19 is provided in the interior wall of the upper case 11. As will be further described below, recess 19 receives a snap ring 66 for holding the upper sleeve 60 in a locked position. Likewise, O-ring seals 101 and 87 are provided to assist in sealing off flow to cementing ports 16. As shown in Fig. 2, the stepped channel 90 has a top opening 91, a top shoulder 92, a mid portion 93, a mid shoulder 94, a threaded portion 95, a lower shoulder 98 and a bottom opening 99. The stepped channel 90 may be inclined at any angle which permits fluid flow through the body 81 and which ensures that other parts do not restrict flow through the stage tool 10. Nevertheless, it is preferred that the axis of the stepped channel 90 be at an angle of 15° tilted away from the stage tool's longitudinal axis (as indicated). This angle of 15° facilitates alignment between a top surface 72 of a puncture pin 41 and an angled lower lip 71 on the upper sleeve 60. An hydraulic lock alleviation apparatus 40 (including the stepped channel 90) includes the puncture pin 41, a puncturable disc 42, a seal 45, and a gland nut 43 disposed in the threaded portion 95 of the stepped channel 90. It is preferred that the puncture pin 41 be made from a drillable material such as brass or aluminium. The puncture pin 41 has a step 44 which abuts the top shoulder 92 to prevent the puncture pin 41 from escaping inadvertently through the top opening 91. The seal 45 abuts the mid shoulder 94, and the puncturable disc 42 abuts the seal 45. The puncturable disc 42 effectively seals off the stepped channel 90 to the flow of fluid therethrough. The puncturable disc 42 is fabricated to withstand a certain amount of pressure and to be rupturable in response to a certain amount of pressure. In this embodiment, the puncture pin 41 has a pointed rim 46 to assist in puncturing the puncturable disc 42. The lower portion 97 of the stepped channel 90 has interior threads 47 which mate with threads 48 on the gland nut 43. The gland nut 43 retains the puncturable disc 42 and the seal 45 in position. The gland nut 43 has an interior bore 49 which is so dimensioned as to receive the puncture pin 41. When released, the puncture pin 41 can pass through the interior bore 49. Turning again to Figs. 1A to 1E, the upper sleeve 60 (which is preferably made from steel) is generally circular. The upper sleeve 60 has an exterior surface 61, an interior surface 62 defining a generally circular bore 73, and the aforesaid downwardly extending member 63. The downwardly extending member 63 is disposable in the groove 100 of the lower sleeve 80 for anti-rotational locking. An O-ring seal 64 (aforementioned) is disposed in a recess 65 in the exterior surface 61. An O-ring seal 69 is disposed in recess 70 (Fig. 1E) in the exterior surface 61. A snap ring 66 (aforementioned) is disposed in recess 67 (Fig. 1E) in the exterior surface 61. A diffuser groove 68 (Fig. 1E) is formed in the exterior surface 61. This diffuser groove 68 interrupts or diffuses the flow of fluid flowing to the cementing ports 16. As will be further described this flow, if uninterrupted, could damage the seal 64. The upper sleeve 60 has an angled lower lip 71 (aforementioned). In this embodiment, as shown in Fig. 2, the angled lower lip 71 is configured at an angle to meet flush and parallel with the top surface 72 of the puncture pin 41. This alignment facilitates a more accurate pushing on the puncture pin 41. The upper seat 30 has an exterior surface 31, an interior surface 32, a generally circular bore 33, and an interior cylindrical surface 34 at the termination of ridges 35 and 36. The lower portion of the upper seat 30 is threadedly connected to the top of the upper sleeve 60 by means of threads 39 on the upper seat 30 and threads 74 on the upper sleeve 60 (Fig. 1E). Shear balls 37 rest in and are disposed partially in apertures 38 in the exterior surface 31. The shear balls 37 are also disposed partially in and held by a circumferential recess 21 in the upper case 11 (Fig. 1A). Each shear ball 37 is initially inserted by lining up an aperture 38 with a hole 22 in upper case 11, then dropping that shear ball 37 into the aperture 38. The upper seat 30 is then rotated until another aperture 38 appears under the hole 22 and another shear ball 37 is inserted. The shear balls 37 move in the circumferential recess 21 on the interior surface 24 of the upper case 11. After the shear balls 37 are inserted, a plug 23 is placed in the hole 22 to seal it. The shear balls 37 are fabricated so that they will shear at a desired pressure thereby to release the upper seat 30. Figs. 3B, 4 and 5 illustrate various stages in the operation of the stage tool 10. As shown in Fig. 3A, the stage tool 10 is arranged between two casings 25, 26 in a wellbore 18. Firstly as shown in Fig. 3B, an opening plug 50 has been inserted into the stage tool 10 which is emplaced in a wellbore (Fig. 3A). A plate 51 of the plug 50 has contacted the ridge 83 of the lower sleeve 80. The force exerted by plate 51 has pushed the lower sleeve 80 downwardly with force sufficient to break the shear plugs 15. This resulted in the freeing of the lower sleeve 80 and enabled it to move downwardly to a point where its motion is stopped by the abutment of a lip 102 of the lower sleeve 80 against a shoulder 124 of the lower case 12 (as shown in Fig. 3B). Anti-rotation pins 106, which are carried by the upper case 11, then become located in and held by recesses 104 in the exterior surface 85 of the lower sleeve 80. These anti-rotation pins 106 then prevent rotation of the sleeve 80 relative to the upper case 11. Once the shear plugs 15 are broken and the lower sleeve 80 moves, the cementing ports 16 are open to the flow of cementing fluid. This fluid flows from the interior of the stage tool 10 to the annulus 27 (Fig. 3A) between the interior surface 28 of the wellbore and the exterior of the stage tool 10. The plate 51 is provided with a seal 105 which in the position illustrated in Fig. 3B contacts the ridge 83. In this position the seal 105 ensures that cementing fluid is inhibited from flowing downwardly beyond the plate 51. As shown in Fig. 3B, the head 103 of a broken shear plug 15 has fallen out of and away from the cementing port 16. The head 103 is larger in diameter than a portion 29 of the cementing port 16. This ensures that the head 103 cannot fall into the stage tool 10. With the cementing ports 16 open, circulation may be established to prepare the annulus 27 for cementing or cementing through the cementing port 16 may begin immediately. As cementing progresses to the final stages, a considerable hydrostatic pressure builds up. However, this pressure is not sufficient to cause the puncture pin 41 to rupture the puncturable disc 42. As shown in Fig. 4 a closing plug 107 is inserted in the upper case 11 towards the end of the cementing operation (or stage thereof). The initial function of the closing plug 107 is to displace residual quantities of cement slurry through the cementing ports 16. As shown the closing plug 107 has landed on the upper seat 30. This results in a pressure-tight bridge being formed across the internal surface bore 24 of the stage tool 10. As surface casing pressure increases, a sufficient downward force is imparted to the shear balls 37 to break them. This then allows the upper sleeve 60 and the upper seat 30 to shift downward. A recess 20 (Fig. 3B) is provided in the interior surface of the upper case 11 adjacent the O-ring seal 69. The recess 20 permits the equalizing of the pressure in the small space 109 between the seals 69, 64, the upper sleeve 60 and the upper case 11) with cement slurry pump pressure in the volume 110 between the opening plug 50 and the closing plug 107 (as the upper sleeve 60 moves from its Fig. 3B position to its Fig. 4 position). This pressure equalization prevents the seal 64 from being urged into the cementing port 16 and cut as the upper sleeve 60 slides past the cementing port 16 to its Fig. 4 position. As shown in Fig. 4, the internal diameter of the upper sleeve 11 decreases below the cementing ports 16. At the transition there is a recompression angle 112. When the angled lower lip 71 slides past the recompression angle 112, cement slurry inside volume 110 begins to create high velocity jets in space 115. This slurry exists through the space 115 between the upper sleeve 60, the snap ring 66 and the interior surface 24 in proximity to the cementing ports 16. These jets of fluid are extremely small in volumetric flow rate as compared to the volumetric flow rates of the cementing ports 16. This decreases in volumetric flow rate and the incompressible nature of the cement slurry imparts a braking force to the upper sleeve 60. The braking force causes the upper sleeve 60 to slow down in its remaining travel during which fluid slowly meters out in the space 115 through the cementing port 16. The high velocity flow of these fluid jets close to cementing ports 16 could impart a sudden pressure differential. Such a pressure differential could lift the seal 64 out of the recess 65 and into the cementing port 16 and cut it (as the upper sleeve 60 slides close). For this reason a diffuser groove 68 is provided in the upper sleeve 60. Diffuser groove 68 causes a more even flow pattern around the circumference of the upper sleeve 60. This modified flow pattern disrupts the lifting force and prevents or inhibits seal damage. As entrapped fluid continues to flow slowly from volume 110 into space 115 and to the port 16, the upper sleeve 60 slowly moves into position as shown in Fig. 4. The angled lower lip 71 of the upper sleeve 60 comes into contact with the top surface 72 of the puncture pin 41. Downward force emanates from the surface (using pressure above the closing plug 107). This downward force is continuously being applied via the closing plug 107 and upper seat 30 to the upper sleeve 60. This force is now imparted to the puncture pin 41. The pointed rim 46 of the lower end of the puncture pin 41 is driven through the puncturable disc 42 which is held in place by the gland nut 43. This action takes place before the seal 64 reaches recompression angle 112 to seal off the cementing ports 16. Further movement of the upper sleeve 60 drives the puncture pin 41 into the interior bore 49 of the gland nut 43. As the seal 64 reaches the recompression angle 112, an hydraulic lock is effected. This hydraulic lock inhibits or freezes any further travel of the upper sleeve 60 until entrapped fluid in the volume 110 helps to push the puncture pin 41 out of the stepped channel 90 and into the volume 113. As the puncture pin 41 enters the volume 113, cement slurry from the volume 110 may flow freely into the volume 113. This action will relieve the hydraulic lock and allow the upper sleeve 60 to travel to the position shown in Fig. 5. As the entrapped fluid exits through the stepped channel 90 of the lower sleeve 80, the upper sleeve 60 travels downward until it abuts the lower sleeve 80. The snap ring 66 is now adjacent a groove 114 in the upper case 11. Then, the snap ring 66 springs outwardly, to permanently lock the upper sleeve 60 in place. The seals 64 and 69 are positioned across cementing ports 16 to effect a pressure-tight seal. Closing the cementing ports 16 completes the cementation process of this wellbore stage. Other wellbore stages may be cemented or the drill out of the opening plug 50 and closing plug 107 and the upper seat 30 and lower seat 80 may be performed. The above-described embodiment presents a significant improvement over apparatuses as disclosed in U.S. Patents 3,811,500 and 3,842,905. The alleviation means in these Patents comprise a single shear device to secure a release rod in place. This single shear device must withstand loads placed on it by cementing pressures pushing on the rod. Thus, it must have a relatively high resistance to shear to prevent premature activation. However this same shear device must also shear when desired to release the rod. This latter factor means that a high shear resistance is not desirable. The problem which results is that the easier it can be for the shear device to shear and release the rod, the greater the risk of premature action of the shear device. The above-described embodiment has an advantageous hydraulic lock alleviation apparatus. The apparatus 40 has a puncturable disc 42 which is capable of withstanding the high cementing pressures. The apparatus 40 also has a puncture pin 41 which is displaceable by a relatively small force. The actuation of the puncture-pin 41 (by the upper sleeve 60) does not disrupt sleeve travel or tool operation. Thus, the apparatus 40 combines the attributes of resistance to high pressure via the puncturable disc 42 with the ability to release the trapped fluid in response to a relatively low force on the puncture pin 41. These same attributes are also realized with the embodiments described below. Referring to Fig. 6 a hydraulic lock alleviation apparatus 210 is shown which can be disposed in the lower sleeve 80 of Fig. 2 in place of the device 40. Apparatus 210 includes a rupturable disc 242, a seal 245, a stepped channel 290. Seal 245 comprises an O-ring and is arranged to abut a shoulder 294. The rupturable disc 242 abuts the seal 245. The rupturable disc 242 effectively seals off channel 290 to the flow of fluid therethrough. The rupturable disc 242 is fabricated to withstand a certain amount of pressure and to be rupturable at a certain amount of pressure. The lower portion 297 of the stepped channel 290 has interior threads 247 which mate with threads 248 on the gland nut 243. The gland nut 243 retains the rupturable disc 242 and the seal 245 in position. The gland nut 243 has an interior bore 249 through which fluid may flow. A pressure increase in the volume above the lower sleeve 80 will be transmitted through the stepped channel 290 to the rupturable disc 242. When the rupture pressure of the rupturable disc 242 is reached, the disc 242 will be ruptured. This allows fluid to flow from above the lower sleeve 80, through the stepped channel 290 and into a second volume 250 below the apparatus 210. As this occurs, an upper sleeve (such as sleeve 60 in Fig 2) will be permitted to move to abut the lower sleeve 80 and any hydraulic lock will be relieved. An hydraulic lock alleviation apparatus 310 is shown in Figs. 7a, 7b, and 7c. This apparatus 310 includes a channel 390 and a knock-off plug 320. It is preferred that the knock-off plug 320 be made from plastics material so that the plug may break in the proper manner as described below. The knock-off plug 320 has a threaded portion 311 which can mate with threads 397 of channel 390. A groove 315 of the knock-off plug 320 receives a seal 316. Seal 316 abuts with a shoulder 393 of the channel 390 to effectively seal off the channel 390 to the flow of fluid therethrough. The knock-off plug 320 is secured in place by the threads. The knock-off plug 320 is designed to sustain extremely high pressures that would not even be expected in cementing operations. The knock-off plug 320 has a recess 313 that extends downwardly to an end face 317 and past the groove 315, but recess 313 does not extend upwardly through end 314. A thread relief recess 318 has a fracture point 312 (Fig. 7B). The knock-off plug 320 is designed to break at fracture point 312 if sufficient force is put on end 314 or side 319. The apparatus 310 may be disposed, for example, in a lower sleeve such as the lower sleeve 80 (Fig. 2) in place of apparatus 40. Reference is again made to the operation of the stage tool (see Fig. 4). When apparatus 310 is incorporated in the lower sleeve 80, then before the seal 64 contacts the recompression angle 112, the angled lower lip 71 of the upper sleeve 60 comes into contact with the end 314 of the knock-off plug 320. Downward force, that is continuously being applied (via the closing plug 107 and upper seat 30) to the upper sleeve 60, is now applied to the knock-off plug 320. The knock-off plug 320 breaks at the fracture point 312 and channel 390 opens to volume 110 through bore 321 (Fig. 7A) through the knock-off plug 320. Cement slurry from volume 110 (Fig. 4) may flow freely into volume 113 to prevent an hydraulic lock. The upper sleeve 60 may travel until it hits lower sleeve 80. If desired, the knock-off plug 320 may be made from a suitable crushable material (e.g., ceramics or glass) which crushes instead of being sheared. An hydraulic lock alleviation apparatus 410 is shown in Figs. 8A and 8B. Apparatus 410 includes a channel 490 (e.g., in the lower sleeve 80 of the above-described stage tool 10), a valve spool 420, shear pins 430, 431 and a seal 422. It is preferred that the valve spool 420 be made from a drillable material such as brass or aluminium. The valve spool 420 has a groove 421 in a surface 428. Groove 421 accepts the seal 422. The valve spool 420 has shear pins 431 and 430 pressed into holes 424 and 423, respectively, to prevent the valve spool 420 from inadvertently falling out or shearing out of lower sleeve 80 under cement pressures. The valve spool 420 effectively seals off the channel 490 to the flow of fluid therethrough. The shear pins 431 and 430 are made to withstand a certain amount of shear force to hold the valve spool 420 in place. The valve spool 420 has a channel 440 that consists of a recess 442 and holes 441a, b. The recess 442 extends axially from the end 427 into the valve spool 420 until it intersects the holes 411a, b. The holes 441a, b are located in close proximity to the groove 421, but on the opposite side of groove 421 relative to the hole 423. Reference is again made to the operation of the stage tool (see Fig. 4). For descriptive purposes, it will be assumed that the apparatus 410 is disposed in a sleeve of a stage tool such as the lower sleeve 80 of the tool of Figs. 2 and 4. With this arrangement, before the seal 64 hits the recompression angle 112, the angled lower lip 71 of the upper sleeve 60 comes into contact with the end 427 of valve spool 420. Downward force applied to the valve spool 420 breaks the shear pin 431. Further movement of the upper sleeve 60 causes an edge 425 of a shoulder 429 to abut with an edge 481 of the lower sleeve 80. In turn, this causes the holes 441a, b to travel into the bottom opening 99. Cement slurry now flows freely from volume 110 to volume 113 to prevent an hydraulic lock from occurring. The upper sieeve 60 may travel uninterrupted until abutting with the lower sleeve 80. Another hydraulic lock alleviation apparatus 510 is shown in Fig. 9A. The apparatus 510 is like apparatus 410 but the volume spool 520 is solid and has no shoulder like shoulder 429, and no channel 440. For descriptive purposes, it will be assumed that the apparatus 510 is disposed in the lower sleeve 80 as in Fig. 2 in place of the apparatus 40. Before the seal 64 hits recompression angle 112, the angled lower lip 71 of the upper sleeve 60 comes into contact with the end 527 of valve spool 520. Downward force is now imparted to the valve spool 520 to break a shear pin 531. Further movement of the upper sleeve 60 causes the seal 64 to hit the recompression angle 112. An hydraulic lock will be effected temporarily. This hydraulic lock inhibits or freezes any further travel of the upper sleeve 60 until entrapped fluid in volume 110 helps to push the valve spool 520 out of channel 590 in the lower sleeve 80 and into the volume 113. As the valve spool 520 enters volume 113, cement slurry from the volume 110 may flow freely into the volume 113 to relieve the hydraulic lock. A further hydraulic lock alleviation apparatus 610 is shown in Fig. 10. Apparatus 610 includes a valve spool 650, a seal 653, and a lock member 630. It is preferred that the valve spool 650, the lock member 630 and a pivot pin 640 be made from a drillable material such as aluminium or brass. The lock member 630 has a hole 633 into which the pivot pin 640 slides. This apparatus 610 may be used in place of apparatus 40 in the lower sleeve 80 of Fig. 2. The pivot pin 640 has an upset head 642 that cannot pass through hole 633 of member 630. Member 630 is thus pivotally mounted on the pivot pin 640 between the upset head 642 on one side and by the side 682 on the other. The valve spool 650 has a groove 654 in a side 651 that accepts an extension 638 of a lower arm 635 of the member 630. A groove 652 on the side 651 accepts the seal 653. The valve spool 650 effectively seals off the channel 690 to the flow of fluid therethrough. The extension 638 of lock member 630 is designed to withstand a certain amount of shear force and thereby to withstand a certain amount of cement pressure. The pressure pushes the spool 650 until the side 655 of the recess 654 hits a side 634 of the extension 638. The member 630 (with the pin 640) is designed to cooperate with the spool 650. The manner of cooperation is such that no rotational motion is imparted to member 630 by the spool 650 from cement pressures in the area above it, which would prematurely release it. The member 630 has break-off rod 632 whose side 637 abuts with a side 683 of a recess 681. This abutment prevents any clockwise rotation of member 630. The break-off rod 632 is designed to break at a fracture point at corner 639. Fracture occurs after the application of a predetermined amount of force. The break-off rod 632 may be fashioned to break in response to fluid pressure or in response to a member pushing down on it. Once broken at corner 639, member 630 is rotated to withdraw the extension 638 from groove 654. For descriptive purposes, it will be assumed that the apparatus 610 is disposed in the lower sleeve 80 of the structure of Fig. 2. Before the seal 64 hits the recompression angle 112 (Fig. 4), the angled lower lip 71 of the upper sleeve 60 hits the edge 631 of an extension 636 of the lock member 630. Downward force is now imparted to the member 630. The corner 639 is broken as the edge 637 is forced against edge 683 thereby imparting breaking stresses to corner 639. Break-off rod 632 is broken off of member 630. Member 630 then rotates around pin 640 to retract extension 638 from groove 654. As the seal 64 reaches the recompression angle 112, an hydraulic lock will be effected. This hydraulic lock inhibits or freezes any further travel of the sleeve 60 until entrapped fluid in the volume 110 helps to push the spool 650 out of bore 690 and into volume 113. As the spool 650 enters volume 113, the cement slurry from volume 110 may flow freely into the volume 113 to relieve the hydraulic lock. This allows the upper sleeve 60 to continue to travel until it abuts the lower sleeve 80.

Claims: 1. An hydraulic lock alleviation apparatus (40, 210, 310, 410, 510, 610) for disposition adjacent a first volume (110) in a wellbore (18) in which an hydraulic lock can be created and a second volume (113) into which fluid trapped in the first volume (110) may be communicated by the hydraulic lock alleviation apparatus (40, 210, 310, 410, 510, 610), the apparatus comprising a body member (81) having an opening (82) therethrough permitting fluid communication between the first and second volumes (110, 113), said alleviation apparatus being operable to relieve an hydraulic lock when said opening (82) is closed to the flow of fluid therethrough, characterized in that, in addition to said opening (82), there is provided a channel (90, 290, 390, 490, 590, 690) through the body member (81) in fluid communication with both the first volume (110) and the second volume (113) so that fluid communication is allowed between the two volumes (110, 113) through the channel (90, 290, 390, 490, 590, 690), a pressure responsive member (42, 242, 320, 420, 520, 650) sealingly disposed in the channel (90, 290, 390, 490, 590, 690) to inhibit the flow of fluid from the first volume (110) into the second volume (113) through the channel (90, 290, 390, 490, 590, 690) thereby trapping fluid in the first volume (110), the pressure responsive member (42, 242, 320, 420, 520, 650) being actuable to permit flow of the trapped fluid through the channel (90, 290, 390, 490, 590, 690) from the first volume (110) into the second volume (113) thereby alleviating the formation of an hydraulic lock by the trapped fluid in the first volume (110). 2. Apparatus as claimed in Claim 1, characterized in that the pressure responsive member (42) is a puncturable disc (42) disposed across and closing off the channel (90) and the apparatus includes a puncture pin (41) disposed in the channel (90) and movable to puncture the puncturable disc (42) thereby permitting fluid to flow from the first volume (110) into the second volume (113). 3. Apparatus as claimed in Claim 2, characterized in that the puncture pin (41) is configured so that it passes through the puncturable disc (42) once it has been punctured and exits from the channel (90). 4. Apparatus as claimed in any one of Claims 1 to 3, characterized in that a seal member (45) is disposed in contact with the pressure responsive member (42) and between the pressure responsive member (42) and the channel (90) to provide a seal between the pressure responsive member (42) and the channel (90). 5. Apparatus as claimed in Claim 1, characterized in that the pressure responsive member is a rupturable disc (244) disposed across and closing off the channel (290). 6. Apparatus as claimed in Claim 5, characterized in that a gland nut (243) with a bore (249) therethrough is disposed in the channel (290) to hold the rupturable disc (242) in place in the channel (290), the channel (290) being in communication with the bore (249) of the gland nut (243) so that the fluid is able to flow through the bore (249) in the gland nut (243) and into the second volume (113) upon rupture of the rupturable disc (242). 7. Apparatus as claimed in Claim 1, characterized in that the pressure responsive member (320) is a breakable plug (320) disposed partially in the channel (390) and partially disposed in the first volume (110), the breakable plug (320) having an interior bore (321) extending through the part of the plug (320) disposed in the channel (390) and communicating with the channel (390) and extending into the part of the plug (320) disposed in the first volume (110), the bore (321) not being in communication with the first volume (110), and the plug (320) breakable so that the bore (321) provides communication between the channel (390) and the first volume (110). 8. Apparatus as claimed in Claim 1, characterized in that the pressure responsive member (420, 520) is a valve spool (420, 520) disposed in and movable in the channel (490, 590), the valve spool (420, 520) being held immobile in the channel by shear pin means (430, 431 or 530, 531) extending from within the body (81) to within the valve spool (420, 520), the spool (420, 520) being movable upon shearing of the shear pin means (431 or 531) to permit the flow of fluid from the first volume (110) through the channel (490, 590). 9. Apparatus as claimed in Claim 8, characterized in that the spool (420) has a shoulder (429) for preventing it from falling out of the channel (490) into the second volume (113). 10. Apparatus as claimed in either Claim 8 or 9, characterized in that the spool (420) has a central bore (440) in communication with the first volume (110) and at least one hole (441a, b) in the spool (420) in communication with the bore (440), the spool (420) being movable in the channel (490) so that the hole(s) (441a, b) may be moved into communication with the channel (490) so that fluid may flow from the first volume (110) into the second volume (113). 11. Apparatus as claimed in Claim 8, characterized in that the valve spool (520) is configured to be passable through and out of the channel (590) upon shearing of the shear pin means (531). 12. Apparatus as claimed in Claim 1, characterized in that the pressure responsive member (650) comprises a valve spool (650) movably disposed in the channel (690) and closing it off to flow, a movable arm (630) pivotably mounted to the body member (81) above the spool (650), the arm (630) having a finger (635) extending into a recess (654) on the spool (650), the spool (650) being movable upon release of the finger (635) from the recess (654), the arm (630) being inhibited from movement by a break-off member (632) of the arm (630) which abuts the body member (81) thereby inhibiting movement of the arm (630) and is breakable to permit movement of the arm (630), the member (632) being breakable either in response to the pressure of fluid in the first space (110) or by the force of a member (60) urged against the arm (630). 13. A stage tool (10) for well cementing operations, the tool (10) disposable between and connectible to lengths of casing (25, 26) in a string of casing within a wellbore (18), the stage tool comprising a hollow outer case (11, 12) having a top end (13), a bottom end (14), and a case bore (24) therethrough for communicating with casing (25, 26) connected to the top end (13) and bottom end (14) of the case, the case (11, 12) having cementing port means (16) therethrough for permitting the flow of cementing fluid from the case bore (24) through the cementing port means (16) to the exterior (28) of the case (11, 12), a hollow lower sleeve (80) secured in the case (11) and blocking the cementing port means (16) and inhibiting the flow of fluid therethrough, the lower sleeve (80) being movable in response to a predetermined amount of force to unblock the cementing port means (16), the lower sleeve (80) having disposed therein and therethrough means for alleviating an hydraulic lock between an upper sleeve (60) and the lower sleeve (80), and the upper sleeve (60) being secured in the case (11, 12) above the lower sleeve (80), the upper sleeve (60) being movable in response to a predetermined amount of force to contact and move the lower sleeve (80) and to block the cementing port means (16) after cementing fluid has flowed through the port means (16), characterized in that said alleviating means comprises an hydraulic lock alleviation apparatus as claimed in any one of Claims 1 to 12. 14. A tool as claimed in Claim 13, including the apparatus as claimed in Claim 2, characterized in that the puncture pin (41) is disposed so that it can be contacted and moved by a lower portion (71) of the upper sleeve (60). 15. A tool as claimed in Claim 14, characterized in that the puncture pin (41) and channel (90) are disposed at an angle from the longitudinal axis of the stage tool (10). 16. A tool as claimed in Claim 15, characterized in that the angle is 15° and is inclined toward the body member (80). 17. A tool as claimed in any of Claims 13 to 16, characterized in that the lower sleeve (80) is secured in the case (11, 12) by shear plug means (15) which extends both into a recess (76) in the lower sleeve (80) and into the cementing port means (16), the shear plug means (15) being shearable upon movement of the lower sleeve (80) to open the cementing port means (16). 18. A tool as claimed in any of Claims 13 to 17, characterized in that the sleeves (60, 80) have seat means (35, 83) for receiving plugs (50, 107) for moving the sleeves (60, 80). 19. A tool as claimed in any one of Claims 13 to 18, characterized in that seal means (64) are provided on the upper sleeve (60) for sealing between the exterior surface (61) of the upper sleeve (60) and the case bore (24), and a diffuser groove (68) is formed around the upper sleeve (60) so that when the upper sleeve (60) becomes subjected to the flow of fluid to the cementing ports means (16) the diffuser groove (68) diffuses this flow thereby inhibiting damage to the seal means (64). 20. A method for alleviating an hydraulic lock about a device (80) sealed in a wellbore (18), the device (80) having a body member (81) having a central bore (82) therethrough permitting fluid communication between a first volume (110) above the device (80) and a second volume (113) apart from the first volume (110), characterized in that the method comprises the steps of: (a) providing, in addition to the central bore (82), a channel (90) through the body member (81) between the first volume (110) and the second volume (113); (b) providing a pressure responsive member (42) in contact with trapped fluid in the first volume (110), the pressure responsive member (42) being sealingly disposed across the channel (90) to close it off; and (c) actuating the pressure responsive member (42) to open the channel (90) so that fluid entrapped in the first volume (110) may flow from the first volume (110) to the second volume (113). 21. A method according to Claim 20, wherein the pressure responsive member (42 or 242) is a disc which is rupturable in response to a predetermined fluid pressure or puncturable in response to mechanical action. 22. A method according to Claim 21, in which a puncture pin (41) is disposed adjacent the disc (42) and is movable to puncture the disc (42) to permit the flow of trapped fluid. 23. A method according to Claim 22, in which a movable member (61) disposed above the puncture pin (41) moves in response to a plug (107) pushing on the movable member (60), the movable member (60) being movable to contact the puncture pin (41) and push it through the puncturable disc (42). 24. A method according to Claim 20, wherein the pressure responsive member (42) is a spool (420, 520) mounted in the channel (490, 590) and held therein by a shear pin (431 or 531) which, when sheared permits the spool (420, 520) to move thereby opening the channel (490, 590) to the flow of entrapped fluid.

Inventors: SCHNEIDER, DAVID E., TIMMERMAN, TERRY D.
Applicants: WEATHERFORD U.S. INC.
Application year: 1989
Main classification: E21B33
IPC codes: E21B34, E21B33