Abstract:
An apparatus for connecting an outer tubular ( 236 ) and an inner tubular ( 218 ) on a well platform by applying a crimping force to the outer tubular ( 236 ) when the outer tubular ( 236 ) is disposed about the inner tubular ( 218 ) and the inner tubular ( 218 ) is suspending from the well platform. The apparatus includes a support assembly ( 244 ) operably associated with the well platform and a crimping assembly ( 242 ) operably associated with the support assembly ( 244 ). The crimping assembly ( 242 ) is operable to mechanically deform the outer tubular ( 236 ) into contact with the inner tubular ( 218 ).

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This is a divisional of co-pending application Ser. No. 12/821,733, filed Jun. 23, 2010. 
     
    
     TECHNICAL FIELD OF THE INVENTION 
       [0002]    This invention relates, in general, to equipment utilized in conjunction with operations performed in subterranean wells and, in particular, to an apparatus and method for fluidically coupling tubular sections on a well platform to establish a dual flow path between adjacent tubular sections and the tubular system formed thereby. 
       BACKGROUND OF THE INVENTION 
       [0003]    Without limiting the scope of the present invention, its background will be described with reference to producing fluid from a hydrocarbon bearing subterranean formation, as an example. 
         [0004]    During the completion of a well that traverses a hydrocarbon bearing subterranean formation, production tubing and various completion equipment are installed in the well to enable safe and efficient production of the formation fluids. For example, to prevent the production of particulate material from an unconsolidated or loosely consolidated subterranean formation, certain completions include one or more sand control screens positioned proximate the desired production interval or intervals. In other completions, to control the flow rate of production fluids into the production tubing, it is common practice to install one or more flow control devices within the tubing string. Attempts have been made to utilize fluid flow control devices within completions requiring sand control. For example, in certain sand control screens, after production fluids flows through the filter medium, the fluids are directed into a flow control section. The flow control section may include one or more flow restrictors such as flow tubes, nozzles, labyrinths or the like. Typically, the production rate through these flow control screens is fixed prior to installation by individually adjusting the flow restrictors of the flow control screens. 
         [0005]    It has been found, however, that the use of flow control screens as each of the screening elements in a completion string adds unnecessary cost and complexity to the completion. Accordingly, a need has arisen for a completion string that is operable to control the inflow of formation fluids in a completion requiring sand control that does not require the use of flow control screens as each of the screening elements. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention disclosed herein comprises an apparatus and method for fluidicially coupling tubular sections on a well platform to establish a dual flow path between adjacent tubular sections and the tubular system formed thereby. In one implementation, the tubular system may be in the form of a completion string that is operable to control the inflow of formation fluids in a completion requiring sand control that does not require the use of flow control screens as each of the screening elements. 
         [0007]    In one aspect, the present invention is directed to a method for connecting tubular sections on a well platform. The method includes providing a crimping assembly, providing first and second tubular sections, the second tubular section having a sleeve disposed thereabout, suspending the first tubular section from the well platform, threadably engaging the second tubular section with the first tubular section forming a coupled joint, locating the sleeve over the coupled joint, wherein a first portion of the sleeve is disposed about the first tubular section and a second portion of the sleeve is disposed about the second tubular section, crimping the second portion of the sleeve with the crimping assembly to connect the sleeve to the second tubular section and crimping the first portion of the sleeve with the crimping assembly to connect the sleeve to the first tubular section. 
         [0008]    In one embodiment, the method may involve establishing a flow path between the first and second tubular sections in a region between the interior of the sleeve and the exterior of the coupled joint. In another embodiment, the method may involve pneumatically operating the crimping assembly or hydraulically operating the crimping assembly. 
         [0009]    The method may further involve providing first and second tubular screen sections, suspending the first tubular section from a screen table located on the well platform, threadably engaging the second tubular section with the first tubular section forming a coupled joint, removing the screen table, supporting the first and second tubular screen sections with a block assembly of the well platform and establishing a flow path between the first and second tubular screen sections in a region between the interior of the sleeve and the exterior of the coupled joint. 
         [0010]    In another aspect, the present invention is directed to an apparatus for connecting an outer tubular and an inner tubular on a well platform by applying a crimping force to the outer tubular when the outer tubular is disposed about the inner tubular and the inner and outer tubulars are suspended from the well platform. The apparatus includes a support assembly operably associated with the well platform and a crimping assembly operably associated with the support assembly. The crimping assembly is operable to crimp the outer tubular into contact with the inner tubular. 
         [0011]    In one embodiment, the crimping assembly includes an enclosure having a pipe receiving region. The enclosure has a rear assembly and a pair of oppositely disposed arm assemblies. The arm assemblies are rotatable relative to the rear assembly between an open position wherein the enclosure is operable to receive and release the outer tubular member and a closed position wherein the enclosure is operable to crimp the outer tubular into contact with the inner tubular. In this embodiment, the crimping assembly may include a locking assembly for maintaining the crimping assembly the closed position during crimping. Also, in this embodiment, the crimping assembly may include a plurality of radially actuated piston members operable to engage the outer tubular member and crimp the outer tubular member into contact with the inner tubular member. In one embodiment, the crimping assembly may include a pneumatic motor. In another embodiment, the crimping assembly may include a hydraulic motor. In one embodiment, the support assembly may be a support wire on which the crimping assembly may be slidably mounted. In another embodiment, the support assembly may be the derrick of the well platform. In a further embodiment, the support assembly may be the hoisting apparatus of the well platform. In certain embodiments, the crimping assembly may be operable to mechanically deform the outer tubular into contact with the inner tubular forming, for example, a close fitting relationship between the outer tubular and the inner tubular, a sand tight relationship between the outer tubular and the inner tubular or a fluid tight relationship between the outer tubular and the inner tubular. 
         [0012]    In another aspect, the present invention is directed to a completion assembly for installation in a wellbore positioned below a well platform. The completion assembly includes first and second tubular screen sections that are threadably engaged with one another to form a coupled joint on the well platform. The tubular screen sections each have a nonperforated base pipe, an outer housing disposed about the base pipe and forming a fluid flow path therebetween and a filter medium disposed about the base pipe. A sleeve is positioned over the coupled joint, wherein a first portion of the sleeve is crimped on the well platform into contact with the outer housing of the first tubular screen section and wherein a second portion of the sleeve is crimped on the well platform into contact with the outer housing of the second tubular screen section, such that the sleeve establishes a flow path between the first and second tubular screen sections in a region between the interior of the sleeve and the exterior of the coupled joint. 
         [0013]    In one embodiment, the completion assembly includes a flow control assembly that is in fluid communication with the first and second tubular screen sections. The flow control assembly is operable to control fluid inflow into an interior of the completion assembly. In another embodiment, the outer housing of the second tubular screen section includes a disconnection ring. In this embodiment, the sleeve is crimped into contact with the disconnection ring which enables threadable release of the sleeve from the second tubular screen section. Also, in this embodiment, the disconnection ring and the sleeve may each have a mating profile for locating the sleeve relative to the first and second tubular screen sections prior to crimping. In another embodiment, a seal may be positioned between the sleeve and the outer housing of the second tubular screen section, the outer housing of the first tubular screen section or both. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which: 
           [0015]      FIG. 1  is a schematic illustration of a completion assembly formed according to an embodiment of the present invention that is being installed from an offshore well platform; 
           [0016]      FIGS. 2A-2B  are cross sectional views of consecutive axial sections of a completion assembly formed according to an embodiment of the present invention; 
           [0017]      FIGS. 3A-3E  are side views of a completion assembly in various assembly stages being formed according to an embodiment of the present invention; 
           [0018]      FIGS. 3F-3G  are side views of a completion assembly in various disassembly stages according to an embodiment of the present invention; 
           [0019]      FIG. 4A  is a top view of a crimping assembly operable to mechanically connect pipe sections on a well platform according to an embodiment of the present invention; and 
           [0020]      FIG. 4B  is an enlarged view of a crimping assembly operable to mechanically connect pipe sections on a well platform according to an embodiment of the present invention during a crimping process. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention. 
         [0022]    Referring initially to  FIG. 1 , therein is depicted a completion string embodying principles of the present invention being deployed from an offshore well platform that is schematically illustrated and generally designated  10 . As depicted, a semi-submersible well platform  12  is centered over a submerged oil and gas formation  14  located below sea floor  16 . A subsea conduit  18  extends from well floor  20  of platform  12  to wellhead installation  22  including subsea blow-out preventers  24 . Platform  12  has a rotary table  26 , a derrick  28 , a travel block  30 , a hook  32  and a swivel  34  for raising and lowering pipe strings, such as a tubing string  36 . A wellbore  38  extends through the various earth strata including formation  14 . Wellbore  38  has a substantially vertical section  40 , the upper portion of which has a casing string  42  cemented therein. Wellbore  38  also has a substantially horizontal section  44  that extends through formation  14 . As illustrated, substantially horizontal section  44  of wellbore  38  is open hole. 
         [0023]    Tubing string  36  provides a conduit for formation fluids to travel from formation  14  to the surface. At its lower end, tubing string  36  is coupled to a completion string  46  that has been installed in the completion interval of wellbore  38 . Completion string  46  includes a plurality of packers  48 ,  50 ,  52  that divide the completion interval into production intervals  54 ,  56 . Within each production interval  54 ,  56 , completion string  46  includes a completion assembly  58 ,  60  that is operable to filter particulate matter out of the production fluid stream and control the inflow rate of the production fluid stream. 
         [0024]    As illustrated, completion assembly  58  includes a flow control device  62  that may be in the form of a fixed or variable choke or other flow restricting device having an orifice or utilizing flow tubes, nozzles, labyrinths or the like that are operable to control the flow rate of fluids from formation  14  into the interior of flow control device  62 . Completion assembly  58  also includes a plurality of sand control screen assemblies  64  that may have one or more wire wrapped filter media, a prepacked filter media, a multilayer wire mesh filter media or the like that are operable to allow fluid flow therethrough but prevent the passages of particles of a predetermined sized from passing therethrough. Each of the sand control screen assemblies  64  is fluidically coupled to an adjacent sand control screen assembly  64  with a dual path sleeve assembly  66  that is operable to create a fluid flow path between adjacent sand control screen assemblies  64  in the region between the interior of dual path sleeve assembly  66  and the exterior of the coupled joint that connects adjacent sand control screen assemblies  64 . As illustrated, flow control device  62  may be integral with one of the sand control screen assemblies  64  or may be a standalone tool within completion assembly  58 . In a like manner, completion assembly  60  includes a flow control device  68  and a plurality of sand control screen assemblies  70  having dual path sleeve assemblies  72  positioned therebetween. 
         [0025]    During assembly, and by way of example, dual path sleeve assemblies  66 ,  72  are mechanically deformed into contact with sand control screen assemblies  64 ,  70  on well platform  12  using a crimping assembly  74 . Preferably, crimping assembly  74  is located proximate to rotary table  26  and is movable relative thereto. In the illustrated embodiment, crimping assembly  74  is being supported by a support assembly  76  that includes a support wire  78  that enables crimping assembly  74  be slidably maneuvered into position to receive and crimp dual path sleeve assemblies when completion assemblies  58 ,  60  are being supported by block  30 . Alternatively, crimping assembly  74  could be supported within derrick  28  or by the hoisting apparatus of well platform  12 . 
         [0026]    Once completion assemblies  58 ,  60  are installed in wellbore  38 , production fluid from formation  14  enters production intervals  54 ,  56 , passing through completion assemblies  58 ,  60  before entering tubing string  36 . By way of example, the production fluid that enters production interval  54  passes through the filter medium of one of the sand control screen assemblies  64  and travels toward flow control device  62 . Preferably, each of the sand control screen assemblies  64  has a base pipe that is in the form of a blank pipe with no perforations such that the fluid entering completion interval  54  may pass through any one of the sand control screen assemblies  64  but must travel through flow control device  62  in order to enter tubing string  36 . More specifically, the production fluid that enters one of the sand control screen assemblies  64  that is not adjacent to flow control device  62  passes through one or more dual path sleeve assemblies  66  that create a fluid path around the exterior of the sand control screen assemblies  64  over the jointed connections or couplings. In this manner, a single flow control device  62  can be used to control the flow rate of the production fluid stream being produced through a plurality of sand control screen assemblies  64 . 
         [0027]    Even though  FIG. 1  depicts completion assemblies  58 ,  60  in an open hole environment, it should be understood by those skilled in the art that the apparatuses, systems and methods of the present invention are equally well suited for use in cased wells. Also, even though  FIG. 1  depicts a specific number of sand control screen assemblies being fluidically coupled together with dual path sleeve assemblies in each production interval, it should be understood by those skilled in the art that any number of sand control screen assemblies that are fluidically coupled together with dual path sleeve assemblies may be deployed within a production interval without departing from the principles of the present invention. In addition, even though  FIG. 1  depicts a single completion assembly in each production interval, it should be understood by those skilled in the art that any number of completion assemblies may be deployed within a production interval without departing from the principles of the present invention. Further, even though  FIG. 1  depicts an offshore well platform, it should be understood by those skilled in the art that the apparatuses, systems and methods of the present invention are equally well suited for use in association with onshore well platforms. 
         [0028]    Even though  FIG. 1  depicts a horizontal completion, it should be understood by those skilled in the art that the apparatuses, systems and methods of the present invention are equally well suited for use in well having other directional configurations including vertical wells, deviated wells, slanted wells, multilateral wells and the like. Accordingly, it should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward, left, right, uphole, downhole and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure, the uphole direction being toward the surface of the well and the downhole direction being toward the toe of the well. 
         [0029]    Referring next to  FIGS. 2A-2B , therein are depicted consecutive axial sections of a completion assembly formed according to an embodiment of the present invention that is generally designated  100 . Completion assembly  100  includes upper and lower tubular screen sections  102 ,  104  that are threadably engaged with one another to form a coupled joint  106 . Screen section  102  includes a base pipe  108  depicted as a blank pipe having no perforations. Screen section  102  also includes a filter medium  110  that is depicted as a single layer wire wrapped screen but may be any desired screen type suitable for the intended purpose of completion assembly  100  as would be known by those skilled in the art. At its lower end, filter medium  110  is coupled to an outer housing  112 . Preferably, filter medium  110  and outer housing  112  are welded together but other suitable coupling techniques could alternatively be used. In the illustrated embodiment, outer housing  112  forms an annulus  114  with base pipe  108  that is in fluid communication with an annulus  116  between filter medium  110  and base pipe  108 . Threadably coupled to the lower end of outer housing  112  is a disconnection ring  118 . Similarly, screen section  104  includes a base pipe  120  depicted as a blank pipe having no perforations. Screen section  104  also includes a filter medium  122 . At its upper end, filter medium  122  is coupled to an outer housing  124 . In the illustrated embodiment, outer housing  124  forms an annulus  126  with base pipe  120  that is in fluid communication with an annulus  128  between filter medium  122  and base pipe  120 . Coupled joint  106  includes an internally threaded collar  130  that receives the lower threaded pin end  132  of base pipe  108  and the upper threaded pin end  134  of base pipe  120 . In this manner, an internal fluid path  136  is formed within completion assembly  100 . 
         [0030]    Completion assembly  100  includes a dual path sleeve assembly  138  that extends between the lower end of outer housing  112  and the upper end of outer housing  124 . In the illustrated embodiment, the upper end of sleeve assembly  138  has an internal mating profile  140  that receives an external mating profile  142  of disconnection ring  118 . This interaction enables proper positioning of sleeve assembly  138  relative to the other parts of completion assembly  100  to insure proper alignment prior to crimping sleeve assembly  138  in place. Preferably, the upper end of outer housing  120  includes a seal element, depicted as o-ring  144 , which provides as seal between sleeve assembly  138  and outer housing  124  upon crimping. Alternatively or additionally, a seal element may be positioned between sleeve assembly  138  and outer housing  112 . Once sleeve assembly is positioned as illustrated and is mechanically deformed into crimping contact with outer housing  112  and outer housing  124 , a fluid pathway  146  is established between upper and lower tubular screen sections  102 ,  104  between the interior of sleeve assembly  138  and the exterior of coupled joint  106 . In embodiments that do not include a seal between sleeve assembly  138  and either outer housing  112 , outer housing  120  or both, a metal-to-metal seal may be established therebetween. It should be understood by those skilled in the art, however, that the relationship between sleeve assembly  138  and outer housings  112 ,  120  need only be sufficiently close fitting to exclude sand particles of a size to also be excluded by filter media  110 ,  122 , but not necessarily fluid tight, i.e., a sand control fit. In this configuration, fluid entering annulus  128  through filter medium  122  travels through annulus  126  into fluid pathway  146 , then through annulus  114  and annulus  116 . In a similar manner, fluid entering any such tubular screen section of a completion assembly of the present invention travels along a similar flow path until such fluid encounters a flow control device as discussed above and enters the interior of the tubing string. 
         [0031]    Referring next to  FIGS. 3A-3E , therein are depicted a completion assembly  200  of the present invention in various assembly stages. In  FIG. 3A , a lower tubular section depicted as tubular screen section  202  is being supported by the well platform and specifically suspended from a screen table assembly  204 . Screen table assembly  204  includes a support platform  206  that is attached to rotary table  208  generally located on well floor  210  of the well platform. Use of screen table assembly  204  is preferred when installing tubular screen sections to prevent damaging the screen sections during assembly. As the screen sections are being run in the wellbore, capture doors  212 ,  214  are positioned below the collar  216  of tubular screen section  202  enabling completion assembly  200  to be suspended from screen table assembly  204  while an upper tubular section depicted as tubular screen section  218  is maneuvered into position above screen section  202  using the hoisting apparatus of the well platform. Once screen sections  202  and  218  are threadably connected to form coupled joint  220 , completion assembly  200  may be supported by the hoisting apparatus of the well platform. Thereafter, capture doors  212 ,  214  of screen table assembly  204  may be opened to release completion assembly  200  and screen table assembly  204  may be relocated. 
         [0032]    As best seen in  FIG. 3B , completion assembly  200  is similar in design to completion assembly  100 . In the illustrated portions, screen section  202  includes a base pipe  222 , a filter medium  224  and an outer housing  226  that forms an annulus with base pipe  222 . Similarly, screen section  218  includes a base pipe  228 , a filter medium  230  and an outer housing  232  that forms an annulus with base pipe  228  and includes a disconnection ring  234 . In  FIG. 3B , completion assembly  200  is being supported by the hoisting apparatus of the well platform after screen table assembly  204  has been relocated. In this position, a dual path sleeve assembly  236 , which is originally carried by screen section  218 , may be shifted downwardly into position traversing coupled joint  220  and extending between screen section  218  and screen section  202 , as best seen in  FIG. 3C . As discussed above, the upper end of sleeve assembly  236  may preferably include an internal mating profile that receives an external mating profile of disconnection ring  234 , which enables proper positioning of sleeve assembly  236  relative to the other parts of completion assembly  200  and specifically to align crimping collar  238  of sleeve assembly  236  with disconnection ring  234  and crimping collar  240  of sleeve assembly  236  with outer housing  226  of screen section  202 . 
         [0033]    As best seen in  FIG. 3D , once sleeve assembly  236  is properly positioned, a crimping assembly  242  deployed from a support assembly  244  of the well platform may be maneuvered into position around completion assembly  200 . As best seen in  FIG. 4A , crimping assembly  242  includes an enclosure assembly  246  having a pipe receiving region  248 . Enclosure assembly  246  includes a rear assembly  250  and a pair of oppositely disposed arm assemblies  252 ,  254  that are rotatably coupled to rear assembly  248 , respectively at hinges  256 ,  258  to enable crimping assembly  242  to receive and release tubular members. Enclosure assembly  246  also includes locking assembly  260  for maintaining crimping assembly  242  in the closed position during crimping operations. Crimping assembly  242  includes a lift assembly  262  that is operable to be coupled to support assembly  244  of the well platform and to allow movement of crimping assembly  242  relative to completion assembly  200 . Crimping assembly  242  also has a control system  264  that includes a motor  266 , such as a hydraulic motor, a pneumatic motor or the like that may be connected to one or more supply/return lines  268 ,  270  of the well platform, as well as power control switch  272 . 
         [0034]    Returning to  FIG. 3D , once sleeve assembly  236  and crimping assembly  242  are properly positioned around completion assembly  200 , crimping assembly  242  may be operated to mechanically deform crimping collar  238  into contact with disconnection ring  234 . As best seen in  FIG. 4B , crimping assembly  242  includes a plurality of radially actuated piston members  274  that are operable to engage the surface of crimping collar  238  and create a sufficient crimping force such that a mechanical connection is formed between crimping collar  238  and disconnection ring  234 . After the crimping process of crimping collar  238  is complete, the crimping force is released and completion assembly  200  may be lifted by the hoisting apparatus of the well platform to align crimping collar  240  with crimping assembly  242 , as best seen in  FIG. 3E . The crimping process described above is then repeated to establish a mechanical connection between crimping collar  240  and outer housing  226  of screen section  202 . As described above, once sleeve assembly  236  mechanically attached to screen section  202  and screen section  218 , a flow path is created between screen section  202  and screen section  218  in a region between the interior of sleeve assembly  236  and the exterior of coupled joint  220 . Thereafter, the screen section connection and sleeve crimping process can be repeated for addition sections of screen to be attached within completion assembly  200 . 
         [0035]    If it is desired to remove completion assembly  200  from the wellbore, the present invention enables disassembly of completion assembly  200 . As best seen in  FIG. 3F , completion string  200  may be lifted out of the wellbore using the hoisting apparatus of the well platform. Using standard tong and chain techniques, sleeve assembly  236  can be disconnected from screen section  218  as sleeve assembly  236  was initially mechanically connected to disconnection ring  234  which enables sleeve assembly  236  to be threadably released from screen section  218  by threadably decoupling disconnection ring  234  from outer housing  232 . Sleeve assembly  236  may then be positioned around screen section  202  to expose coupled joint  220 . Thereafter, screen table assembly  204  may be returned to its position proximate rotary table  208 . As illustrated in  FIG. 3G , capture doors  212 ,  214  are positioned below the collar  216  of screen section  202  enabling completion assembly  200  to be suspended from screen table assembly  204 . Screen section  218  may then be threadably decoupled from screen section  202 . This process can be repeated as required for additions screen sections. 
         [0036]    While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.