Patent Publication Number: US-11021925-B2

Title: Pressure control device

Description:
RELATED APPLICATIONS 
     The present application is a U.S. National Stage application under 35 USC 371 of PCT Application Serial No. PCT/GB2016/053947, filed on 15 Dec. 2016; which claims priority from GB Patent Application No. 1522135.1, filed 15 Dec. 2015, the entirety of both of which are incorporated herein by reference. 
     FIELD 
     The present invention relates to a pressure control device for use in oil and gas wells; in particular, the invention relates to a pressure control device for modulating pressure in a portion of a wellbore. 
     BACKGROUND 
     In the oil and gas exploration and extraction industries it is often desirable to be able to modulate downhole pressure when required. For example, it may be desirable to isolate a section of wellbore to create sections of differential pressure within the bore. A pressure control device may be used to create a seal within the bore, such that fluid pressure on one side of the seal increases relative to fluid pressure on the other side of the seal. 
     As wells get deeper, there is an increasing need to be able to transmit signals from surface to downhole locations which can be many miles away. Communication lines have to pass many restrictions including pressure control devices such as flexible cup seals. To bypass seals such as these, the conduit is separated and attached to either side of the seal to provide a continuous passage which maintains the integrity of the seal. However, with more sophisticated communication lines, such as a fibre-optic cable, the quality of information can be severely affected by splitting the cable in this way. 
     SUMMARY 
     According to a first aspect of the present invention there is provided a pressure control device for use in an oil well, the pressure control device comprising: 
     a support member configured to be located on a mandrel or a tubular, the support member defining at least one conduit throughbore configured to receive a conduit; and 
     a flexible cup member mounted to the support member; 
     wherein, in use, a conduit can pass through the pressure control device intact. 
     In an embodiment of the present invention, a pressure control device is provided which can seal the annulus between a tubular and the casing and permit a well conduit, located in the annulus, to pass without the need to break the conduit, or pin the conduit against the tubular. This is of particular utility where the conduit is, for example, a fibre-optic cable, for relaying information from a downhole environment to the surface, as the integrity of the cable is paramount. 
     For the avoidance of doubt, by conduit it is meant an apparatus configured to carry information, signals, pressure, or any other form of communicating between a surface location and a downhole location. The conduit may be the communication conduit itself or a protective shell around the communication conduit. 
     The pressure control device may have a longitudinal axis. 
     In at least one embodiment, the longitudinal axis, in use, is aligned with a tubular or mandrel located in an oil well. 
     The support member may fully define the at least one conduit throughbore. 
     The/each support member conduit throughbore may comprise an at least one conduit seal configured, in use, to form a seal with the conduit. 
     The/each support member conduit throughbore may be configured to allow a single conduit to pass therethrough. 
     The support member may comprise a first section and a second section. 
     Each support member section may define a portion of the/each conduit throughbore. 
     Each support member section may define a longitudinal portion of the/each conduit throughbore. 
     The support member sections may be configured to be engaged, in use, to clamp, secure and/or seal the/each conduit in a conduit throughbore. 
     Each support member section may define an engaging surface, the support member first section engaging surface being complementary to the support member second section engaging surface, such that the respective engaging surfaces come into contact when the support member sections are engaged. 
     The support member section engaging surfaces may be adapted to form a seal therebetween. 
     The support member section engaging surfaces may define complementary interlocking surfaces. 
     The support member may comprise at least one support member seal adapted to form a seal between the support member sections. 
     At least a region of the support member first section engaging surface and at least a region of the support member second section engaging surface are arranged such that a pressure applied to an internal surface of the support member increases the seal between the support member sections. 
     The support member may be adapted to be mounted to a mandrel. 
     The support member may be adapted to be mounted to a mandrel such that rotational movement of the pressure control device with respect to the mandrel is prevented. 
     The flexible cup member may be configured to move between a run-in configuration and a deployed configuration. 
     In use, when used to form a seal with a tubular, the flexible cup member maximum diameter may be less than the tubular minimum internal diameter. 
     The flexible cup member may comprise a first section and a second section. 
     The flexible cup member first section may be associated with the support member first section and the flexible cup member second section may be associated with the support member second section. 
     Each flexible cup member section may define an engaging surface, the flexible cup member first section engaging surface being complementary to the second flexible cup member engaging surface, such that the respective engaging surfaces come into contact when the flexible cup member sections are engaged. 
     The flexible cup member section engaging surfaces may define complementary interlocking surfaces. 
     The flexible cup member section engaging surfaces may be adapted to form a contact seal therebetween. 
     At least a region of the flexible cup member first section engaging surface and at least a region of the second flexible cup member engaging surface are arranged such that a pressure applied to an internal surface of the flexible cup member increases the seal between the flexible cup member sections. 
     At least a region of the first flexible cup member section engaging surface may be defined by an internal surface of the first flexible cup member section and least a region of the second flexible cup member section engaging surface may be defined by an external surface of the second flexible cup member section. 
     The second flexible cup member section may be configured to extend around the majority of the circumference of the support member. In turn this would mean that the second flexible cup member section extends around the majority of the circumference of the mandrel or tubular to which the pressure control device is attached. 
     The flexible cup member may define an interface surface for engaging a support member interface surface, the support member interface surface defining a rib, the rib forming a contact seal with the flexible cup member interface surface. 
     The rib may be a circumferential rib. 
     According to a second aspect of the present invention there is provided a method of installing a pressure control device in an oil well: 
     attaching a pressure control device to a mandrel, the pressure control device having a support member and a flexible cup member, the flexible cup member being mounted to the support member, the support member defining at least one conduit throughbore configured to receive a conduit; and passing a conduit through a support member conduit throughbore. 
     According to a third aspect of the present invention there is provided a method of installing a pressure control device in an oil well: 
     attaching a pressure control device first portion to the mandrel, the pressure control device first portion comprising a support member first section and a flexible cup member first section; 
     laying a conduit in a conduit throughbore first section, the conduit throughbore first section defined by the support member first section; 
     attaching a pressure control device second portion to the mandrel, the pressure control device second portion comprising a support member second section and a flexible cup member second section, the support member second section defining a conduit throughbore second section; and 
     connecting the pressure control device first portion to the pressure control device second section such that conduit throughbore first and second sections come together to form the conduit throughbore through the support member. 
     According to a fourth aspect of the present invention there is provided a pressure control device for use in an oil well, the pressure control device comprising: 
     a support member configured to be located on a mandrel or a tubular, the support member defining at least one conduit throughbore configured to receive a conduit; and 
     a seal member mounted to the support member; 
     wherein, in use, a conduit can pass through the pressure control device intact. 
     The seal member may be a cup member. 
     The cup member may be flexible. 
     It will be understood that the features listed as non-essential features listed in respect of one aspect may be equally applicable to other aspects but have not been repeated for brevity. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       An embodiment of the present invention will now be described with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of a pressure control device for use in an oil well shown fitted to a mandrel; 
         FIG. 2  is a section of the pressure control device  10  of  FIG. 1 ; 
         FIG. 3  is a perspective view of the pressure control device of  FIG. 1  shown with the pressure control device sections separated; 
         FIG. 4  is a perspective view, from below, of the pressure control device upper section; 
         FIG. 5  is a perspective view, from above, of the support member first section; 
         FIG. 6  is a plan view of the support member second section; 
         FIG. 7  is a section through the pressure control device upper section; and 
         FIGS. 8 to 11  are a sequence of side views showing the installation of the pressure control device of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Reference is first made to  FIG. 1 , a perspective view of a pressure control device, generally indicated by reference numeral  10 , for use in an oil well (not shown) and  FIG. 2 , a section of the pressure control device  10  of  FIG. 1 , according to a first embodiment of the present invention. 
     The pressure control device  10  comprises a support member  12  located on a mandrel  14  and a flexible cup member  16  mounted to the support member  12 . 
     Running up the side of the mandrel  14  from a downhole location to a surface location are five fibre-optic cables  18  of which one is shown for clarity. The cables  18  pass through the pressure control device  10 , and particularly each cable  18  passes through a throughbore  19  in the support member  12 , the throughbore  19  being one of five such throughbores  19  defined by the support member  12 , as will be discussed in due course. 
     Such an arrangement permits the cables  18  to pass through the pressure control device  10  without the need for the fibre-optic cables  18  to be split. 
     Referring to  FIG. 3 , a perspective view of the pressure control device  10  of  FIG. 1 , it will be seen that the support member  12  comprises a support member first section  20  and a support member second section  22 , and the flexible cup member  16  comprises a flexible cup member first section  24  and a flexible cup member second section  26 . 
     The support member first section  20  and the flexible cup member first section  24  together form a pressure control device lower section  28 , and the support member second section  22  and the flexible cup member second section  26  together form a pressure control device upper section  30 . 
     The pressure control device lower and upper sections  28 ,  30  come together to form the pressure control device  10 . Particularly, an engaging surface  32  defined by the support member first section  20  and an engaging surface  34  (not visible on  FIG. 3 ) defined by the support member second section  22  are complementary and engage when the upper and lower sections  30 ,  28  are brought together. 
     The support member second section engaging surface  34  can be seen on  FIG. 4 , a perspective view, from below, of the pressure control device upper section  30 . Looking at  FIG. 4  and also  FIG. 5 , a perspective view from above of the support member first section  20 , it can be seen that both of the support member sections  20 ,  22  define part of the five throughbores  19   a - 19   e , such that engagement of the engaging surfaces  32 ,  34  create the fully defined throughbores  19 . 
     As will also be noted from  FIG. 4  and  FIG. 5 , the support member sections  20 ,  22  define a series of throughbore recesses  36  configured to receive a semicircular seal  37  (shown only on  FIG. 3 ) to prevent leakage of pressure along the throughbores  19 , depleting the effect of the pressure control device  10 . 
     Again referring to  FIG. 5 , a further seal recess  38  extends along the support member first section engaging surface  32 , the seal recess  38  being configured to receive a rubber seal  39  (shown only on  FIG. 3 ). 
     The extreme edges of the support member first section engaging surface  32  are defined by support member faces  40 ,  42  which receive complementary support member faces  44 ,  46  defined by the support member second section when the pressure control device  10  is formed. 
     It will be noted from  FIG. 3  that the support member faces  40 ,  42 ,  44 ,  46  are cut at an angle to the vertical axis  50  of the pressure control device  10 ; and, from  FIG. 6 , a plan view of the support member second section  22 , is also cut at an angle to the radius  52  of the pressure control device  10 . This arrangement ensures that, in use, pressure inside the flexible cup member  16  does not force the pressure control device support member sections  20 ,  22  apart. Indeed, the horizontal and vertical components of a force applied to a flexible cup member interior  48  would only act to increase the pressure on the interface between the support member faces  40 ,  42 ,  44 ,  46 . 
     Referring to  FIGS. 4 and 5 , it will be noted from  FIG. 5  that the support member first section  20  defines a throughbore  54  configured to receive the mandrel  14 , and, from  FIG. 4 , the flexible cup member second section  26  includes an extending section  58  which defines a throughbore  56 ; the extending section being configured to wrap around the circumference of the mandrel  14 . 
     The extending section  58  includes a cut  60  which, as will be shown in due course, permits the extending section  58  to be opened to allow the pressure control device upper section  30  to be fitted to the mandrel  14 . 
     As is visible from  FIG. 4 , the extending section  60  is at an angle both to the vertical axis  50  (not shown on  FIG. 4 ) of the pressure control device  10 , and also at an angle to the radius  52  (not shown on  FIG. 4 ) of the pressure control device  10 . 
     Reference is now made to  FIG. 7 , a section through the pressure control device upper section  30 . As can be seen, the flexible cup member  16  includes an elastomeric portion  62  and a mesh backup portion  64 . 
     The flexible cup member  16  is bonded to the support member  12 . 
     Installation of the pressure control device  10  will now be described with reference to  FIGS. 8 to 11 , a sequence of side views showing the installation of the pressure control device  10  of  FIG. 1 . 
     The pressure control device lower section  28  is slid down the mandrel  14  to the desired location. A collar  86  (shown in  FIG. 1 ) may be installed to support the pressure control device lower section  28 . Although not visible in  FIG. 8 , a threaded bore is provided on the pressure control device lower section  28  to allow the pressure control device lower section  28  to be secured to the mandrel  14 . This threaded bore  88  can be seen on  FIG. 3 . 
     Referring to  FIG. 9 , the fibre-optic cables  18 , of which one is shown, are positioned on the mandrel  14  and laid into the pressure control device throughbores  19 . 
     Referring to  FIG. 10 , the pressure control device upper section  30  is brought into engagement with the mandrel  14 ; the extending section cut  60  being opened up to allow the pressure control device upper section  30  to be fitted to the mandrel  14 . 
     It will be noted that each of the pressure control device sections  28 ,  30  include an alignment hole  90 ,  92 . These alignment holes  90 ,  92  are used to align the pressure control device sections  28 ,  30  when they are brought together as shown in  FIG. 11 . 
     Once brought into near alignment, a dowel (not shown) can be tapped into the alignment holes  90 ,  92 , to complete alignment. 
     The pressure control device lower and upper sections  28 ,  30  are then bolted together and to the mandrel  14  through countersunk threaded bores  94  which secure the pressure control device to the mandrel. This completes the seal between the pressure control device sections  28 ,  30  and sealingly traps the fibre optic cables  18  within the pressure control device support member  12 , such that the pressure control device  10  enables the fibre optic cables  18  to pass through the pressure control device  10  without severance, termination or damage in any form. 
     Various modifications and improvements may be made to the above-described embodiments without departing from the scope of the present invention. For example, although five conduit throughbores are shown, any suitable number may be utilised. In other embodiments, where less than five conduit throughbores are required, a plug may be provided to seal unused throughbores.