Patent ID: 12258835

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This disclosure relates to a pressure containment system, for example a back-pressure valve (BPV) system or a two-way check valve (TWCV) system, for dislodging a stuck or clogged pressure isolator (e.g., a pressure valve, two-way check valve, back-pressure valve). The pressure containment system is deployed to isolate a well or high-pressure zone of a well so that high pressures (e.g., between 0 psi to 15,000 psi, inclusive) are maintained in the isolated well or zone. The pressure containment systems, can be used, for example, as a permanent, semi-permanent barrier, or as a temporary barrier to isolate a well or a portion of the well (a first zone of the well). Temporary isolation operations include, for example, replacing a production tree (Christmas tree, tree) or master valves in a nipple up and/or down-installation and/or removal operation. The pressure containment system can be manually or hydraulically powered.

In use, an isolator or pressure valve of the system is arranged in a tubing hanger of the production tree and forms a contact seal with an internal profile of the tubing hanger. The pressure valve is rotatable relative to the tubing hanger. The seal between the pressure valve and the tubing hanger is maintained when the pressure valve is rotated relative to the tubing hanger. BPV/TWCV and tubing hanger can be decoupled and the seal disengaged by axially distancing the pressure valve from the tubing hanger (for example in a first, uphole direction). The lodged debris prevents axial and rotational movement of the pressure valve relative to the tubing hanger. BPV/TWCV could become stuck in the tubing hanger of the wellhead when debris is lodged between the pressure valve and the tubing hanger. In some instances, additional rotational force required to rotate the BPV/TWCV in the tubing hanger profile.

To dislodge the pressure valve from the debris, the pressure containment system can separate a housing to expose a lubricator rod connected to the pressure valve. The lubricator rod connects to an external torque generator (e.g., a high power wrench) and transfer a high amount of torque (e.g., about 1,000 ft-lbs to about 20,000 ft-lbs) to the pressure valve. The torque force overcomes the static frictional force from the debris and severs a connection between the debris and the pressure valve. The pressure containment system then disengages the torque generator, unites the separated housing, and operates normally to axially distance the unstuck pressure valve form the tubing hanger.

FIG.1is a front view of a pressure containment system (lubricator system)100having a pressure containment device (lubricator)102connected to a production tree104. The pressure containment device102can be a lubricator, for example a PBV lubricator or a TWCV lubricator. The pressure containment system100(lubricator system) defines a first pressure zone Z1 between a wellhead106of the production tree104and a tubing hanger108of a production tree104. A second pressure zone Z2 is defined between the tubing hanger108and a wellbore casing111connected to the tubing hanger108. The tubing hanger108can engage with a pressure valve122(FIG.2) of the lubricator102The pressure containment system102is mounted to a production tree104. At least one portion of the lubricator102moves axially to engage and/or disengage the tubing hanger108of the production tree104. When engaged, the pressure containment system100isolates a casing/tubing111connected to or part the wellhead106. The tubing hanger108is part of a wellhead equipment106. The lubricator102can contain pressures of up to 15,000 psi, 10,000 psi, 20,000 psi on at least one side of the pressure containment device102. Some pressure containment devices hold high pressures on both sides (e.g., using a two-way check valve).

FIG.2is a cross-sectional front view of the pressure containment device102(lubricator). The lubricator102includes a needle valve arrangement112. The needle valve arrangement may equalize and/or bleed off pressure in the lubricator102. The needle valve arrangement112includes several needle valves and a pressure gauges. Some needle valve arrangements can include more than four needle valves, less than four needle valves, or valves different from needle valves. In some cases, the needle valve arrangement can create a third pressure. In such a configuration, the second pressure zone extends from the pressure valve to a needle valve in the needle valve arrangement and the third pressure zone extends from the needle valve in the needle valve arrangement at least to the first end of the lubricator. The needle valve arrangement112can receive and guide pressure P from the well head110to a barrel of the lubricator housing to equalize a pressure at the first end114of the lubricator102and a second end116of the lubricator102. The needle valve arrangement112includes pressure tubing113connecting the needle valves and pressure gauges.

The lubricator102includes a separable lubricator housing118, a lubricator rod120arranged in the lubricator housing118, and a pressure valve122(e.g., a BPV122or TWCV) mounted on the lubricator rod120. The pressure valve122is axially and rotationally constrained to the rod120. The rod120is movable within the lubricator housing118along an axis. In use, the lubricator housing118can be separated so that the rod120can engaged an external force generator, receive a torque force from the connectable torque generator, and transfer the torque force to the to the pressure valve122. The torque force applied to the pressure valve via the rod can be about 200 feet per pound (ft/lbs) to about 20,000 ft/lbs (e.g., about 300 ft/lbs to about 20,000 ft/lbs).

FIGS.3A and3Bare cross-sectional front views of a separable lubricator housing118of the lubricator102in a closed position and an open position, respectively. The lubricator housing118extends from a first end118aof the lubricator housing118to a second end118bof the lubricator housing118. The first end118aand second end118bof the lubricator housing118define an axis119.

The lubricator housing118includes a barrel (first portion)130extending from the first end118aand a yoke132(second portion) extending from the second end118b. The barrel130and yoke132are centered on the axis119. The barrel130is releasably connected to the yoke132by an ACME threaded connection144. In the closed position, the barrel130and the yoke132are connected and able to contain a pressure. In the open position, the barrel130and the yoke132are disengaged and axially distanced from each other. The lubricator rod120extends from the barrel130, though the yoke132, and wellhead110, when the lubricator102is connected to a production tree104. In the open position, at least a portion of the yoke132is exposed to environmental pressure.

The barrel130defines an interior bore134(hollow cavity or channel) centered on the axis119when the lubricator housing118is in the closed position (FIG.3A). The interior bore134receives and retains a portion of the lubricator rod120in the closed position. The lubricator rod120is movable along the axis119within the interior bore134. The barrel130includes an eye138or hook on a first end140of the barrel130and an ACME thread142at a second end144of the barrel130. The second end144of the barrel130engages and disengages with the yoke132to cover and/or expose an internal aperture146of the yoke132. The eye138receives or connects to lifting and alignment machinery (not shown). The alignment machinery (not shown) can position the lubricator on the wellhead and can separate the barrel form the yoke.

The yoke132of the lubricator housing118includes a barrel (first) end150connectable to the barrel130and a wellhead (second) end152connectable to the wellhead110. The connection between the wellhead110and the yoke132may be threaded, flanged, or a combination thereof. The yoke132defines a yoke aperture146. The connection between the barrel end150of the yoke132and the barrel130is an ACME threaded connection (e.g., a hand tightened ACME threaded connection). The yoke defines the yoke aperture146which extends from the barrel end150of the yoke132to the wellhead end152of the yoke132. The aperture is centered on the axis119and (axially) aligned with the interior bore134of the barrel130(e.g., aligned along the axis). The aperture146is sized to receive the lubricator rod120. The lubricator rod120is slidably arranged in the yoke aperture146in the open position (FIG.3A) and in the closed position (FIG.3B). In this configuration the first end118acan detach from the second end118bof the lubricator housing118. Prior to separation, the needle valve arrangement112isolates the first end118afrom the second end118bsuch that pressure in the first end118acan be bled off while the pressure in the second end118bremains constant (e.g., remains at a high pressure).

The yoke aperture146includes a first cavity156(first channel) and a second cavity158(second channel). The first cavity156is arranged on the barrel end150of the yoke132and the second cavity158is arranged on the wellhead end152of the yoke132. The first and second cavities156,158are separated by a window160defined in the yoke132. The window160provides access to a portion of the lubricator rod120(radially) aligned with the window160. The section of the lubricator rod exposed by the window can be manually manipulated, for example by a manual gripping tool (e.g., a parmalee wrench or strap wrench). The window160has a length of about 1 ft to about 2 ft and a width of about 2 to about 6. Seals159(e.g., scaling elements) are mounted to the first cavity156and second cavity158. The seals159contact or mate with the lubricator rod120to form a pressure seal. Some seals are mounted in walls of the yoke such that the first and second cavities are at least partially defined by the seals and inner walls of the yoke. The seals can form a pressure seal of up to 15,000 psi. The seals can maintain the pressure seal when the lubricator rod translates axially (e.g., along the axis) and when the lubricator rod rotates on the axis.

The interior bore134of the barrel130is centered on the axis119when the barrel130is connected to the yoke132. The first cavity156extends from the barrel end150to the window160. The second cavity158extends from the window160to the wellhead end152of the yoke132.

In some cases, the window forms a third cavity between the first and second cavities. The first cavity and second cavity are axially aligned with the axis. In some cases, the first and second cavities of the yoke define the axis. In some lubricator housings, the interior bore, the first cavity, the window, the second cavity, and/or a combination thereod form a rod channel of the lubricator housing.

FIG.4is a perspective, exploded, cross-sectional view of the ACME connection between the barrel130and yoke132of the lubricator housing118. The barrel130is releasably connected to the yoke132by the ACME threaded connection (a first set of ACME connectors). The ACME connection (e.g., a hand tight 4TPI-2G ACME Threaded connection) occurs when a first ACME thread162on the on the barrel end150of the yoke engages with a second ACME thread164on the second end144of the barrel130. The first and second ACME threads162,164form seals that can disconnect and re-connect without using hammer or applying high torques (e.g., torques over 1,000 ft/lbs). Hand tight, ACME connections can maintain a seal of up to about 15,000 psi. The lubricator may also include a second set of ACME threads to connect the lubricator housing to the production tree. The barrel end150is shown as integral to the yoke132, however, some barrel ends connect to the yoke by a flange.

FIG.5is a front view of the lubricator rod120of the lubricator102. In use, the lubricator rod120is arranged on or parallel with the axis119. The lubricator rod120extends from an engagement end170(first end) to valve end172(second end). The engagement end170can releasably connect to a torque generator (e.g., a wrench) and the valve end172connects to the pressure valve122(e.g., a back pressure valve122(BPV or TWCV)) of the lubricator102. The lubricator rod120includes a polished section174and a non-polished section176. The polished section has a length lpand the non-polished section has a length lnp. The non-polished length lnpis less than the polished length lp. In use, the polished section174forms pressure seals with various proportional to the polished length, for example, about 5% to about 40% of the polished length (e.g., 5%, 10%, 15%, 20%, or 25% of the polished length). In use, the polished section174forms pressure seals with the seals159(FIG.3B) in the first and second cavities156,158of the yoke130(FIG.3B). The seals159(FIG.3B) maintain contact with the polished section174in operational use (e.g., as the lubricator rod axially translates and/or rotates), and in the open and closed positions of the lubricator housing102.

The polished section174extends from the valve end172of the lubricator rod120towards the engagement end170of the lubricator rod120. The non-polished section176extends from the engagement end170of the lubricator rod120towards the valve end172of the lubricator rod120. In some cases, the non-polished section is arranged between the engagement end and the valve end of the lubricator rod.

The non-polished section176of the lubricator rod120includes a non-polished surface178. The non-polished surface178is at least partially formed by a textured surface180. The textured surface of the lubricator rod120can be threaded connection to polished section or can be manufactured as a union piece. In some cases, the on-polished surface section has a larger diameter or cross sectional area than the polished section of the lubricator rod. The textured surface can be or include a gritty texture or rubber to increase the static friction coefficient of the non-polished section. In use, the non-polished section can move along the axis between a location adjacent (above) the seal in the first cavity and a location in the interior bore at the second end of the barrel.

The lubricator102also includes a nut182with and hole184defined by an internal face (not shown). The internal face (not shown) is threaded (not shown) and mates with the threads180of the non-polished section176of the lubricator rod120and rotations relative to the rod120along the threads180until reaching a stopper185. The stopper may be on or in the threads. In some cases, the stopper is at the termination of the thread (e.g., an end wall of the thread). After engaging with or reaching the stopper185, the nut182is releasably connected to the lubricator rod120at the non-polished surface178and rotationally coupled to rod120. In this configuration, the nut182transfers rotational and vibrational forces from an external machine, to the lubrication rod120and connected valve122. For some cases hexagonal nut can be manufacture as a union piece (e.g., integral or permanently connected) without requiring any threading on the rod. Some devices include at least two nuts. In some cases, the nut can be attached to the lubricator rod after separating the barrel from the yoke.

In use, the lubricator rod120is slidably arranged in the aperture146of the yoke132, the bore134of the barrel130, and production tree104. The non-polished section176of the lubricator rod120is aligned with or arranged in the interior bore134so that the separation of the barrel130from the yoke132exposes the non-polished section176of the lubricator rod120. The nut182can engage with an external torque generator206(FIGS.6B,6C) to rotate the lubricator rod120and BPV122at the valve end152of the lubricator rod120.

Some rods120include an engagement body integral with or fixed to the non-polished section rather than a threadedly engaged with the non-polished section. The engagement body can include a similar profile to a nut (e.g. hexagonal) or may be shaped to have a width greater than the width of the lubricator rod. the engagement body extends radially from the textured surface of the non-polished section. The engagement body is sized and shaped to mate with an external torque generator. The engagement body can include grooves and/or keyholes for receiving compatible torque generators. The engagement body can wholly or partially be a metal or composite materials for example, stainless steel (e.g., AISI—4130 Low Alloy Steel 75,000 psi).

FIGS.6A-Dare cross-sectional views of the pressure containment system100in use. InFIG.6Athe lubricator rod120is arranged in the aperture146of the yoke132of the lubricator housing118and the bore134of the barrel130of the lubricator housing118. The rod120also extends from the second cavity128of the aperture146of the yoke132into the production tree104. The BPV122is connected to the valve end172of the lubricator rod120(e.g., by a polished rod adapter). The BPV122is engaged with the tubing hanger108and forms a seal with the tubing hanger108, isolating the casing/tubing111from the production tree104. Debris202has built-up between the tubing hanger108and the BPV122. The debris202limits or inhibits the freedom of the BPV122rotationally and axially relative to the tubing hanger108. In this configuration, the BPV/TWCV122is stuck within the production tree104and cannot be safely removed from the production tree104. To release or dislodge BPV122from the tubing hanger108, an operator or external machine decouples the Acme connection between the barrel130and the yoke132to separate the lubricator housing118and exposes the engagement end170of the lubricator rod120.

Prior to decoupling and/or separating the lubricator housing118, the needle valve arrangement112closes the needle valves to isolate the (high) pressure at the second end118bof the lubricator housing118(e.g., below the window160) from the pressure at the barrel130and/or at the first end118aof the lubricator housing118. In this configuration, a high pressure in the second end116of the lubricator102is maintained while the pressure at the first end114of the lubricator102is be bled off prior to disengaging the ACME connection.

InFIG.6B, the non-polished section176of the lubricator rod120is exposed after the barrel130is disconnected from the yoke132and axially distanced from the yoke132. The user may attach a nut182to threads180of the non-polished section176, forming an engagement body on the non-polished surface178. In some systems, the non-polished surface includes an integral or fixed engagement body. In some systems, the textured surface of the non-polished section is an engagement surface that can be coupled to a torque generator. The system can include support struts204that are releasably attachable to the Acme threads of the yoke. A torque generating tool (e.g., a wrench, hydraulic torque machine, impact wrench machine, hydraulic torque wrench, or wrench sharp dies).

FIG.6Cis a cross-sectional front view of the system with the force generator mounted on support struts204. The support struts204provide mechanical support and or a mountable structure for a torque generator206. When the support struts204are engaged with the Acme threads up the yoke132, at least a portion of the non-polished section176extends past the support struts204. In the lubricator102, the nut it's also exposed outside the support struts204. For some cases support struts can connect directly to wellhead or production tree for higher supports.

The external torque generator206engages with the nut182and rotates the BPV122through rotation of the lubricator rod120. The torque generator206applies a predetermined amount of rotational force to the nut182, rod120, and BPV122to rupture or sever the debris208from the BPV122. The ruptured debris208does not prevent or inhibit axial movement of the BPV122relative to the tubing hanger108.

In use, the external torque generator206rotates the BPV a fraction of a full (360 degrees) turn. For example the torque generator may rotate the BPV1221/10thof a turn, ⅕thof a turn, ¼thof a turn, ⅓rdof a turn, or ½ a turn, ⅔rdof a turn, or ¾ths of a turn. In some systems, the lubricator rod120rotates at least one half of a full turn (180 degree turn), for example 1 turn.

FIG.6Dis a cross-sectional front view of the dislodged BPV122and reconnected housing118. The partial or full rotation of the BPV122ruptures the debris208and dislodges the BPV122. After BPV/TWCV started to rotate upper part of the lubricator install again through ACME threads and establish pressure equalization to continue BPV/TWCV retrieving process. The torque generator and structs are removed and the barrel130is reconnected to the yoke132to unify the lubricator housing118. The device can then be repressurized and the PBV122can be axially moved from contact with the tubing hanger108. After reconnection of the barrel130by the ACME connection, the pressure at the second end116of the lubricator102will equalize between second end116and the first end114. When the pressure are equalized, BPV/TWCV122can be retrieved safely.

The torque applied at the non-polished section of the lubricator rod can be generated by pipe wrench/hydraulic or pneumatic pipe tong dies

While a torque generator has been described, some rods receive a vibrational force from a vibration generator. In some cases, the external torque generator applies torque and a vibrational force to the non-polished section of the lubricator rod.

A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made. Accordingly, other embodiments are within the scope of the following claims.