Wellhead System Having a Tubular Hanger Securable to Wellhead and Method of Operation
A tubular hanger and tubular hanger seal are installed in a wellhead with a setting tool. The tubular hanger has a locking ring that is driven outward into engagement with a profile in the wellhead. The setting tool rotates a moveable member of the tubular hanger relative to the tubular hanger body so as to drive the moveable member to expand the locking ring outward to engage the profile in the wellhead. The moveable member may be wedged between the locking ring and the tubular hanger body. The setting tool enables the moveable member and the tubular hanger body to be rotated independently. The annulus between the tubular hanger and the wellhead may be sealed by a seal that has a plurality of sealing elements that are coupled together by a series of catches.
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This application is a divisional of Ser. No. 12/432,252, filed Apr. 29, 2009. The invention relates generally to wellhead systems for use with oil and gas wells. In particular, the invention relates to a wellhead system having a tubular hanger that is securable to a wellhead.
BACKGROUNDA typical oil and/or gas well utilizes strings of casing that are supported from a casing hanger that is, in turn, supported by a wellhead assembly. The strings of casing serve many purposes. For example, casing strings may be used to define the wellbore at various stages of drilling to keep formation fluids out of the wellbore and drilling mud in the wellbore.
Thermal changes in the casing string may produce forces that drive the casing string to lengthen or shorten. For example, if the well is shut-in, warm production fluid will not flow through the well. This allows the casing string to be cooled down by its surroundings. For example, seawater may cool down the wellhead and casing in a subsea well. This cooling may produce thermal contraction of the casing string. Conversely, when a flow of production fluid is initiated, the warm temperature of the production fluid may produce thermal expansion of the casing string.
Oil and/or gas, typically, are produced from the wellbore via production tubing, rather than from a casing string. The production tubing is supported from a tubing hanger. The location of the tubing hanger in a wellhead is important to enable an external device to be coupled to the tubing hanger. Typically, a tubing hanger is supported by a casing hanger disposed within a wellhead. However, as noted above, thermal forces may cause the casing string to expand or contract, thus causing the position of the tubing hanger to vary.
As a result, there is a need for a technique that addresses some or all of the problems described above. The techniques described below may address one or more problems described above.
BRIEF DESCRIPTIONA technique is provided for installing a tubular hanger and tubular hanger seal in a wellhead. The technique comprises installing the tubular hanger with a setting tool. In an exemplary embodiment, the tubular hanger comprises a locking ring that is driven outward into engagement with a profile in the wellhead. The setting tool is adapted to rotate a moveable member of the tubular hanger relative to the tubular hanger body so as to drive the moveable member to expand the locking ring outward to engage a profile in the wellhead. In the exemplary embodiment, the tubular hanger also comprises a feeler ring to engage a second profile in the wellhead. The engagement of the feeler ring with the second profile in the wellhead aligns the locking ring with the profile in the wellhead so that the locking ring engages the profile when it is driven outward. The setting tool is then rotated in an opposite direction to disengage the setting tool from the tubular hanger.
The setting tool is adapted to enable the moveable member and the tubular hanger body to be rotated independently. This enables the setting tool to be rotated in a first direction to secure the tubular hanger to the wellhead and rotated in a second direction to release the setting tool from the tubular hanger.
The annulus between the tubular hanger and the wellhead may be sealed by a seal that has a plurality of sealing elements that are coupled together by a series of catches. The seal may be rotated to drive the sealing elements outward. If it is desired to remove the seal, the seal is rotated in the opposite direction and then lifted. During lifting, the catches of an upper sealing element engage the catches of a lower sealing element, pulling the lower sealing element upward.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Referring now to
In the illustrated embodiment, an outer casing string 32 is supported from the high pressure wellhead 24 by a first casing hanger 34. The outer casing string 32 extends from the first casing hanger 34 into the wellbore. An inner casing string 36 is supported from the high pressure wellhead 24 by a second casing hanger 38. The inner casing string 36 extends from the second casing hanger 38, through the outer casing string 32, and into the wellbore beyond the bottom of the outer casing string 32. As will be discussed in more detail below, this embodiment of the second casing hanger 38 is an adjustable casing hanger that enables the height of the inner casing string 36 to be varied by applying a tensile force to the inner casing string 36.
Production tubing 40 is supported from the high pressure wellhead 24 by a tubing hanger 42. The production tubing 40 extends from the tubing hanger 42 through the inner casing string 36 to a desired depth. Because the second casing hanger 38 is adjustable, there may be some vertical movement of the second casing hanger 38. As will be discussed in more detail below, the illustrated embodiment of the tubing hanger 42 is not supported by the second casing hanger 38. Instead, the tubing hanger 42 is located above the second casing hanger 38 and is rigidly locked to, and supported by, the high pressure wellhead 24, so that the production tubing 40 is unaffected by any changes in the position of the second casing hanger 38 or the inner casing string 36.
In the illustrated embodiment, an axis 44 has been provided to divide the wellhead assembly 20 in half to illustrate a pre-installed configuration 46 of the tubing hanger 42 and an installed configuration 48 of the tubing hanger 42. The left portion 46 reflects the wellhead assembly 20 prior to securing the tubing hanger 42. The right portion reflects the wellhead assembly 20 after the tubing hanger 42 is secured in the wellhead assembly 20 with a setting tool 50. The installed configuration 48 of the wellhead assembly 20 also illustrates a tubing hanger seal 52 that is provided to form a seal between the tubing hanger body 53 and the high pressure wellhead 24.
The wellhead assembly 20 has several additional components. The tubing hanger 42 has ports 54 that extend through the tubing hanger body 53 to enable fluid from control lines 56 to pass through the tubing hanger 42. The control lines 56 are used to control a downhole safety valve (not shown). The control lines 56 are connected to connectors 57 on the tubing hanger 42. The control lines 56 may be accessed by control line terminations 58 that extend through the high pressure wellhead 24. In addition, a variety of valve assemblies are provided to enable access to annulus portions of the bore 30. A first valve assembly 60 is provided to drain the annulus above the outer casing string 32 and the bore 30 of the wellhead assembly 20. A second valve assembly 62 is provided to drain the annulus above the first casing hanger assembly 34 and below the adjustable casing hanger 38. A third valve assembly 64 is provided to drain the annulus above the adjustable casing hanger 38 below the tubing hanger 42.
Referring generally to
The primary means of securing the tubing hanger 42 to the high pressure wellhead 24 is a load-bearing ring 72 that is expanded outward to engage a first profile portion 74 of the high pressure wellhead 24. The load-bearing ring 72 is carried into the wellhead 24 on the tubing hanger 42. In the illustrated embodiment, the load-bearing ring 72 is a split ring. However, the load bearing ring 72 is biased inward in this embodiment. The tubing hanger 42 has a first angled ring 76 with an upward-facing angled surface 78 and a second angled ring 80 with a downward-facing angled surface 82 in this view. The load-bearing ring 72 is disposed between the first angled ring 76 and the second angled ring 80. The load-bearing ring 72 has a corresponding downward-facing angled surface 84 and an upward-facing angled surface 86.
In the illustrated embodiment, a threaded ring 88 is disposed on the tubing hanger 42 and rotated in a right-handed direction relative to the tubing hanger 42 to expand the load-bearing ring 72 outward and secure the tubing hanger 42 to the wellhead 24. The right-handed rotation of the threaded ring 88 causes the threaded ring to travel axially down a threaded portion 90 of the tubing hanger 42. The downward travel of the threaded ring 88 drives the second angled ring 80 against the load-bearing ring 72, which is, in turn, driven against the first angled ring 76. The angled surfaces of the load-bearing ring 72, the first angled ring 76, and the second angled ring 80 cooperate to produce a mechanical advantage that drives the load-bearing ring 72 outward to engage the first profile portion 74 of the wellhead 24 as the second angled ring 80 is driven downward by the threaded ring 88. The engagement between the load-bearing ring 72 and the second profile 74 of the wellhead secures the tubing hanger 42 to the wellhead 24. In addition, as the second angled ring 80 is driven downward by the threaded ring 88, the angled surfaces of the load-bearing ring 72, the first angled ring 76, and the second angled ring 80 cooperate to produce a mechanical advantage that drives the first angled ring 76 and the second angled ring 80 inward against the tubing hanger body 53, wedging the first angled ring 76 and the second angled ring 80 between the tubing hanger body 53 and the load-bearing ring 72. This locks the load-bearing ring 72 in the outward position. In addition, driving the first angled ring 76 and the second angled ring 80 against the tubing hanger body 52 produces friction that prevents movement of the first angled ring 76 and the second angled ring 80 relative to the tubing hanger body 53, thereby locking the load-bearing ring 72 rigidly to the tubing hanger body 53. This also locks the tubing hanger 42 rigidly to the wellhead 24, preventing axial movement of the tubing hanger 42 relative to the wellhead 24. In this embodiment, the threaded ring 88 is disposed on the tubing hanger 42 and rotated in a right-handed direction to expand the load-bearing ring 72 outward. However, the tubing hanger 42 and threaded ring 88 may be configured to expand the load-bearing ring 72 outward by rotating the threaded ring 88 in a left-handed direction relative to the tubing hanger 42.
Referring generally to
The illustrated embodiment of the setting tool 50 comprises a selector assembly 112 that enables the upper stem section 96 to be selectively coupled to the lower stem section 92 and the outer sleeve 98. In this embodiment, a selector switch 114 enables a user to select between two states: a first state and a second state. In the first state, right-handed rotation of the upper stem section 96 is coupled to the lower stem section 92, but not left-handed rotation of the upper stem section 96. Conversely, left-handed rotation of the upper stem section 96 is coupled to the outer sleeve 98, but not right-handed rotation of the upper stem section 96. The first state is selected to secure the setting tool 50 to the tubing hanger 42. This state enables the lower stem section 92 to be threaded to the tubing hanger 42 by rotating the upper stem section 96 in a right-handed direction and using the outer sleeve 98 to hold the tubing hanger 42 so that it does not rotate. In the second state, left-handed rotation of the upper stem section 96 is coupled to the lower stem section 92, but not right-handed rotation of the upper stem section 96. Conversely, right-handed rotation of the upper stem section 96 is coupled to the outer sleeve 98, but not left-handed rotation of the upper stem section 96.
The selector assembly 112 comprises a first engagement member 116 and a second engagement member 118 that are disposed on a rotatable shaft 120 and positioned by the selector switch 114 between two positions. The first position corresponds to the first state and the second position corresponds to the second state. The first engagement member 116 is adapted to interact with the lower stem section 92 and the second engagement member is adapted to interact with the outer sleeve 98. As will be discussed in more detail below, when the selector switch is positioned to the first position, the first engagement member 116 engages the lower stem section 92 when the upper stem section 96 is rotated in a right-handed direction, but the first engagement member 116 ratchets when the upper stem section 96 is rotated in a left-handed direction. On the other hand, when the selector switch is positioned to the first position, the second engagement member 118 engages the outer sleeve 98 when the upper stem section 96 is rotated in a left-handed direction, but ratchets when the upper stem section 96 is rotated in the right-handed direction. The opposite interactions occur when the selector switch 114 is positioned in the second position.
To secure the setting tool 50 to the tubing hanger 42, the selector switch 114 is positioned in the first position, the position corresponding to the first state. The tabs 104 of the telescopic sleeve 102 of the setting tool 50 are inserted into the slots 106 of the threaded ring 88 of the tubing hanger 42. The upper stem section 96 is rotated in a right-handed direction causing the first engagement member 116 to drive lower stem section to thread into the threaded portion 94 of the tubing hanger 42. The second engagement member 118 ratchets along outer sleeve 98 as the upper stem section 96 is rotated.
Referring generally to
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Referring again to
The setting tool 50 is used to install and remove the seal 52, as well. As will be discussed in more detail below, the setting tool 50 may be used to stab into the seal 52 so that the setting tool 50 may be used to thread the seal 52 onto a threaded portion 121 of the tubing hanger 42. The process of threading the seal 52 onto the tubing hanger 42 secures the seal 52 to the tubing hanger 42 and expands the sealing elements of the seal 52 outward to engage the tubing hanger 42 on one side and the wellhead 24 on the other. Similarly, the setting tool 50 may be stabbed into the seal 52 to unthread and remove the seal 52 from the tubing hanger 42.
To remove the tubing hanger 42 from the wellhead 24, the selector switch 114 is selected to the first position. The setting tool 50 is re-deployed into the wellhead assembly 20 so that the tabs 104 of the telescopic sleeve 102 engage the slots 106 of the tubing hanger 42. The upper stem section 96 is rotated in a left-handed direction. The left-handed rotation of the upper stem section 96 is transmitted to the outer sleeve 98 via the second engagement member 118. The outer sleeve 98, in turn, drives the telescopic sleeve 102, which, in turn, drives the threaded ring 88. The left-handed rotation of the threaded ring 88 causes the threaded ring 88 to move axially upward, in this view, relative to the threaded portion 90 of the tubing hanger 42. This axial movement of the threaded ring 88 enables the load-bearing ring 72 to retract from the first profile portion 74 of the wellhead 24. The setting tool 50 may then be raised to remove the tubing hanger 42 from the wellhead 24. The feeler ring 68 will be retracted into the nose ring 66 as the tubing hanger 42 is raised and eventually removed from the wellhead assembly 20.
Referring generally to
Referring generally to
Referring generally to
When the selector switch 114 is in the first position, the second tip 132 of the second engagement member 118 is positioned so that it is received by the second end 160 of the recessed portion 156 of the outer sleeve 98. When the upper stem section 96 is rotated in the left-handed direction 154, the second tip 132 of the second engagement member 118 is driven against the second end 160 of the recessed portion 156 of the outer sleeve 98, driving the outer sleeve 98 into rotation in the left-handed direction 154. Conversely, the first tip 124 of the first engagement member 116 ratchets against the second end 152 of the recessed portion 146 of the lower stem section 92 when the upper stem section 96 is rotated in the left-handed direction and the selector switch 114 is positioned in the first position.
Referring generally to
When the selector switch 114 is in the second position, the first tip 130 of the second engagement member 118 is positioned so that it is received by the first end 158 of the recessed portion 156 of the outer sleeve 98. When the upper stem section 96 is rotated in the right-handed direction 150, the first tip 130 of the second engagement member 118 is driven against the first end 158 of the recessed portion 156 of the outer sleeve 98, driving the outer sleeve 98 into rotation in the right-handed direction 150. Conversely, the first tip 125 of the first engagement member 116 ratchets against the first end 148 of the recessed portion 146 of the lower stem section 92 when the upper stem section 96 is rotated in the right-handed direction and the selector switch 114 is positioned in the second position.
Referring generally to
As noted above, the setting tool 50 is stabbed into the seal 52 to enable the setting tool 50 to position the seal 52. In this embodiment, the threaded ring 162 of the seal 52 has a series of J-slots 172 that form a catch for the tabs 104 (
In the illustrated embodiment, the sealing element 170 of the seal 52 comprises a plurality of sealing members; a first sealing member 176, a second sealing member 178, and a third sealing member 180 that are coupled together. The sealing members may be comprised on an elastomeric material, such as polyaryletheretherketone (PEEK). In this embodiment, the first energizing ring 166 is inserted into the first sealing member 176, the second energizing ring 168 is inserted into the second sealing member 178, and the first and second sealing members 176, 178 are inserted into the third sealing member 180. The sealing members 176, 178, 180 and energizing rings 166, 168 are configured with sloping sides that cooperate to expand the sealing members 176, 178, 180 outward as the sealing members 176, 178, 180 are driven into compression by the energizing rings 166, 168. In addition, each of the first energizing ring 166, the second energizing ring 168, and the sealing members 176, 178, 180 have catches 182. Each catch 182 engages a corresponding catch 182 in an opposite component to facilitate assembly of the seal 52 and removal of the seal 52. When the seal 52 is removed, a lifting force is applied to the first energizing ring 166, the catch 182 of the first energizing ring 166 engages its opposite catch 182 on the first sealing member 176 and transmits the lifting force to the first sealing member 176. In turn, the first sealing member 176 applies a lifting force to the third sealing member 180, and so on until the lifting force is transmitted to the second energizing ring 168, lifting the seal 52 from its position in the wellhead assembly 20.
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. For example, the techniques described above may be used to secure tubular hangers other than a tubing hanger to a wellhead, such as a casing hanger.
Claims
1.-13. (canceled)
14. A setting tool for installing a wellhead component in a wellhead, comprising:
- a first rotatable member coupleable to a prime mover for rotation;
- a second rotatable member;
- a third rotatable member; and
- a selector assembly adapted to selectively couple the first rotatable member to the second rotatable member and the third rotatable member, wherein in a first state of the selector assembly, when the first rotatable member is rotated in a first direction, the selector assembly couples the first rotatable member to the second rotatable and de-couples the first rotatable member from the third rotatable member, and when the first rotatable member is rotated in a second direction opposite the first direction, the selector assembly couples the first rotatable member to the third rotatable member and de-couples the first rotatable member from the second rotatable member.
15. The setting tool as recited in claim 14, wherein in a second state of the selector assembly, when the first rotatable member is rotated in the second direction, the selector assembly couples the first rotatable member to the second rotatable and de-couples the first rotatable member from the third rotatable member, and when the first rotatable member is rotated in the first direction, the selector assembly couples the first rotatable member to the third rotatable member and de-couples the first rotatable member from the second rotatable member.
16. The setting tool as recited in claim 15, wherein the second rotatable member is adapted to be threaded to the wellhead component and the third rotatable member is adapted to rotate a wellhead component member relative to the wellhead component to perform an action, the selector assembly being set in the first state to enable the third rotatable member to rotate the wellhead component member in the second direction relative to the wellhead component to perform the action and to enable the second rotatable member to be rotated in the first direction relative to the wellhead component to unthread the second rotatable member from the wellhead component.
17. The setting tool as recited in claim 16, wherein the selector assembly is set in the first state to enable the second rotatable member to rotate in the second direction relative to the wellhead component to thread the second rotatable member to the wellhead component and to enable the third rotatable member to rotate the wellhead component member in the second direction relative to the wellhead component to reverse the action.
18. The setting tool as recited in claim 15, wherein the selector assembly comprises:
- a first engagement member adapted to selectively couple the first rotatable member to the second rotatable member; and
- a second engagement member adapted to selectively couple the first rotatable member to the third rotatable member, wherein the selector assembly ratchets the first engagement member when the selector assembly decouples the first rotatable member from the second rotatable member and ratchets the second engagement member when the selector assembly decouples the first rotatable member from the third rotatable member.
19. A seal for sealing the annulus between a first wellhead component and a second wellhead component, comprising:
- a first seal member having a male portion with a first catch; and.
- a second seal member having a female portion with a second catch, the first seal member being disposed within the second seal member, wherein the first catch engages the second catch to secure the first seal member and second seal member together.
20. The seal as recited in claim 19, wherein at least one of the first and second seal members comprises an elastomeric material.
21. A method of securing a first wellhead component to a second wellhead component using a setting tool having a first rotatable member, a second rotatable member, and a third rotatable, comprising:
- establishing the setting tool in a state of operation wherein rotation of the first rotatable member is coupled to the second rotatable member only when the first rotatable member is rotated in a first direction and rotation of the first rotatable member is coupled to the third rotatable member only when the first rotatable member is rotated in a second direction opposite the first direction;
- reducing the displacement between the first wellhead component and the second wellhead component until an outwardly-biased member of the first wellhead component engages a first profile in the second wellhead component;
- rotating the first rotatable member in a first direction to rotate the second rotatable member in the first direction to drive an inwardly-biased member of the first wellhead component outward to engage the second wellhead component; and
- rotating the first rotatable member in the second direction to rotate the third rotatable member in the second direction to unthread the third rotatable member from the first wellhead component.
Type: Application
Filed: Feb 13, 2012
Publication Date: Feb 21, 2013
Applicant: Vetco Gray Inc. (Houston, TX)
Inventor: Charles E. Jennings (Tomball, TX)
Application Number: 13/372,106
International Classification: E21B 33/03 (20060101); E21B 33/04 (20060101); E21B 23/00 (20060101);