Wellhead Sealing System and Method
A system for sealing a wellhead. The system includes a setting frame, a driver cylinder selectively applying an axial motion, an adaptor attached to the wellhead, and a power mandrel operatively attached to the driver cylinder. The system may also include a setting sleeve attached to the power mandrel, with the setting sleeve having a packer element, wherein the setting sleeve is responsive to a pressure applicator and retractor device so that the packer element is expanded within the master valve. A method of isolating a wellbore is also disclosed.
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This invention relates to a packer assembly and method. More particularly, but not by way of limitation, this invention relates to a packer assembly used with a wellhead and a method of sealing a wellhead.
In the drilling and production of hydrocarbons, various valves are used to control the flow of subterranean liquids and gas. A wellhead is used to isolate a wellbore from the surface, as readily understood by those of ordinary skill in the art. The wellbore may be in communication with a subterranean reservoir. The wellhead may contain several valves arranged to flow the well, shut-in the well, as well as kill the well if required.
Various components may be placed into an inner portion of a wellhead. For instance, a tubing hanger may be placed in the wellhead for attaching a tubing string that extends from the wellhead to the subterranean reservoir. Operators may conduct test during the life of a well to ensure that the valves associated with the wellhead are functioning properly. Due to the high pressure, flammability and toxicity of hydrocarbons, operators may perform many types of test to ensure proper operability of the wellhead and associated components. Valves will be tested for proper sealing. If a valve and/or seal is found to be leaking, remedial action is required in a timely fashion.
SUMMARY OF THE INVENTIONAn apparatus for sealing a surface wellhead containing a master valve. In one embodiment, the apparatus comprises a driver cylinder for selectively applying an axial motion, an adaptor, operatively attached to the wellhead, with the adaptor having an inner bore in communication with an inner portion of the wellhead, and a setting frame operatively attached to the adaptor. This embodiment further includes a packing stack member operatively attached to the adaptor, with the packing stack member having a seal unit, a power mandrel operatively attached to the driver cylinder, a setting sleeve operatively attached with the power mandrel, with the setting sleeve having a packer element and wherein the setting sleeve is adapted to sealingly engage said seal unit, and pressure applicator and retractor means, operatively attached to the power mandrel, for transferring an applied rotational force to the setting sleeve so that the packer element is expanded within an inner bore of the master valve. In this embodiment, the wellhead may contain a tubing hanger that has a tubing string hanging therefrom, and the apparatus further comprises internal engaging means, operatively attached to the power mandrel, for selectively engaging the inner bore of the wellhead. In one embodiment, the internal engaging means includes a distal mandrel attached to the power mandrel and a protrusion rotatably attached to the distal mandrel, with the protrusion having a radial position and an axial position, wherein in the radial position, the protrusion engages an inner portion of the tubing hanger. In another embodiment, the internal engaging means includes a grapple-spear assembly for anchoring into the internal portion of the master valve.
In one embodiment, the pressure applicator and retractor means comprises an external thread means located on the power mandrel, a nut member disposed about the setting sleeve, with the nut member having an internal thread means operatively associated with the external thread means on the power mandrel, a shell member engaging the nut member, a set screw for attaching the shell to the setting sleeve, and wherein rotation of the nut member moves the setting sleeve relative to the power mandrel.
A method of isolating a wellbore having a master valve is also disclosed. The method comprises closing the master valve so that the wellbore is isolated, and attaching a master valve adaptor to the wellhead and installing a packer assembly to the master valve adaptor. In one embodiment, the packer assembly comprises: a setting frame; a setting sleeve operatively associated with a power mandrel, with the setting sleeve having a packer element, a pressure applicator and retractor device, threadedly connected to the power mandrel, for providing a rotational force transferred to the setting sleeve, wherein the setting sleeve is responsive to the transferred rotational force so that the packer element is expanded within an inner bore of the master valve. The method includes forming a seal with the setting sleeve engaging a packing stack on the master valve adaptor, opening the master valve and retaining a pressure from the wellbore at the packing stack. The method may also include placing a downward force on the power mandrel so that the power mandrel and the setting sleeve are pushed down into the wellhead and applying a rotational force with the pressure applicator and retractor device and transferring the rotational force to the setting sleeve so that the setting sleeve is moved downward and the packer element is compressed and expanded within an inner bore of the master valve. The method may also include opening a vent valve in the adaptor, testing whether the packer element is sealing pressure and removing the setting frame from the packer assembly. Next, the master valve can be removed from the wellhead.
In one embodiment, the method may include observing a rise in the pressure from the wellhead and reattaching the master valve adaptor to the wellhead. In one preferred embodiment, the packer assembly further comprises internal engaging means, operatively attached to the power mandrel, for selectively engaging the internal portion of the master valve. In one embodiment, the method may include mounting a driver cylinder to the packer assembly, attaching the driver cylinder to the power mandrel, creating an upward force so that a set of shear dogs engage a tubing hanger, shearing the shear dogs and pulling the power mandrel and the setting sleeve from the master valve. In another embodiment, the method would include mounting a driver cylinder to the packer assembly, attaching the driver cylinder to the power mandrel, rotating the power mandrel in order to set the internal engaging means which includes a grapple-spear assembly, pulling up on the power mandrel in order to cause the grapple-spear assembly to anchor the packer assembly in the internal portion of the master valve.
A system for sealing a wellhead is also disclosed. This system may include an adaptor, operatively attached to the wellhead, with the adaptor having an inner bore in communication with an inner portion of the wellhead, a driver cylinder for selectively applying an axial motion, with the driver cylinder being operatively associated with the adaptor, a power mandrel operatively attached to the driver cylinder, and a setting sleeve operatively attached with the power mandrel, the setting sleeve having a packer element, and wherein the setting sleeve is adapted to sealingly engage the seal unit. The system may also include a pressure applicator and retractor means, operatively attached to the power mandrel, for transferring an applied rotational force to the setting sleeve, wherein the setting sleeve being responsive to the rotation force so that the packer element is expanded within an inner bore of the master valve, and an internal engaging means, operatively attached to the power mandrel, for selectively engaging an internal portion of the wellhead. In one embodiment, the internal engaging means comprises a distal mandrel attached to the packer mandrel and a protrusion pivotly attached to the distal mandrel, the protrusion having a radial position and an axial position, wherein in the radial position, the protrusion engages an inner portion of a tubing hanger. In this embodiment, the packer mandrel may be operatively associated with a shear member for shearing the packer mandrel from the distal mandrel. In another embodiment, the internal engaging means may comprise a grapple having an outer profile and an inner profile; and a spear having an outer spiral, the outer spiral of the spear operatively engaged with the inner profile of the grapple in order to selectively engage and disengage the grapple with the internal portion of the wellhead.
In yet another embodiment a method of isolating a wellbore having a master valve is disclosed. In this embodiment, the includes closing the master valve so that the wellbore is isolated, attaching an adaptor to the master valve, installing a packer assembly to the adaptor, with the packer assembly containing a setting sleeve and a power mandrel, forming a seal by engaging a packing stack member within the adaptor with the setting sleeve, opening the master valve, retaining a pressure from the wellbore at the packing stack member and placing a downward force on the power mandrel and the setting sleeve of the packer assembly so that the power mandrel is pushed down into the wellhead. This method further includes applying a rotational force to a pressure applicator and retractor device and transferring the rotational force to the setting sleeve and creating a downward force on a packer element on the packer assembly thereby compressing and expanding the packer element in the inner portion of the master valve. The method may then include setting a grapple-spear assembly in the inner portion of the master valve. The grapple-spear assembly contains an inner spear mandrel operatively associated with an outer grapple member. The method may also include opening a vent valve in the adapter and testing whether the packer element is sealing pressure.
The packer assembly 2 further includes a polished setting sleeve 24 wherein the outer surface 26 of the polished setting sleeve 24 will cooperate with and engage the seal unit 18. The setting sleeve 24 contains a recess 25, sometimes referred to as a profile 25. The packer assembly 2 also includes the packer mandrel 28, sometimes referred to as the power mandrel 28, wherein the power mandrel 28 contains the outer thread means 29. As
Referring now to
Returning to
In accordance with the first embodiment and referring collectively to
In operation, the grapple-spear assembly 100 is set (i.e. outer ridges of grapple engaging inner bore 58) so that the grapple-spear 100 is anchored in the inner portion 58, the setting sleeve 24 is moved downward (via rotation of nut top portion 70 as previously described) which in turn sets the packer element 36. Reference is now made to
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
Claims
1. An apparatus for sealing a surface wellhead, wherein said wellhead contains a master valve, the apparatus comprising:
- a driver cylinder for selectively applying an axial motion;
- an adaptor, operatively attached to the wellhead, said adaptor having an inner bore in communication with an inner portion of the wellhead;
- a setting frame operatively attached to said adaptor;
- a packing stack member operatively attached to said adaptor, said packing stack member having a seal unit;
- a power mandrel operatively attached to said driver cylinder;
- a setting sleeve operatively attached with said power mandrel, said setting sleeve having a packer element and wherein said setting sleeve is adapted to sealingly engage said seal unit,
- pressure applicator and retractor means, operatively attached to said power mandrel, for transferring an applied rotational force to said setting sleeve so that said packer element is expanded within an inner bore of the master valve.
2. The apparatus of claim 1 wherein the wellhead further contains a tubing hanger that has a tubing string hanging therefrom, the apparatus further comprising:
- internal engaging means, operatively attached to said power mandrel, for selectively engaging the inner bore of the wellhead.
3. The apparatus of claim 2 wherein the internal engaging means comprising:
- a distal mandrel attached to said power mandrel;
- a protrusion rotatably attached to said distal mandrel, said protrusion having a radial position and an axial position, wherein in the radial position, said protrusion engages an inner portion of the tubing hanger.
4. The apparatus of claim 2 wherein said internal engaging means comprises a grapple-spear assembly for anchoring into the internal portion of the master valve.
5. The apparatus of claim 2 wherein said pressure applicator and retractor means comprises:
- an external thread means located on said power mandrel;
- a nut member disposed about said setting sleeve, said nut member having an internal thread means operatively associated with the external thread means on said power mandrel;
- a shell member engaging said nut member;
- a set screw for attaching said shell member to said setting sleeve;
- and wherein rotation of said nut member moves said setting sleeve relative to said power mandrel.
6. A method of isolating a wellbore having a master valve, the method comprising:
- closing the master valve so that the wellbore is isolated;
- attaching a master valve adaptor to the wellhead;
- installing a packer assembly to the master valve adaptor, wherein said packer assembly comprises: a setting frame; a setting sleeve operatively associated with a power mandrel, said setting sleeve having a packer element; a pressure applicator and retractor device, threadedly connected to said power mandrel, for providing a rotational force transferred to said setting sleeve, wherein said setting sleeve being responsive to the transferred rotational force so that said packer element is expanded within an inner bore of the master valve;
- forming a seal with said setting sleeve engaging a packing stack on said master valve adaptor;
- opening the master valve;
- retaining a pressure from the wellbore at the packing stack;
- placing a downward force on said power mandrel so that said power mandrel and said setting sleeve are pushed down into the wellhead;
- applying a rotational force with said pressure applicator and retractor device and transferring the rotational force to said setting sleeve so that said setting sleeve is moved downward and said packer element is compressed and expanded within an inner bore of said master valve.
7. The method of claim 6 further comprising:
- opening a vent valve in said adaptor;
- testing whether said packer element is sealing pressure.
8. The method of claim 7 further comprising:
- removing the setting frame from the packer assembly.
9. The method of claim 8 further comprising:
- removing said master valve adaptor from the wellhead.
10. The method of claim 9 further comprising:
- observing a rise in the pressure from the wellhead;
- reattaching the master valve adaptor to the wellhead.
11. The method of claim 6 wherein the packer assembly further comprises internal engaging means, operatively attached to said power mandrel, for selectively engaging the internal portion of the master valve, and the method further comprises:
- mounting a driver cylinder to said packer assembly;
- attaching the driver cylinder to said power mandrel;
- creating an upward force so that a set of shear dogs engage a tubing hanger;
- shearing said shear dogs;
- pulling said power mandrel and said setting sleeve from said master valve.
12. The method of claim 6 wherein the packer assembly further comprises a grapple-spear assembly, operatively attached to said power mandrel, for selectively anchoring to the internal portion of the master valve, and the method further comprises:
- mounting a driver cylinder to said packer assembly;
- attaching the driver cylinder to said power mandrel;
- rotating the power mandrel in order to set the grapple-spear assembly;
- pulling up on the power mandrel in order to cause the grapple-spear assembly to anchor said packer assembly in the internal portion of the master valve.
13. A system for sealing a wellhead, said wellhead containing a tubing hanger therein, the system comprising:
- an adaptor, operatively attached to said wellhead, said adaptor having an inner bore in communication with an inner portion of the wellhead;
- a driver cylinder for selectively applying an axial motion, said driver cylinder being operatively associated with said adaptor;
- a power mandrel operatively attached to said driver cylinder;
- a setting sleeve operatively attached with said power mandrel, said setting sleeve having a packer element, and wherein said setting sleeve is adapted to sealingly engage said seal unit;
- pressure applicator and retractor means, operatively attached to said power mandrel, for transferring an applied rotational force to said setting sleeve, wherein said setting sleeve being responsive to the rotation force so that said packer element is expanded within an inner bore of the master valve;
- internal engaging means, operatively attached to said power mandrel, for selectively engaging an internal portion of the wellhead.
14. The apparatus of claim 13 wherein the internal engaging means comprising:
- a distal mandrel attached to said packer mandrel;
- a protrusion pivotly attached to said distal mandrel, said protrusion having a radial position and an axial position, wherein in the radial position, said protrusion engages an inner portion of said tubing hanger.
15. The apparatus of claim 14 further comprising:
- a shear member operatively attached to said packer mandrel for shearing the packer mandrel from said distal mandrel.
16. The apparatus of claim 13 wherein the internal engaging means comprise:
- a grapple having an outer profile and an inner profile;
- a spear having an outer spiral, said outer spiral of said spear operatively engaged with the inner profile of the grapple in order to selectively engage and disengage the grapple with the internal portion of the wellhead.
17. A method of isolating a wellbore having a master valve, the master valve having an inner portion in communication with the wellbore, the method comprising:
- closing the master valve so that the wellbore is isolated;
- attaching an adaptor to the master valve;
- installing a packer assembly to the adaptor, said packer assembly containing a setting sleeve and a power mandrel;
- forming a seal by engaging a packing stack member within said adaptor with said setting sleeve;
- opening the master valve;
- retaining a pressure from the wellbore at the packing stack member;
- placing a downward force on said power mandrel and said setting sleeve of said packer assembly so that the power mandrel is pushed down into the wellhead;
- applying a rotational force to a pressure applicator and retractor device and transferring the rotational force to said setting sleeve and creating a downward force on a packer element on said packer assembly thereby compressing and expanding the packer element in the inner portion of the master valve
- setting a grapple-spear assembly in the inner portion of the master valve.
18. The method of claim 17 further comprising:
- opening a vent valve in said adapter;
- testing whether said packer element is sealing pressure.
19. The method of claim 18 further comprising:
- removing said adaptor from the wellhead.
20. The method of claim 17 further comprising:
- observing a rise in the pressure from the wellhead;
- reattaching the adaptor to the master valve.
21. The method of claim 17 wherein the grapple-spear assembly includes an inner spear mandrel operatively associated with an outer grapple member.
Type: Application
Filed: Dec 31, 2012
Publication Date: Jul 3, 2014
Applicant:
Inventors: Gerald J. Cronley (Gretna, LA), Timothy T. Torrez (Aztec, NM)
Application Number: 13/731,290
International Classification: E21B 33/03 (20060101);