Note: Descriptions are shown in the official language in which they were submitted.
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EXPANDABLE DOWNHOLE SEAT ASSEMBLY
BACKGROUND
[001] A variety of different operations may be performed when preparing a well
for
production of oil or gas. Some operations may be implemented to help increase
the productivity
of the well and may include the actuation of one or more downhole tools.
Additionally, some
operations may be repeated in multiple zones of a well. For example, well
stimulation
operations may be performed to increase the permeability of the well in one or
more zones. In
some cases, a sleeve may be shifted to provide a pathway for fluid
communication between an
interior of a tubing string and a formation. The pathway may be used to
fracture the formation or
to extract oil or gas from the formation. Another well stimulation operation
may include
actuating a perforating gun to perforate a casing and a formation to create a
pathway for fluid
communication. These and other operations may be performed using a various
techniques, such
as running a tool into the well on a conveyance mechanism to mechanically
shift or inductively
communicate with the tool to be actuated, pressurizing a control line, and so
forth.
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SUMMARY
[002] The summary is provided to introduce a selection of concepts that are
further
described below in the detailed description. This summary is not intended to
be used in limiting
the scope of the claimed subject matter.
[003] In an example implementation, a technique includes deploying a seat
assembly
having a plurality of segments into a tubing string installed in a well and
expanding the seat
assembly at a downhole location in the well to secure the assembly to the
tubing string and form
a seat that is adapted to receive an untethered object. The technique includes
receiving the
untethered object in the seat of the seat assembly. The received untethered
object in the seat
assembly may be used to perform a downhole operation in the well.
[004] In another example implementation, an apparatus usable with a well
includes a
plurality of segments. The apparatus is deployable in a tubing string
installed in the well and the
plurality of segments is adapted to expand to form a seat in the tubing string
to receive an
untethered object.
[005] In yet another example implementation, a system includes a tubing
string, an
untethered object and a seat assembly. Segmented members of the seat assembly
are adapted to
be deployed into a tubing string, be radially expanded and be axially
contracted to form a seat
that is adapted to receive the untethered object.
[006] Advantages and other features will become apparent from the following
drawing,
description and claims.
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BRIEF DESCRIPTION OF THE DRAWINGS
[007] Fig. 1 is a schematic diagram of a well according to an example
implementation.
[008] Fig. 2 illustrates a stimulation operation in a stage of the well of
Fig. 1
according to an example implementation.
[009] Fig. 3A is a schematic diagram of a well illustrating multiple stages
with
sleeves according to an example implementation.
[0010] Fig. 3B illustrates a seat assembly installed in a stage of the well of
Fig.
3A according to an example implementation.
[0011] Fig. 3C illustrates an untethered object landing on the seat assembly
of
Fig. 3B according to an example implementation.
[0012] Fig. 3D illustrates a sleeve in a stage of the well shifted by the
untethered
object of Fig. 3C according to an example implementation.
[0013] Fig. 3E illustrates the shifted sleeve of Fig. 3D with the untethered
object
dissolved according to an example implementation.
[0014] Fig. 4 is a schematic view illustrating an expandable, segmented seat
assembly in a contracted state and inside a tubing string according to an
example
implementation.
[0015] Fig. 5 is a cross-sectional view taken along line 5-5 of Fig. 4
according to
an example implementation.
[0016] Fig. 6 is a cross-sectional view taken along line 6-6 of Fig. 4
according to
an example implementation.
[0017] Fig. 7 is a perspective view of the seat assembly in an expanded state
according to an example implementation.
[0018] Fig. 8 is a top view of the seat assembly of Fig. 7 according to an
example
implementation.
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[0019] Fig. 9 is a flow diagram depicting a technique to deploy and use an
expandable seat assembly according to an example implementation.
[0020] Fig. 10 is a cross-sectional view of the seat assembly in an expanded
state
inside a tubing string according to an example implementation.
[0021] Fig. 11 is a cross-sectional view of the seat assembly in an expanded
state
inside a tubing string and in receipt of an activation ball according to an
example
implementation.
[0022] Figs. 12 and 13 are perspective views of expandable seat assemblies
according to further example implementations.
[0023] Fig. 14 is a cross-sectional view of the seat assembly taken along line
14-
14 of Fig. 13 when the seat assembly is in receipt of an activation ball
according to an
example implementation.
[0024] Fig. 15 is a flow diagram depicting a technique to deploy and use an
expandable seat assembly according to a further example implementation.
[0025] Fig. 16A is a perspective view of a seat assembly setting tool and a
segmented seat assembly according to an example implementation.
[0026] Fig. 16B is a bottom view of the seat assembly setting tool and seat
assembly of Fig. 16A according to an example implementation.
[0027] Fig. 16C is a cross-sectional view taken along line 16C-16C of Fig. 16A
according to an example implementation.
[0028] Fig. 17 is a cross-sectional view of a seat assembly setting tool and a
segmented seat assembly according to a further example implementation.
[0029] Figs. 18A, 18B, 18C, 18D, 18E and 18F are cross-sectional views
illustrating use of the setting tool to expand an upper segment of the seat
assembly to
transition the seat assembly to an expanded state according to an example
implementation.
[0030] Figs. 19A, 19B, 19C, 19D, 19E and 19F are cross-sectional views
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illustrating use of the setting tool to expand a lower segment of the seat
assembly to
transition the seat assembly to the expanded state according to an example
implementation.
[0031] Figs. 20A, 20B, 20C and 20D are cross-sectional views illustrating use
of
a setting tool to expand an upper segment of the seat assembly to transition
the seat
assembly to the expanded state according to a further example implementation.
[0032] Figs. 21A, 21B, 21C and 21D are cross-sectional views illustrating use
of
a setting tool to expand a lower segment of the seat assembly to transition
the seat
assembly to the expanded state according to a further example implementation.
[0033] Figs. 22A, 22B, 22C, 22D, 22E and 22F are cross-sectional views of a
setting tool and a segmented seat assembly illustrating use of the setting
tool to expand an
upper segment of the seat assembly to transition the seat assembly to the
expanded state
according to an example implementation.
[0034] Fig. 22G is a cross-sectional view taken along line 22G-22G of Fig. 22A
according to an example implementation.
[0035] Figs. 22H, 221, 22J and 22K are cross-sectional views of the setting
tool
and the segmented seat assembly illustrating use of the setting tool to expand
a lower
segment of the seat assembly to transition the seat assembly to the expanded
state
according to an example implementation.
[0036] Fig. 23 is a flow diagram depicting a technique to use a setting tool
to
transition a segmented seat assembly between contracted and expanded states
according
to example implementations.
[0037] Figs. 24A and 24B illustrate surfaces of the rod and mandrel of a seat
assembly setting tool for a two layer seat assembly according to an example
implementation.
[0038] Figs. 25A, 25B and 25C illustrate surfaces of the rod and mandrel of a
seat
assembly setting tool for a three layer seat assembly according to an example
implementation.
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[0039] Figs. 26A, 26B, 26C and 26D illustrate surfaces of the rod and mandrel
of
a seat assembly setting tool for a four layer seat assembly according to an
example
implementation.
[0040] Fig. 27 is a perspective view of a seat assembly according to an
example
implementation.
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DETAILED DESCRIPTION
[0041] Systems and techniques are disclosed herein to deploy and use a seat
assembly. In some embodiments, the systems and techniques may be used in a
well for
purposes of performing a downhole operation. In this regard, the seat assembly
that is
disclosed herein may be run downhole in the well in a passageway of a tubing
string that
was previously installed in the well and secured to the tubing string at a
desired location
in which a downhole operation is to be performed. The tubing string may take
the form
of multiple pipes coupled together and lowered into a well. The downhole
operation may
be any of a number of operations (stimulation operations, perforating
operations, and so
forth) that rely on an object being landed in a seat of the seat assembly.
[0042] The seat assembly is an expandable, segmented assembly, which has two
states: an unexpanded state and an expanded state. The unexpanded state has a
smaller
cross-section than the expanded state. The smaller cross-section allows
running of the
seat assembly downhole inside a tubing string. The expanded state forms a seat
(e.g., a
ring) that is constructed to catch an object deployed in the string. The seat
and the object
together may form a downhole fluid obstruction, or barrier. In accordance with
example
implementations, in its expanded state, the seat assembly is constructed to
receive, or
catch, an untethered object deployed in the tubing string. In this context,
the "untethered
object" refers to an object that is communicated downhole through the tubing
string
without the use of a conveyance line (a slickline, a wireline, a coiled tubing
string and so
forth) for at least a portion of its travel through the tubing string. As
examples, the
untethered object may take the form of a ball (or sphere), a dart or a bar.
[0043] The untethered object may, in accordance with example implementations,
be deployed on the end of a tool string, which is conveyed into the well by
wireline,
slickline, coiled tubing, and so forth. Moreover, the untethered object may
be, in
accordance with example implementations, deployed on the end of a tool string,
which
includes a setting tool that deploys the segmented seat assembly. Thus, many
variations
are contemplated and the appended claims should be read broadly as possibly to
include
all such variations.
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[0044] In accordance with example implementations, the seat assembly is a
segmented apparatus that contains multiple curved sections that are
constructed to
radially contract and axially expand into multiple layers to form the
contracted state.
Additionally, the sections are constructed to radially expand and axially
contract into a
single layer to form a seat in the expanded state of the seat assembly to
catch an object.
A setting tool may be used to contact the sections of the seat assembly for
purposes of
transitioning the seat assembly between the expanded and contracted states, as
further
described herein.
[0045] In accordance with some implementations, a well 10 includes a wellbore
15. The wellbore 15 may traverse one or more hydrocarbon-bearing formations.
As an
example, a tubing string 20, as depicted in Fig. 1, can be positioned in the
wellbore 15.
The tubing string 20 may be cemented to the wellbore 15 (such wellbores are
typically
referred to as "cased hole" wellbores); or the tubing string 20 may be secured
to the
surrounding formation(s) by packers (such wellbores typically are referred to
as "open
hole" wellbores). In general, the wellbore 15 may extend through multiple
zones, or
stages 30 (four example stages 30a, 30b, 30c and 30d, being depicted in Fig.
1, as
examples), of the well 10.
[0046] It is noted that although Fig. 1 and other figures disclosed herein
depict a
lateral wellbore, the techniques and systems that are disclosed herein may
likewise be
applied to vertical wellbores. Moreover, in accordance with some
implementations, the
well 10 may contain multiple wellbores, which contain tubing strings that are
similar to
the illustrated tubing string 20 of Fig. 1. The well 10 may be a subsea well
or may be a
terrestrial well, depending on the particular implementations. Additionally,
the well 10
may be an injection well or may be a production well. Thus, many
implementations are
contemplated, which are within the scope of the appended claims.
[0047] Downhole operations may be performed in the stages 30 in a particular
directional order, in accordance with example implementations. For example,
downhole
operations may be conducted in a direction from a toe end of the wellbore to a
heel end of
the wellbore 15, in accordance with some implementations. In further
implementations,
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these downhole operations may be connected from the heel end to the toe end
(e.g.,
terminal end) of the wellbore 15. In accordance with further example
implementations,
the operations may be performed in no particular order, or sequence.
[0048] Fig. 1 depicts that fluid communication with the surrounding
hydrocarbon
formation(s) has been enhanced through sets 40 of perforation tunnels that,
for this
example, are formed in each stage 30 and extend through the tubing string 20.
It is noted
that each stage 30 may have multiple sets of such perforation tunnels 40.
Although
perforation tunnels 40 are depicted in Fig. 1, it is understood that other
techniques may be
used to establish/enhance fluid communication with the surrounding formation
(s), as the
fluid communication may be established using, for example, a jetting tool that
communicates an abrasive slurry to perforate the tubing string wall; opening
sleeve
valves of the tubing string 20; and so forth.
[0049] Referring to Fig. 2 in conjunction with Fig. 1, as an example, a
stimulation
operation may be performed in the stage 30a by deploying an expandable,
segmented seat
assembly 50 (herein called the "seat assembly") into the tubing string 20 on a
setting tool
(as further disclosed herein) in a contracted state of the assembly 50. In the
contracted
state, the assembly 50 has an outer diameter to allow it to be run-in-hole.
The seat
assembly 50 is expanded downhole in the well. In its expanded state, the seat
assembly
50 has a larger outer diameter than in its contracted state. Additionally, the
seat assembly
50 is shorter longitudinally in the expanded stated than the contracted state.
In the
expanded state, the seat assembly 50 engages, and is secured on, an inner
surface of the
tubing string 20 at a targeted location in the stage 30a. For the example
implementation
depicted in Fig. 2, the seat assembly 50 is secured in the tubing string 20
near the bottom,
or downhole end, of the stage 30a. Once secured inside the tubing string 20,
the
combination of the seat assembly 50 and an untethered object (here, an
activation ball
150) form a fluid tight obstruction, or barrier, to divert fluid in the tubing
string 20 uphole
of the barrier. That is, fluid is unable to pass from uphole of the seat
assembly 50 and
activation ball 150 to downhole of the seat assembly and activation ball.
Thus, for the
example implementation of Fig. 2, the fluid barrier may be used to direct
fracture fluid
(e.g., fracture fluid pumped into the tubing string 20 from the Earth surface)
into the stage
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30a.
[0050] Fig. 3A depicts an example tubing string 312 of a well 300, which has a
central passageway 314 and extends through associated stages 30a, 30b, 30c and
30d of
the well 300. Each stage 30 has an associated sleeve 240, which resides in a
recess 231
of the tubing string 312. The sleeve 240 may have been previously positioned
in the
stage 30. For the state of the well 300 depicted in Fig. 3A, the sleeve 240 is
positioned in
the well in a closed state and therefore covers radial ports 230 in the tubing
string wall.
As an example, each stage 30 may be associated with a given set of radial
ports 230, so
that by communicating an untethered object downhole inside the passageway 314
of the
tubing string 312 and landing the ball in a seat of a seat assembly 237 (see
Fig. 3B), a
corresponding fluid barrier may be formed to divert fluid through the
associate set of
radial ports 230.
[0051] Referring to Fig. 3B, as shown, the seat assembly 237 has been deployed
(attached, anchored, swaged) to the sleeve 240. A shoulder 238 on the sleeve
240 which
engages a corresponding shoulder of the seat assembly 237 may be provided to
connect
the seat assembly 237 and the sleeve 240. Other connection methods may be
used, such
as recess on the sleeve 240, a direct anchoring with the seat assembly 237,
and so forth.
[0052] It is noted that the seat assemblies 237 may be installed one by one
after
the stimulation of each stage 30 (as discussed further below); or multiple
seat assemblies
237 may be installed in a single trip into the well 300. Therefore, the seat,
or inner
catching diameter of the seat assembly 237, for the different assemblies 237,
may have
different dimensions, such as inner dimensions that are relatively smaller
downhole and
progressively become larger moving in an uphole direction (e.g., towards
surface). This
can permit the use of differently-sized untethered objects to land on the seat
assemblies
237 without further downhole intervention. Thus, continuous pumping treatment
of
multiple stages 30 may be achieved.
[0053] Referring to Fig. 3C, this figure depicts the landing of the untethered
object 150 on the seat assembly 237 of the stage 30a. At this point, the
untethered object
150 has been caught by the seat assembly 237.
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[0054] Referring to Fig. 3D, due to the force that is exerted by the
untethered
object 150, due to, for example, either the momentum of the untethered object
150 or the
pressure differential created by the untethered object, the sleeve 240 and the
seat
assembly 237 can be shifted downhole, revealing the radial ports 230. In this
position, a
pumping treatment (the pumping of a fracturing fluid, for example) may be
performed in
the stage 30a.
[0055] Fig. 3E depicts the stage 30a with the sleeve 240 in the opened
position
and with the seat assembly 237 and untethered object 150 being dissolved, as
further
discussed below.
[0056] As an example, Fig. 4 is a perspective of the seat assembly 50, and
Figs. 5
and 6 illustrate cross-sectional views of the seat assembly 50 of Fig. 4, in
accordance
with an example implementation. Referring to Fig. 4, this figure depicts the
seat
assembly 50 in a contracted state, i.e., in a radially collapsed state having
a smaller outer
diameter, which facilitates travel of the seat assembly 50 downhole to its
final position.
The seat assembly, 50 for this example implementation, has two sets of arcuate
segments:
three upper segments 410; and three lower segments 420. In the contracted
state, the
segments 410 and 420 are radially contracted and are longitudinally, or
axially, expanded
into two layers 412 and 430.
[0057] The upper segment 410 can have a curved wedge that has a radius of
curvature about the longitudinal axis of the seat assembly 50 and can be
larger at its top
end than at its bottom end. The lower segment 420 can have an arcuate wedge
that has a
radius of curvature about the longitudinal axis (as the upper segment 410) and
can be
larger at its bottom end than at its top end. Due to the relative
complementary profiles of
the segments 410 and 420, when the seat assembly 50 expands (i.e., when the
segments
410 and 420 radially expand and the segments 410 and 420 axially contract),
the two
layers 412 and 430 longitudinally, or axially, compress into a single layer of
segments
such that each upper segment 410 is complimentarily received between two lower
segments 420, and vice versa, as depicted in Fig. 7. In its expanded state,
the seat
assembly 50 forms a tubular member having a seat that is sized to catch an
untethered
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object deployed in the tubing string 20.
[0058] An upper curved surface of each of the segments 410 and 420 can form a
corresponding section of a seat ring 730 (i.e., the "seat") of the seat
assembly 50 when
the assembly 50 is in its expanded state. As depicted in Fig. 8, in its
expanded state, the
seat ring 730 of the seat assembly 50 defines an opening 710 sized to control
the size of
objects that pass through the seat ring 730 and the size of objects the seat
ring 730
catches.
[0059] Thus, referring to Fig. 9, in accordance with example, implementations,
a
technique 900 includes deploying (block 902) a segmented seat assembly into a
tubing
string and radially expanding (block 904) the seat assembly to attach the seat
assembly to
a tubing string at a downhole location and form a seat to receive an
untethered object.
Pursuant to the technique 900, a seat of the seat assembly catches an object
and is used to
perform a downhole operation (block 908).
[0060] The seat assembly 50 may attach to the tubing string in numerous
different
ways, depending on the particular implementation. For example, Fig. 10 depicts
an
example tubing string 20 that contains a narrowed seat profile 1020, which
complements
an outer profile of the seat assembly 50 in its expanded state. In this
regard, as depicted
in Fig. 10, the segments 410 and 420 contain corresponding outer profiles 1010
that
engage the tubing profile 1010 to catch the seat assembly 50 on the profile
1020. In
accordance with example implementations, at the seat profile 1020, the tubing
string 50
has a sufficiently small cross-section, or diameter for purposes of forming
frictional
contact to allow a setting tool to transition the seat assembly 50 to the
expanded state, as
further disclosed herein.
[0061] Moreover, in accordance with example implementations, the full radial
expansion and actual contraction of the seat assembly 50 may be enhanced by
the
reception of the untethered object 150. As shown in Fig. 11, the untethered
object 150
has a diameter that is sized to land in the seat ring 730 and further expands
the seat
assembly 50.
[0062] Further systems and techniques to run the seat assembly 50 downhole and
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secure the seat assembly 50 in place downhole are further discussed below.
[0063] Other implementations are contemplated. For example, Fig. 12 depicts a
seat assembly 1200 that has similar elements to the seat assembly 50, with
similar
reference numerals being used to depict similar elements. The seat assembly
1200 has
segments 1220 that replace the segments 420. The segments 1220 can be arcuate
and
wedge-shaped sections similar to the segments 420. However, unlike the
segments 420,
the segments 1220 have anchors, or slips 1230, that are disposed on the outer
surface of
the segments 1220 for purposes of securing or anchoring the seat assembly 1200
to the
tubing string wall when the segments 1220 radially expand. As another example,
Fig. 13
depicts a seat assembly 1300 that that has similar elements to the seat
assembly 1200,
with similar reference numerals being used to depict similar elements.
[0064] The seat assembly 1300 can contain fluid seals. In this manner, in
accordance with example implementations, the seat assembly 1300 has fluid
seals 1320
that are disposed between the axially extending edges of the segments 410 and
1220. The
fluid seals 1320 help to create a fluid seal when an object lands on the seat
assembly
1300. Moreover, the seat assembly 1300 includes a peripherally extending seal
element
1350 (an o-ring, for example), which extends about the periphery of the
segments 410
and 1220 to form a fluid seal between the outer surface of the expanded seat
assembly
1300 and the inner surface of the tubing string wall. Fig. 14 depicts a cross-
sectional
view of the seat assembly 1300 of Fig. 13 in the radially expanded state when
receiving
an untethered object 150.
[0065] The collective outer profile of the segments 410 and 420 may be
contoured in a manner to form an object that engages a seat assembly that is
disposed
further downhole. In this manner, after the seat assembly 1300 performs its
intended
function by catching the untethered object, the seat assembly may then be
transitioned
(via a downhole tool, for example) into its radially contracted state so that
the seat
assembly (or a portion thereof) may travel further downhole and serve as an
untethered
object to perform another downhole operation.
[0066] A segmented seat assembly 2700 of Fig. 27 may be used having upper seat
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segments 410 and lower seat segments 420 similar to the seat segments
discussed above.
The segmented seat assembly 2700 includes a lower contoured cap 2710, which is
profiled. For example, the lower contoured cap 2710 may include beveled
features, as
depicted at reference number 2714. The lower contoured cap 2710 may form a
contoured
profile to engage a seat that is positioned below the segmented seat assembly
2700 after
the segmented seat assembly 2700 is released. As an example, in accordance
with some
implementations, the cap 2710 may be attached to the lower seat segments 420.
[0067] Referring to Fig. 15, in accordance with an example implementation, a
technique 1500 includes releasing (block 1502) a first seat assembly from
being attached
to a tubing string and receiving (block 1504) a bottom profile of the first
seat assembly in
a second seat assembly. Pursuant to the technique 1500, the received first
seat assembly
may then be used to perform a downhole operation (block 1506).
[0068] Referring to Fig. 16A, in accordance with an example implementation, a
setting tool 1600 may be used to transition the seat assembly 50 between its
contracted
and expanded states. As further disclosed herein, the setting tool 1600
includes
components that move relative to each other to expand or contract the seat
assembly 50: a
rod 1602 and a mandrel 1620 which generally circumscribes the rod 1602. The
relative
motion between the rod 1602 and the mandrel 1620 causes surfaces of the
mandrel 1620
and rod 1602 to contact the upper 410 and lower 420 segments of the seat
assembly 50 to
radially expand the segments 410 and 420 and longitudinally contract the
segments into a
single layer to form the seat, as described above.
[0069] As depicted in Fig. 16A, the rod 1602 and mandrel 1620 may be generally
concentric with a longitudinal axis 1601 and extend along the longitudinal
axis 1601. An
upper end 1612 of the rod 1602 may be attached to a conveyance line (a coiled
tubing
string, for example). A bottom end 1610 of the rod 1602 may be free or
attached to a
downhole tool or string, depending on the particular implementation.
[0070] Referring to Fig. 16B in conjunction with Fig. 16A, in accordance with
example implementations, the rod 1602 contains radially extending vanes 1608
for
purposes of contacting inner surfaces of the seat assembly segments 410 and
420: vanes
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1608-1 to contact the upper segments 410; and vanes 1608-2 to contact the
lower
segments 420. For the specific example implementation that is illustrated in
Figs. 16A
and 16B, the setting tool 1600 includes six vanes 1608, i.e., three vanes 1608-
1
contacting for the upper segments 410 and three vanes 1608-2 for contacting
the lower
segments 420. Moreover, as shown, the vanes 1608 may be equally distributed
around
the longitudinal axis 1601 of the setting tool 1600, in accordance with
example
implementations. Although the examples depicted herein show two layers of
three
segments, the possibility of many combinations with additional layers or with
a different
number of segments per layer may be used (combinations of anywhere from 2 to
20 for
the layers and segments, as examples) are contemplated and are within the
scope of the
appended claims.
[0071] Referring to Fig. 16C, relative motion of the rod 1602 relative to the
mandrel 1620 longitudinally compresses the segments 410 and 420 along the
longitudinal
axis 1601, as well as radially expands the segments 410 and 420. This occurs
due to the
contact between the segments 410 and 420 with the inclined faces of the vanes
1608,
such as the illustrated incline faces of the vanes 1608-1 and 1608-2
contacting inner
surfaces of the segments 410 and 420, as depicted in Fig. 16C.
[0072] Fig. 17 depicts a cross-sectional view for the seat assembly setting
tool
1600 according to a further implementation. In general, for this
implementation, the
setting tool 1600 includes a bottom compression member 1710 that is disposed
at the
lower end of the rod 1602. As further disclosed below, the compression member
1710
aids in exerting a radial setting force on the segments 410 and 420 and may be
released
from the setting tool 1600 and left downhole with the expanded seat assembly
(after the
remainder of the setting tool 1600 is retrieved from the well) to form a
retaining device
for the seat assembly, as further discussed below.
[0073] Fig. 18A depicts a partial cross-sectional view of the setting tool
1600,
according to an example implementation, for purposes of illustrating forces
that the tool
1600 exerts on the lower segment 410. It is noted that Fig. 18a depicts one
half of the
cross-section of the setting tool 1600 about the tool's longitudinal axis
1601, as can be
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appreciated by the skilled artisan.
[0074] Referring to Fig. 18A, an inclined, or sloped, surface 1820 of the vane
1608-1 and a sloped surface 1824 of the mandrel 1620 act on the upper segment
410 as
illustrated in Fig. 18A. In particular, the sloped surface 1820 of the vane
1608-1 forms
an angle al (with respect to the longitudinal axis 1601), which contacts an
opposing
sloped surface 1810 of the segment 410. Moreover, the sloped surface 1824 of
the
mandrel 1620 is inclined at an angle 01 with respect to the longitudinal axis
1601. The
sloped surface 1824 of the mandrel 1820, in turn, contacts an opposing sloped
surface
1812 of the upper segment 410. The surfaces 1820 and 1824 have respective
surface
normals, which, in general, are pointed in opposite directions along the
longitudinal axis
1601. Therefore, by relative movement of the rod 1602 in the illustrated
uphole direction
1830, the surfaces 1820 and 1824 of the setting tool 1600 produce a net
outward radial
force 1834 on the segment 410, which tends to radially expand the upper
segment 410.
Moreover, the relative movement of the rod 1602 and mandrel 1620 produces a
force
1832 that causes the segment 410 to longitudinally translate to a position to
compress the
segments 410 and 420 into a single layer.
[0075] Referring to Fig. 19A, for the lower segment 420, the vane 1608-2 of
the
rod 1602 has a sloped surface 1920, which contacts a corresponding sloped
surface 1910
of the lower segment 420; and the mandrel 1620 has a sloped surface 1914 that
contacts a
corresponding opposing sloped surface 1912 of the lower segment 420. As
depicted in
Fig. 19A, the slope surfaces 1914 and 1920 having opposing surface normals,
which
cause the relative movement between the rod 1602 and mandrel 1620 to produce a
net
radially outward force 1934 on the lower segment 410. Moreover, movement of
the rod
1602 relative to the mandrel 1620 produces a longitudinal force 1932 to
longitudinally
translate the lower segment 420 into a position to compress the seat assembly
50 into a
single layer. As shown in Fig. 19A, the sloped surfaces 1920 and 1914 have
associated
angles called "P2" and "a2" with respect to the longitudinal axis 1601.
[0076] In accordance with example implementations, the al and a2 angles may
be the same; and the 01 and 132 angles may be same. However, different angles
may be
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chosen (i.e., the al and a2 angles may be different, as well as the 01 and 132
angles, for
example), depending on the particular implementation. Having different slope
angles
involves adjusting the thicknesses and lengths of the segments of the seat
assembly 50,
depending on the purpose to be achieved. For example, by adjusting the
different slope
angles, the seat assembly 50 and corresponding setting tool may be designed so
that the
segments of the seat assembly are at the same height when the seat assembly 50
is fully
expanded or a specific offset. Moreover, the choice of the angles may be used
to select
whether the segments of the seat assembly finish in an external circular shape
or with
specific radial offsets.
[0077] The relationship of the a angles (i.e., the al and a2 angles) relative
to the
0 angles (i.e., the 131 and J32 angles) may be varied, depending on the
particular
implementation. For example, in accordance with some implementations, the a
angles
may be less than the 0 angles. As a more specific example, in accordance with
some
implementations, the 0 angles may be in a range from one and one half times
the a angle
to ten times the a angle, but any ratio between the angles may be selected,
depending on
the particular implementation. In this regard, choices involving different
angular
relationships may depend on such factors as the axial displacement of the rod
1602,
decisions regarding adapting the radial and/or axial displacement of the
different layers of
the elements of the seat assembly 50; adapting friction forces present in the
setting tool
and/or seat assembly 50; and so forth.
[0078] Fig. 18B depicts further movement (relative to Fig. 18A) of the rod
1602
with respect to the upper segment 410 mandrel 1620, resulting in full radial
expansion of
the upper seat segment 410; and Fig. 18B also depicts stop shoulders 1621 and
1660 that
may be used on the mandrel 1620 and rod 1602, in accordance with some example
implementations. In this manner, for the state of the setting that is depicted
in Fig. 18A,
relative travel between the rod 1602 and the mandrel 1620 is halted, or
stopped, due to
the upper end of the upper seat segment 410 contacting a stop shoulder 1621 of
the
mandrel 1620 and a lower stop shoulder 1660 of the vane 1608-2 contacting the
lower
end of segment 410. Likewise, Fig. 19B illustrates full radial expansion of
the lower seat
segment 420, which occurs when relative travel between the rod 1602 and the
mandrel
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1620 is halted due to the segment 420 resting between a stop shoulder 1625 of
the
mandrel 1620 and a stop shoulder 1662 of the vane 1608-2.
[0079] For the setting tool 1600 that is depicted in Figs. 18A-19B, the tool
1600
includes a bottom compression member that is attached to the lower end of the
mandrel
1620 and has corresponding member parts 1850 (contacting the segments 410) and
1950
(contacting the segments 420). In example with example implementations,
compression
members 1850 and 1950 may be the same part but are depicted in the figures at
two
different cross-sections for clarity. Thus, as shown in Figs. 18A and 18B, the
vane 1608-
1 contains a compression member part 1850; and the vane 1608-2 depicted in
Figs. 19A
and 19B depicts a compression member part 1950. In accordance with further
implementations disclosed herein, the mandrel of a setting tool may not
include such an
extension. Moreover, although specific implementations are disclosed herein in
which
the rod of the setting tool moves with respect to the mandrel, in further
implementations,
the mandrel may move with respect to the rod. Thus, many variations are
contemplated,
which are within the scope of the appended claims.
[0080] In accordance with further implementations, the bottom compression
member of the rod 1602 may be attached to the remaining portion of the rod
using one or
more shear devices. In this manner, Fig. 18C depicts the compression member
part 1850
being attached to the rest of the vane 1608-1 using a shear device 1670, such
as a shear
screw, for example. Likewise, Fig. 19C depicts the compression member part
1950 being
attached to the remainder of the vane 1608-2 using a corresponding shear
device 1690.
The use of the compression member, along with the shear device(s) allows the
setting
tool to leave the compression member downhole to, in conjunction with the seat
assembly
50, form a permanently-set seat in the well.
[0081] More specifically, the force that is available from the setting tool
1600
actuating the rod longitudinally and the force-dependent linkage that is
provided by the
shear device, provide a precise level of force transmitted to the compression
member.
This force, in turn, is transmitted to the segments of the seat assembly 50
before the
compression member separates from the rod 1602. The compression member
therefore
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becomes part of the seat assembly 50 and is released at the end of the setting
process to
expand the seat assembly 40. Depending on the particular implementation, the
compression piece may be attached to the segments or may be a separate piece
secured
by one or more shear devices.
[0082] Thus, as illustrated in Figs. 18C and 19B, through the use of the
compression pieces, additional force, i.e., additional longitudinal forces
1674 (Fig. 18C)
and 1680 (Fig. 19C); or additional radial forces 1676 (Fig. 18C) or 1684 (Fig.
19C); or a
combination of both, may be applied to the seat assembly 50 to aid in
expanding the seat
assembly.
[0083] The above-described forces may be transmitted to a self-locking feature
and/or to an anti-return feature. These features may be located, for example,
on the side
faces of the seat assembly's segments and/or between a portion of the segments
and the
compression piece.
[0084] In accordance with some implementations, self-locking features may be
formed from tongue and groove connections, which use longitudinally shallow
angles
(angles between three and ten degrees, for example) to obtain a self-locking
imbrication
between the parts due to contact friction.
[0085] Anti-return features may be imparted, in accordance with example
implementations, using, for example, a ratchet system, which may be added on
the
external faces of a tongue and groove configuration between the opposing
pieces. The
ratchet system may, in accordance with example implementations, contain spring
blades
in front of anchoring teeth. The anti-return features may also be incorporated
between
the segment (such as segment 410) and the compression member, such as
compression
member 1850. Thus, many variations are contemplated, which are within the
scope of
the appended claims.
[0086] Figs. 18D, 19D, 18E, 19E, 18F and 19F depict using of the bottom
compression member along with the shear devices, in accordance with an example
implementation.
[0087] More specifically, Figs. 18D and 19D depict separation of the
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compression member parts 1850 (Fig. 18D) and 1950 (Fig. 18E) from the rod
1602,
thereby releasing the compression member from the rest of the setting tool, as
illustrated
in Figs. 18E and 19E. As depicted in Figs. 18F and 19F, after removal of the
remainder
of the setting tool 1600, the segments 410 (Fig. 18F) and 420 (Fig. 19F) and
corresponding compression member parts 1850 and 1950 remain in the well. Thus,
as
illustrated in Fig. 18F, the compression piece 1850 stands alone with the
upper segment
410; and the compression piece 1950 (see Fig. 19F) stands alone with the lower
segment
420.
[0088] In accordance with some implementations, as discussed above, the
segments 410 and/or 420 of the seat assembly may contain anchors, or slips,
for purposes
of engaging, for example, a tubing string wall to anchor, or secure the seat
assembly to
the string.
[0089] In accordance with some implementations, the setting tool may contain a
lower compression member on the rod, which serves to further expand radially
the
formed ring and further allow the ring to be transitioned from its expanded
state back to
its contracted state. Such an arrangement allows the seat assembly to be set
at a
particular location in the well, anchored to the location and expanded, a
downhole
operation to be performed at that location, and then permit the seat assembly
to be
retracted and moved to another location to repeat the process.
[0090] Figs. 20A, 20B, 20C and 20D depict the actions of setting tool 2000
against the upper seat segment 410; and Figs. 21A, 21B, 21C and 21D depict the
actions
of the setting tool 2000 against the lower seat segment 420. As shown, the
setting tool
2000 does not have a lower compression member, thereby allowing the rod 1602
to be
moved in a longitudinal direction (as illustrated by directions 210 of Fig.
20B and 2014
of Fig. 21B) to radially expand the segments 410 and 420 and leave the
segments 410 and
420 in the well, as illustrated in Figs. 20D and 21D.
[0091] Fig. 22A depicts a seat assembly setting tool 2200 according to further
implementations. For these implementations, a mandrel 2201 of the tool 2200
includes
the above-described inclined faces to contact seat assembly segments. The
mandrel 2201
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also contains an end sloped segment on its outer diameter to ease the radial
expansion of
the segments while having a small axial movement for purposes of reducing
friction and
providing easier sliding movement. In this manner, as depicted in Fig. 22A,
the mandrel
2201 contains a portion 2250 that has an associated sloped surface 2252 that
engages a
corresponding sloped surface 2213 of the upper seat segment 410. The sloped
surface
2252 forms an associated angle (called "V) with respect to the radial
direction from the
longitudinal axis 1601. Likewise, the portion 2250 may have a sloped surface
2253 (see
Fig. 22F) that engages a corresponding sloped surface 2215 of the lower seat
segment
420 and forms an angle (called "c2") with respect to the radial direction. The
angles ci
and c2 may be, equal to or steeper than the steepest of the a angles (the al
and a2 angles)
and the 0 angles (the 01 and J32 angles), in accordance with some
implementations.
[0092] On the other side of the seat segments, an additional sloped surface
may
be added, in accordance with example implementations, in a different radial
orientation
than the existing sloped surface with the angle al for the upper segment 410
and 131 for
the lower segment 420. Referring to Fig. 22A, the tool 2200 includes a lower
compression piece 2204 that includes a sloped surface 2220 having an angle 81
with
respect to the longitudinal axis 1601. The angle 81 may be relatively shallow
(a three to
ten degree angle, for example, with respect to the longitudinal axis 1601) to
obtain a self-
locking contact between the upper seat segment 410 and the compression piece
2204. As
depicted in the cross-section depicted in Fig. 22G, the upper seat segment 410
has sloped
surfaces 2220 with the 81 angle and a sloped surface 2280 with the al angle.
Referring to
Fig. 22F, in a similar manner, the lower seat segment 420 may have surfaces
that are
inclined at angles a2 and 82. The 82 angle may be relatively shallow, similar
to the 81
angle for purposes of obtaining a self-locking contact between the lower seat
segment
420 and the compression piece.
[0093] Depending on the different slopes and angle configurations, some of the
sloped surfaces may be combined into one surface. Thus, although the examples
disclosed herein depict the surfaces as being separated, a combined surface
due to an
angular choice may be advantageous, in accordance with some implementations.
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[0094] For the following example, the lower seat segment 420 is attached to,
or
integral with teeth, or slips 2292 (see Fig. 22H, for example), which engage
the inner
surface of the tubing string 20. The upper seat segment 410 may be attached
to/integral
with such slips, in accordance with further implementations and/or the seat
segments 410
and 420 may be connected to slips; and so forth. Thus, many implementations
are
contemplated, which are with the scope of the appended claims.
[0095] Due to the features of the rod and mandrel, the setting tool 2200 may
operate as follows. As shown in Fig. 22B, upon movement of the rod 1602 along
a
direction 2280, the upper seat segment 410 radially expands due to a resultant
force along
a radial direction 2260. At this point, the rod 1602 and compression piece
2204 remain
attached. Referring to Fig. 22H, the lower seat segment 420 radially expands
as well,
which causes the slips 2292 to engage the tubing string wall. Upon further
movement of
the rod 1602 in the direction 2280, the compression piece 2204 separates from
the
remaining portion of the rod 1602, as illustrated in Fig. 22C. In a similar
manner,
referring to Fig. 221, this separation also occurs in connection with the
components
engaging the lower seat segment 420.
[0096] At this point, the segments are anchored, or otherwise attached, to the
tubing string wall, so that, as depicted in Figs. 22D and 22J, the remaining
rod and
mandrel may be further retracted uphole, thereby leaving the compression piece
and
segment down in the well, as further illustrated in Figs. 22E and 22K.
[0097] Other implementations are contemplated, which are within the scope of
the appended claims. For example, in accordance with some implementations, the
segmented seat assembly may be deployed inside an expandable tube so that
radial
expansion of the segmented seat assembly deforms the tube to secure the seat
assembly in
place. In further implementations, the segmented seat assembly may be deployed
in an
open hole and thus, may form an anchored connection to an uncased wellbore
wall. For
implementations in which the segmented seat assembly has the slip elements,
such as slip
elements 2292 (see Fig. 22K, for example), the slip elements may be secured to
the lower
seat segments, such as lower seat segments 420, so that the upper seat
segments 410 may
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rest on the lower seat segments 420 after the untethered object has landed in
the seat of
the seat assembly.
[0098] In example implementations in which the compression piece(s) are not
separated from the rod to form a permanently-set seat assembly, the rod may be
moved
back downhole to exert radial retraction and longitudinal expansion forces to
return the
seat assembly back into its contracted state.
[0099] Thus, in general, a technique 2300 that is depicted in Fig. 23 may be
performed in a well using a setting tool and a segmented seat assembly.
Pursuant to the
technique 2300, a tool and seat assembly is positioned in a recess of a tubing
string (as an
example) and movement of the tool is initiated, pursuant to block 2304. If the
setting tool
contains an optional compression piece (decision block 2306) and if multiple
expansion
and retraction is to be performed for purposes of performing multiple downhole
operations (decision block 2310), then the technique 2300 includes
transitioning the seat
assembly to an expanded state, releasing the assembly from the tool,
performing a
downhole operation and then reengaging the seat assembly with the setting tool
to
transition the seat assembly back to the contracted state. If more downhole
locations are
to be performed (decision block 2314), then control transitions back to box
2304.
[00100] Otherwise, pursuant to the technique 2300, if the setting
tool does
not contain the compression piece (decision block 2306), then the technique
2300
includes transitioning the seat assembly to the expanded state and releasing
the assembly
from the tool, pursuant to block 2308. If the setting tool contains the
compression piece
but multiple expansions and retractions of the seat assembly is not to be used
(decision
block 2310), then use of the tool depends on whether anchoring (decision block
2320) is
to be employed. In other words, if the seat assembly is to be permanently
anchored, then
the flow diagram 2300 includes transitioning the seat assembly to the expanded
state to
anchor the setting tool to the tubing string wall and releasing the assembly
from the tool,
thereby leaving the compression piece downhole with the seat assembly to form
a
permanent seat in the well. Otherwise, if anchoring is not to be employed, the
technique
2300 includes transitioning the seat assembly to the expanded state and
releasing the seat
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assembly from the tool, pursuant to block 2326, without separating the
compression piece
from the rod of the setting tool, pursuant to block 2326.
[00101] Many variations are contemplated, which are within the scope
of
the appended claims. For example, to generalize, implementations have been
disclosed
herein in which the segmented seat assembly has segments that are arranged in
two axial
layers in the contracted state of the assembly. The seat assembly may,
however, have
more than two layers for its segments in its contracted, in accordance with
further
implementations. Thus, in general, Fig. 24A and 24B depict surfaces 2410 and
2414
(Fig. 24A) for an upper segment of a two layer seat assembly and corresponding
surfaces
2420 and 2424 (Fig. 24B) for the lower segment of the two layer assembly.
Figs. 25A,
25B and 25C depict surfaces 2510 and 2514 (Fig. 25A), 2520 and 2524 (Fig.
25B), and
2530 and 2534 (Fig. 25C) for upper, intermediate and lower segments of a three
layer
seat assembly. Figs. 26A (showing layers 2610 and 2614), 26B (showing layers
2620
and 2624), 26C (showing layers 2630 and 2634) and 26D (showing layers 2640 and
2644) depict surfaces of the rod and mandrel for upper-to-lower segments of a
four layer
segmented seat assembly. Thus, many variations are contemplated, which are
within the
scope of the appended claims.
[00102] While a limited number of examples have been disclosed
herein,
those skilled in the art, having the benefit of this disclosure, will
appreciate numerous
modifications and variations therefrom. It is intended that the appended
claims cover
such modifications and variations.
24
