Travel joint with a dual encapsulated coil stroke system and method for using the same

Abstract

Disclosed herein are various embodiments of a travel joint having a torque system adapted to attach to a tubular string, a release system attached to the torque system, a dual encapsulated coil stroke system attached to the release system and having an inner mandrel that is surrounded by an inner encapsulated coil and an outer encapsulated coil surrounding the inner encapsulated coil. In some embodiments, different types of control lines may be encapsulated within the inner and outer encapsulated coils.

Description

BACKGROUND

[0001] Wellbore completions in ultra-deep rock salt formations may use a disconnect system to allow workover of the upper completion without having to remove the lower completion. The well may be designed to perform the installation of the lower completion in a first run without the upper completion and use an integrity checker system to test if the lower completion is successfully installed in the wellbore. Flow control valves and permanent packers may be installed in the lower completion below the disconnect system. In the upper completion above the disconnect system may be installed any type of safety valves, gas lift mandrels and the tubing hanger in the top of the wellhead. During the reconnection of the upper completion in a second trip operation, it is not possible to exactly match the tubing hanger seat position in the wellhead and the disconnect system position, this is due to the fact that the tubing string has variance on length caused by differences on measurement of the string from the first trip and the string of the second trip. In some instances, the distance between the tubing hanger and the disconnect tool in ultra-deep rock salt formations may reach 4,000 meters or above.BRIEF DESCRIPTION OF THE DRAWINGS

[0002] These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the disclosure.

[0003] FIG. 1 illustrates a cross-sectional view of a well system including a travel joint with a dual encapsulated coil stroke system in accordance with some embodiments of the present disclosure.

[0004] FIG. 2 illustrates a cross-sectional view of the travel joint of FIG. 1, where the section line cuts through the central axis shown in FIG. 1, in accordance with some embodiments of the present disclosure.

[0005] FIG. 3 illustrates a cross-sectional view of a torque system, in accordance with some embodiments of the present disclosure.

[0006] FIG. 4 illustrates a perspective view of a torque system, in accordance with some embodiments of the present disclosure.

[0007] FIG. 5 illustrates a cross-sectional view of a dual encapsulated coil stroke system, in accordance with some embodiments of the present disclosure. The location of section plane A-A is also shown in this Figure.

[0008] FIG. 6 illustrates a perspective cross-sectional view of a dual encapsulated coil stroke system, in accordance with some embodiments of the present disclosure.

[0009] FIG. 7 illustrates a cross-sectional view of a dual encapsulated coil stroke system as taken along section plane A-A, in accordance with some embodiments of the present disclosure.

[0010] FIG. 8 illustrates a cross-sectional view of a dual encapsulated coil stroke system, in accordance with some embodiments of the present disclosure.

[0011] FIG. 9 illustrates a cross-sectional view of another embodiment for a travel joint, in accordance with some embodiments of the present disclosure.

[0012] FIG. 10 illustrates a cross-sectional view of an optional resettable system, in accordance with some embodiments of the present disclosure.

[0013] FIG. 11 illustrates a cross-sectional view of an embodiment for the inner and outer encapsulated coils.

[0014] FIG. 12 illustrates a cross-sectional view of another embodiment for the inner and outer encapsulated coils.DETAILED DESCRIPTION

[0015] Disclosed herein are various embodiments of a travel joint comprising a torque system adapted to attach to a tubular string, a release system attached to the torque system, a dual encapsulated coil stroke system attached to the release system and having an inner mandrel that is surrounded by an inner encapsulated coil, and an outer encapsulated coil surrounding the inner encapsulated coil.

[0016] Some travel joints further having a helical anchor which secures the inner encapsulated coil and the outer encapsulated coil to the inner mandrel. Some travel joints wherein the inner encapsulated coil and the outer encapsulated coil are coiled in opposing directions. Some travel joints further comprising a first set of control lines encapsulated within the inner encapsulated coil. Some travel joints further comprising a second set of control lines encapsulated within the outer encapsulated coil. Some travel joints wherein the first set of control lines are electrical and the second set of control lines are hydraulic.

[0017] Some travel joints wherein the first set of control lines are a different type than the second set of control lines. Some travel joints wherein the first set of control lines are electrical, and the second set of control lines are optical. Some travel joints further comprising an orientation key positioned underneath a cover plate. Some travel joints wherein the orientation key aligns with a slot positioned on the inner mandrel.

[0018] Some travel joints comprising a dual encapsulated coil stroke system comprising an inner mandrel that is surrounded by an inner encapsulated coil, and an outer encapsulated coil surrounding both the inner mandrel and the inner encapsulated coil, a first type of control lines attached to the inner encapsulated coil, and a second type of control lines attached to the outer encapsulated coil.

[0019] Some travel joints wherein the first type of control lines are electrical and the second type of control lines are hydraulic. Some travel joints further comprising an upper bushing and a lower bushing. Some travel joints wherein the upper bushing is anchored to the inner mandrel so that the upper bushing cannot slide or move relative to the inner mandrel. Some travel joints wherein the inner mandrel slides through the lower bushing.

[0020] Also disclosed herein are methods for connecting a top disconnect tool with a downhole bottom disconnect tool using a travel joint comprising the steps of attaching a first end of a travel joint to an upper tubing, attaching a second end of the travel joint to a lower tubing, attaching a top disconnect tool to the lower tubing, running the travel joint and the top disconnect tool downhole until the top disconnect tool makes contact with a bottom disconnect, and allowing a dual encapsulated coil stroke system within the travel joint to stroke after the top disconnect tool makes contact with the bottom disconnect.

[0021] Some methods wherein the dual encapsulated coil stroke system comprises an inner mandrel that is surrounded by an inner encapsulated coil, and an outer encapsulated coil surrounding the inner encapsulated coil. Some methods wherein the step of allowing a dual encapsulated coil stroke system to stroke comprises allowing an inner encapsulated coil to move freely and separately from an outer encapsulated coil.

[0022] Some methods wherein the dual encapsulated coil stroke system comprises an upper bushing which is anchored to an inner mandrel so that the upper bushing cannot slide or move relative to the inner mandrel, and a lower bushing which allows the inner mandrel to slide therethrough. Some methods further comprising aligning an orientation key with a slot positioned on an inner mandrel.

[0023] 10 well system

[0024] 12 tubular string

[0025] 12A upper tubing

[0026] 12B intermediate tubing

[0027] 14 production rig

[0028] 16 wellhead

[0029] 18 lower tubing

[0030] 20 wellbore

[0031] 22 packer

[0032] 23 casing

[0033] 24 travel joint with dual encapsulated coil stroke system

[0034] 25 top disconnect tool

[0035] 26 tubing hanger

[0036] 27 bottom disconnect tool

[0037] 28 wear bushing

[0038] 30 torque system

[0039] 32 release system

[0040] 34 dual encapsulated coil stroke system

[0041] 35 inner mandrel for torque system

[0042] 37 keyway

[0043] 39 sleeve

[0044] 40 key

[0045] 42 grooves

[0046] 44 strap

[0047] 46 control lines

[0048] 48 slot connection

[0049] 50 torque sub

[0050] 52 outer tube

[0051] 54 cap

[0052] 60 cover plate

[0053] 62 helical anchor

[0054] 64 control line guide

[0055] 66 strap

[0056] 68 upper bushing

[0057] 70 helical anchor

[0058] 72 clamp

[0059] 74 clamp

[0060] 76 lower bushing

[0061] 78 anchor for lower bushing

[0062] 80 control line guide

[0063] 82 strap

[0064] 84 inner encapsulated coil

[0065] 86 outer encapsulated coil

[0066] 88 outer tube

[0067] 90 clamp

[0068] 92 clamp

[0069] 94 inner mandrel of dual encapsulated coil stroke system

[0070] 96 orientation key

[0071] 98 slots

[0072] 100 anchor for upper bushing

[0073] 102 sealing element

[0074] 200 resettable system

[0075] 202 outer tube

[0076] 204 collet retainer

[0077] 206 spacer

[0078] 208 collet profile

[0079] 210 collet

[0080] 212 bottom adapter

[0081] 214 guide

[0082] 216 inner mandrel for resettable system

[0083] 220 coil width

[0084] 225 coil thickness

[0085] 240 electrical control line

[0086] 241 electrical control line

[0087] 250 hydraulic control line

[0088] 251 hydraulic control line

[0089] FIG. 1 illustrates a cross-sectional view of a well system 10 including a travel joint with a dual encapsulated coil stroke system 34 in accordance with some embodiments of the present disclosure. A second trip completion in a well system 10 is represented on FIG. 1, in which a production rig 14 may be used to install a tubular string 12 in a wellhead 16. A bottom disconnect tool 27 may be previously installed in the wellbore 23, a top disconnect tool 25 may be installed in a second trip operation to reconnect with the bottom disconnect tool 27. The lower tubing 18 may be connected to the top disconnect tool 25. The lower tubing 18 may be connected to the travel joint with dual encapsulated coil stroke system 34. The intermediate tubing 12B may be connected to the travel joint 24. A packer 22 may be connected above the intermediate tubing 12B. The upper tubing 12A may be connected to the packer 22.

[0090] At the top of the wellhead 16, the upper tubing 12A may be connected with the tubing hanger 26 which may sit on a wear bushing 28. Between the packer 22 and the tubing hanger 26, may be installed any type of safety valves or gas lift mandrels. In a first trip operation, any type of flow control valves, isolation packers or chemical injection systems may be installed below the bottom disconnect tool 27. A central axis is shown travelling vertically down the center of the assembly and is generally shared by each component.

[0091] A travel joint 24 may be used to connect a bottom disconnect tool 27 (which may be positioned downhole within the wellbore 20) with a top disconnect tool 25, with a method that may include the steps of attaching a first end of a travel joint 24 to a tubing string 12, attaching a second end of the travel joint 24 to a lower tubing 18, and attaching a top disconnect tool 25 to the lower tubing 18. The method may further include the steps of running the travel joint 24 and the top disconnect tool 25 downhole until the top disconnect tool 25 makes contact with the bottom disconnect tool 27, and allowing a dual encapsulated coil stroke system 34 (shown and described below) within the travel joint 24 to stroke after the top disconnect tool 25 makes contact with the bottom disconnect tool 27.

[0092] FIG. 2 illustrates a cross-sectional view of the travel joint 24 of FIG. 1, where the section line cuts through the central axis shown in FIG. 1, in accordance with some embodiments of the present disclosure. In this embodiment, the travel joint 24 may connect between an intermediate tubing 12B and a lower tubing 18 and may contain a number of different systems which are connected together. Specifically, a torque system 30 is positioned on the up-hole side of the travel joint 24 and may connect with a release system 32 positioned in a central portion of the travel joint 24. Finally, a dual encapsulated coil stroke system 34 may be positioned on the down-hole side of the travel joint 24, extending downwardly from the release system 32 and mechanically attached to the release system 32. The dual encapsulated coil stroke system 34 may also be mechanically attached to an lower tubing 18 on the opposing end as the release system 32.

[0093] FIG. 3 illustrates a cross-sectional view of a torque system 30, and FIG. 4 illustrates a perspective view of a torque system in accordance with some embodiments of the present disclosure. A keyway 37 may be placed on the inner mandrel 35 in order to transfer torque to the key 40 and allow relative longitudinal movement between the inner mandrel 35 and the outer tube 52. Grooves 42 may be positioned on the inner mandrel 35 to organize the control lines 46. A slot connection 48 may be used to transfer torque from the sleeve 39 to a torque sub 50 and an outer tube 52.

[0094] The torque system 30 may be any keyed type or other design to keep the tool aligned during the stroke, the stroke is the relative axial movement between the outer tube 52 and the inner mandrel 35. The stroke will be linear, without relative rotations between the inner mandrel 35 and the outer tube 52. The torque system may transfer the torque applied to the inner mandrel 35 to the outer tube 52 through a key 40 installed in the outer tube 52 and a keyway 37 in the inner mandrel 35 where the keyway 37 may be oriented longitudinally. The torque system 30 may be used to protect the dual encapsulated coil stroke system 34, such that any torque applied to the tool will be transmitted through the torque system 30 and not through the dual encapsulated coil stroke system 34.

[0095] FIG. 5 illustrates a cross-sectional view of a dual encapsulated coil stroke system 34, in accordance with some embodiments of the present disclosure. The location of section plane A-A is also shown in this Figure, where it is cutting through a cover plate 60. An inner mandrel 94 may be positioned along the central axis and surrounded by an inner encapsulated coil 84 with an outer encapsulated coil 86 surrounding both the inner mandrel 94 as well as the inner encapsulated coil 84. When the dual encapsulated coil system is allowed to or forced to stroke, this may allow the inner encapsulated coil 84 to move freely and separately from the outer encapsulated coil 86. When the dual encapsulated coil system is allowed to or forced to stroke, this may allow the two coils 84 and 86 to move freely and separately from each other.

[0096] FIG. 6 illustrates a perspective cross-sectional view of a dual encapsulated coil stroke system 34, in accordance with some embodiments of the present disclosure. A helical anchor 62 may be used to secure the inner and outer coils 84 and 86 while reducing the stresses on them. The outer coil 86 may be secured at a first end with a clamp 92 while the opposing end of coil 86 may be secured with clamp 74. The inner coil 84 may be secured at a first end with a clamp 90 while the opposing end of coil 84 with a clamp 72. An upper bushing 68 may be used and may have a helical profile. Another helical anchor 70 may be placed on the opposing end as the helical anchor 62 and may be used to secure the opposing ends of the coils 84 and 86. A lower bushing 76 may also have a helical profile. The lower bushing 76 may be anchored to the outer tube 88 using an anchor 78 such that it cannot slide or rotate. A set of control lines 46 may travel along with either the inner coil 84, or the outer coil 86, or both coils. A first type of control lines 46 may be attached to the inner coil 84 while a second type of control lines 46 may be attached to the outer coil 86. In some embodiments, the first type of control lines 46 may be electrical while the second type of control lines may be hydraulic. In other embodiments, the first type of control lines 46 may be optical while the second type of control lines may be hydraulic. In other embodiments, the first type of control lines 46 may be optical while the second type of control lines may be electrical.

[0097] The travel joint 24 with dual encapsulated coil stroke system 34 may be a single piece assembly containing two coils 84 and 86 which may be manufactured with control lines 46, sometimes in flatpacks that may contain a plurality of lines, the lines may be hydraulic, electrical, or optical, or a mixture of these. Each flatpack may contain from two to six different lines, and each flatpack may have an odd or even number of lines. The encapsulated coils 84 and 86 may be coiled in opposing directions, to avoid the tangling of the control lines 46 during the stroke. In other words, one encapsulated coil 84 / 86 could wrap clockwise around the inner mandrel 94 while the other encapsulated coil 84 / 86 could wrap counterclockwise around the inner mandrel 94. The bottom end of both encapsulated coils 84 and 86 are anchored using preferably helical anchors 62 and 70 in the bottom side of the tool to lower anchor with a helical design, the helical design of the anchor reduces the stresses induced on the coils 84 and 86 during the stroke of the tool.

[0098] The helical anchor 70 may have two or more clamps 72 and 74 to keep the encapsulated coils 84 and 86 connected to it. The helical anchor 70 may be connected to an outer tube 88. An outer tube 88 may be connected to a lower tubing string in the bottom end of the tool. The top end of the encapsulated coils 84 and 86 may be anchored to a helical anchor 62 preferably with a helical design, the helical design of the anchor can reduce the stresses on the top end of the encapsulated coils 84 and 86, among other benefits. The helical anchor 62 on the top end of the encapsulated coils 84 and 86 may be connected to an inner mandrel 94. The inner mandrel 94 may be connected to the intermediate tubing 12B and moves axially downwards relative to the outer tube 52 when the travel joint 24 may be released. The flatpack guarantees the uniform distribution of stresses through the control lines 46 in a long space-out. The dual encapsulated coil stroke system 34 reduces the overall length of the tool compared to traditional travel joint systems that may use a single flatpack and thus has a longer space-out compared to bare control lines coiled over a traditional mandrel.

[0099] FIG. 7 illustrates a cross-sectional view of a dual encapsulated coil stroke system 34 as taken along section plane A-A, in accordance with some embodiments of the present disclosure. When in the position shown, the orientation key 96 may be aligned with one or more of the slots 98 positioned on the inner mandrel 94.

[0100] FIG. 8 illustrates a cross-sectional view of a dual encapsulated coil stroke system 34, in accordance with some embodiments of the present disclosure. A cover plate 60 may be positioned at the top of the orientation key 96 in the desired position. An upper bushing 68 may be anchored to the inner mandrel 94 using anchor 100 so that it cannot slide or rotate. The upper bushing 68 may slide through the outer tubing 88. The inner mandrel 94 may slide through the lower bushing 76. A sealing element 102 may be positioned to block tubing / annulus fluid communication through an open bottom end on the inner mandrel 94. Some embodiments may not use the sealing element 102 where the fluid communication with tubing / annulus is desired.

[0101] FIG. 9 illustrates a cross-sectional view of another embodiment for a travel joint 24, in accordance with some embodiments of the present disclosure. In this embodiment, an optional resettable system 200 may be connected to the dual encapsulated coil stroke system 34.

[0102] FIG. 10 illustrates a cross-sectional view of an optional resettable system 200, in accordance with some embodiments of the present disclosure. The collet 210 may have a collet profile 208 which provides a higher resistance to compression and release with a lower resistance to extend and reset the tool. The bottom adapter 212 would preferably be shaped and adapted to connect with the lower tubing 18. A guide 214 may be positioned on the bottom end of the inner mandrel 216 to facilitate the passage of fluids and intervention tools. Any number of collets 210 and guides 214 for collets 210 could be used depending on how much load is required by the user to release and reset the tool, with each one being uniquely designed for each situation.

[0103] FIG. 11 illustrates a cross-sectional view of an embodiment for the inner and outer encapsulated coils 84 and 86. Each of the coils 84 and 86 may contain a number of different control lines 46 which may be a series of electrical conductors encased within a plastic or potting material such that the geometry of the surrounding encasement which forms the coil 84 and 86 has a width 220 along with a thickness 225. Preferably, the coils 84 and 86 have a width 220 that is substantially larger than the thickness 225. In some embodiments, the width 220 of the coils 84 and / or 86 may be 2-5 times the size of the thickness 225. In some embodiments, the coils 84 and 86 may have a rectangular cross-section. In some embodiments, the encasement material surrounding the control lines 46 may have a rectangular cross-section. In some embodiments, the control lines 46 within both the inner coil 84 and outer coil 86 would be the same type (ex. electrical or hydraulic) but they would be placed on different coils depending on their property (ex. diameter, material, or bending properties). Thus, control lines 46 on the inner coil 84 may have similar small diameters (and / or bending strength) while control lines 46 on the outer coil 86 may be similar large diameters (and / or bending strength) when compared to the control lines on the inner coil 84.

[0104] FIG. 12 illustrates a cross-sectional view of another embodiment for the inner and outer encapsulated coils 84 and 86. Here the inner coil 84 contains a set of five control lines 46 where included within this assembly is an electrical control line 240 and electrical control line 241 where electrical control line 240 could be the same or different from control line 241. Additionally, outer coil 86 may contain a set of four control lines 46 where included within this assembly is a hydraulic control line 250 and hydraulic control line 251 where control line 250 could be different or the same as control line 251. In this embodiment, electrical control lines 240 and 241 are of a different type than hydraulic control lines 250 and 251, but these particular control line types are not required, as they could also be optical lines within a surrounding encasement just as the electrical or hydraulic or optical lines combined within the coils shown and described herein.

[0105] Disclosed herein are various embodiments for a system and method for using a travel joint 24 with dual encapsulated coil stroke system 34 to allow the long space-out of the upper completion in second trip operations to safely land the tubing hanger 26 in the wellhead. Some embodiments of the travel joint 24 with dual encapsulated coil stroke system 34 may have a stroke length of 1 to 20 meters. The dual encapsulated coil stroke system 34 may be used to install multiple completions strings like multi-lateral wells. The dual encapsulated coil stroke system 34 may run-in-hole in an extended configuration to land the tubing hanger in a second trip operation or may run-in-hole at half stroke as an integral part of the work string to compensate tubing contraction and elongation. The dual encapsulated coil stroke system 34 isolates the tubing from pressure communication with annulus. A remote command from surface may be used to release the stroke of the travel joint 24, allowing the upper part of the tool to stroke inwards up to total stroke length of the tool. The remote command can be through hydrostatic pressure in a control line or tubing, or through an electronic signal. The dual encapsulated coil stroke system 34 keeps the integrity of multiple electrical, hydraulic or optical lines in the travel joint during the stroke.

[0106] The travel joint 24 with dual encapsulated coil stroke system 34 may be an essential tool when using a disconnect system, especially on a second trip operation in ultra-deep rock salt formations to guarantee the tubing hanger landing and can be designed with a long space out from 1 to 20 meters depending on the completion requirement. This travel joint 24 keeps the integrity of multiple control lines 46 during and after the stroke of the tool. It also provides an alternate method of compensating for tubing contraction and elongation after the tubing hanger installation. It can be run as an integral part of the tubing string to in a first trip operation to compensate tubing contraction and elongation.

[0107] The illustrative embodiments contained herein are not in scale and are not a limitation of this disclosure. Some illustrations are purposedly changed to facilitate the understanding of the embodiment.

[0108] Embodiments of the present disclosure may be applicable to vertical, multilateral, horizontal, deviated, or otherwise nonlinear wellbores in any type of offshore or onshore subterranean formation, in ultra-deep or shallow wells. Embodiments may be applicable to injection or production wells, including hydrocarbon wells.

[0109] In an embodiment, the travel joint 24 with dual encapsulated coil stroke system 34 may be composed of three systems: torque system 30; release system 32 and dual encapsulated coil stroke system 34. The tool may be a single-piece connected to the string and run-in-hole in an extended configuration or at half stroke configuration.

[0110] The release system 32 may keep the tool in the extended configuration or at half stroke configuration depending on the completion design until a remote command is given to release the tool and allow the relative axial movement between the inner mandrel and the outer tube. The release command may be actuated through hydraulic pressure, electrical or electronic signal, and through axial load applied to the string.

[0111] The release through hydraulic pressure may be any pressure induced release method disclosed in U.S. Pat. No. 10,301,888, which is incorporated by reference herein in its entirety. To release through hydraulic pressure, in an embodiment a travel joint contain a bottom seal that is installed on the od of the inner mandrel and the id of the outer tube, when pressure is applied to the tubing, a pressure-induced axial load is generated and keep the tool in the extended position until the pressure is reduced to allow the relative axial downward movement between the inner mandrel and the outer tube.

[0112] The release may be designed to actuate with an electric or electronic device based on electric commands from a local pcb, that can be cabled or wireless. The release system may be actuated under downward force on the tubing string. The release through downward force on the tubing string may be the release method disclosed in U.S. Pat. No. 6,367,552, which is incorporated by reference herein in its entirety.

[0113] In an embodiment, the dual encapsulated coil stroke system 34 shown and described in this disclosure is built with two coils manufactured where either one or both contain a number of different types of control lines 46 such as control line flatpacks that may contain a plurality of line types and line sizes, the lines may be hydraulic, electrical, or optical. Each flatpack may contain from two to six or more different lines, and each flatpack may have an odd or even number of lines. An inner encapsulated coil 84 may be installed over an inner mandrel 94 and an outer encapsulated coil 86 may be installed over the inner encapsulated coil 84. An outer tube 88 may be installed over the outer encapsulated coil 86.

[0114] The encapsulated coils 84 and 86 may be coiled in opposed direction, to avoid the tangling of the flatpacks during the stroke. The bottom end of both encapsulated coils 84 and 86 may be anchored in the bottom side of the tool to with a helical anchor, where the helical design reduces the stresses induced on the flatpack during the stroke of the tool. The lower anchor may have two or more clamps to keep the encapsulated coils connected to it. The lower anchor may be connected to an outer tube 88. An outer tube 88 may be connected to a lower tubing string and with the disconnect tool below it. The top end of the coil flatpacks are anchored to upper anchor with a helical design, to reduce the stresses on the top end of the coil flatpacks.

[0115] The upper anchor on the top end of the encapsulated coils may be connected on an inner mandrel. The inner mandrel may be connected to the upper string and moves axially downwards relative to the outer tube 88 when the travel joint is released. In this disclosure the travel joint may be a sealing type, a dynamic seal may be installed on the outer tube id on the bottom end of the outer tube 88, to seal the od of the inner mandrel. The seal may continuously isolate the inner tubing from pressure communication with annulus when axial relative movement between the inner mandrel and the outer tube 88 occur during the stroke of the tool.

[0116] In an alternate embodiment, the dual encapsulated coil stroke system 34 may be used in multilateral wells to compensate the tubing movement. It may be a modular assembly divided in two pieces, with the lower piece containing the dual encapsulated coil stroke system 34 and the upper piece containing the torque system and the release system.

[0117] The stroke system may be integrated into the dual encapsulated coil stroke system. The key from the stroke system may be installed in the outer diameter of the upper anchor and a longitudinal keyway be included on the outer tube 88.

[0118] The system may include a variation with a resettable system. The resettable system may be designed with multiple collets that would allow the tool to be reset after the first release when extended to the initial configuration with application of tension load in the tool, the tool would be reused without a redress. The tool may be a non-sealing type travel joint, with the design of the tool allowing communication between annulus and tubing fluids.

[0119] The dual encapsulated coil system may be composed of an inner coil flatpack and outer coil flatpack. The outer coil flatpack may be installed over the inner coil flatpack, the coils are manufactured in opposed direction to avoid the tangling of the flatpacks during the stroke. The dual encapsulated coil stroke system 34 reduces the overall length of the tool compared to other travel joint systems that uses a single flatpack and allow longer space-out compared to other systems that uses bare control lines coiled over a mandrel.

[0120] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0121] Therefore, the present embodiments are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.

Examples

Embodiment Construction

[0015]Disclosed herein are various embodiments of a travel joint comprising a torque system adapted to attach to a tubular string, a release system attached to the torque system, a dual encapsulated coil stroke system attached to the release system and having an inner mandrel that is surrounded by an inner encapsulated coil, and an outer encapsulated coil surrounding the inner encapsulated coil.

[0016]Some travel joints further having a helical anchor which secures the inner encapsulated coil and the outer encapsulated coil to the inner mandrel. Some travel joints wherein the inner encapsulated coil and the outer encapsulated coil are coiled in opposing directions. Some travel joints further comprising a first set of control lines encapsulated within the inner encapsulated coil. Some travel joints further comprising a second set of control lines encapsulated within the outer encapsulated coil. Some travel joints wherein the first set of control lines are electrical and the second set...

BACKGROUND

[0001] Wellbore completions in ultra-deep rock salt formations may use a disconnect system to allow workover of the upper completion without having to remove the lower completion. The well may be designed to perform the installation of the lower completion in a first run without the upper completion and use an integrity checker system to test if the lower completion is successfully installed in the wellbore. Flow control valves and permanent packers may be installed in the lower completion below the disconnect system. In the upper completion above the disconnect system may be installed any type of safety valves, gas lift mandrels and the tubing hanger in the top of the wellhead. During the reconnection of the upper completion in a second trip operation, it is not possible to exactly match the tubing hanger seat position in the wellhead and the disconnect system position, this is due to the fact that the tubing string has variance on length caused by differences on measurement of the string from the first trip and the string of the second trip. In some instances, the distance between the tubing hanger and the disconnect tool in ultra-deep rock salt formations may reach 4,000 meters or above.BRIEF DESCRIPTION OF THE DRAWINGS

[0002] These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the disclosure.

[0003] FIG. 1 illustrates a cross-sectional view of a well system including a travel joint with a dual encapsulated coil stroke system in accordance with some embodiments of the present disclosure.

[0004] FIG. 2 illustrates a cross-sectional view of the travel joint of FIG. 1, where the section line cuts through the central axis shown in FIG. 1, in accordance with some embodiments of the present disclosure.

[0005] FIG. 3 illustrates a cross-sectional view of a torque system, in accordance with some embodiments of the present disclosure.

[0006] FIG. 4 illustrates a perspective view of a torque system, in accordance with some embodiments of the present disclosure.

[0007] FIG. 5 illustrates a cross-sectional view of a dual encapsulated coil stroke system, in accordance with some embodiments of the present disclosure. The location of section plane A-A is also shown in this Figure.

[0008] FIG. 6 illustrates a perspective cross-sectional view of a dual encapsulated coil stroke system, in accordance with some embodiments of the present disclosure.

[0009] FIG. 7 illustrates a cross-sectional view of a dual encapsulated coil stroke system as taken along section plane A-A, in accordance with some embodiments of the present disclosure.

[0010] FIG. 8 illustrates a cross-sectional view of a dual encapsulated coil stroke system, in accordance with some embodiments of the present disclosure.

[0011] FIG. 9 illustrates a cross-sectional view of another embodiment for a travel joint, in accordance with some embodiments of the present disclosure.

[0012] FIG. 10 illustrates a cross-sectional view of an optional resettable system, in accordance with some embodiments of the present disclosure.

[0013] FIG. 11 illustrates a cross-sectional view of an embodiment for the inner and outer encapsulated coils.

[0014] FIG. 12 illustrates a cross-sectional view of another embodiment for the inner and outer encapsulated coils.DETAILED DESCRIPTION

[0015] Disclosed herein are various embodiments of a travel joint comprising a torque system adapted to attach to a tubular string, a release system attached to the torque system, a dual encapsulated coil stroke system attached to the release system and having an inner mandrel that is surrounded by an inner encapsulated coil, and an outer encapsulated coil surrounding the inner encapsulated coil.

[0016] Some travel joints further having a helical anchor which secures the inner encapsulated coil and the outer encapsulated coil to the inner mandrel. Some travel joints wherein the inner encapsulated coil and the outer encapsulated coil are coiled in opposing directions. Some travel joints further comprising a first set of control lines encapsulated within the inner encapsulated coil. Some travel joints further comprising a second set of control lines encapsulated within the outer encapsulated coil. Some travel joints wherein the first set of control lines are electrical and the second set of control lines are hydraulic.

[0017] Some travel joints wherein the first set of control lines are a different type than the second set of control lines. Some travel joints wherein the first set of control lines are electrical, and the second set of control lines are optical. Some travel joints further comprising an orientation key positioned underneath a cover plate. Some travel joints wherein the orientation key aligns with a slot positioned on the inner mandrel.

[0018] Some travel joints comprising a dual encapsulated coil stroke system comprising an inner mandrel that is surrounded by an inner encapsulated coil, and an outer encapsulated coil surrounding both the inner mandrel and the inner encapsulated coil, a first type of control lines attached to the inner encapsulated coil, and a second type of control lines attached to the outer encapsulated coil.

[0019] Some travel joints wherein the first type of control lines are electrical and the second type of control lines are hydraulic. Some travel joints further comprising an upper bushing and a lower bushing. Some travel joints wherein the upper bushing is anchored to the inner mandrel so that the upper bushing cannot slide or move relative to the inner mandrel. Some travel joints wherein the inner mandrel slides through the lower bushing.

[0020] Also disclosed herein are methods for connecting a top disconnect tool with a downhole bottom disconnect tool using a travel joint comprising the steps of attaching a first end of a travel joint to an upper tubing, attaching a second end of the travel joint to a lower tubing, attaching a top disconnect tool to the lower tubing, running the travel joint and the top disconnect tool downhole until the top disconnect tool makes contact with a bottom disconnect, and allowing a dual encapsulated coil stroke system within the travel joint to stroke after the top disconnect tool makes contact with the bottom disconnect.

[0021] Some methods wherein the dual encapsulated coil stroke system comprises an inner mandrel that is surrounded by an inner encapsulated coil, and an outer encapsulated coil surrounding the inner encapsulated coil. Some methods wherein the step of allowing a dual encapsulated coil stroke system to stroke comprises allowing an inner encapsulated coil to move freely and separately from an outer encapsulated coil.

[0022] Some methods wherein the dual encapsulated coil stroke system comprises an upper bushing which is anchored to an inner mandrel so that the upper bushing cannot slide or move relative to the inner mandrel, and a lower bushing which allows the inner mandrel to slide therethrough. Some methods further comprising aligning an orientation key with a slot positioned on an inner mandrel.

[0023] 10 well system

[0024] 12 tubular string

[0025] 12A upper tubing

[0026] 12B intermediate tubing

[0027] 14 production rig

[0028] 16 wellhead

[0029] 18 lower tubing

[0030] 20 wellbore

[0031] 22 packer

[0032] 23 casing

[0033] 24 travel joint with dual encapsulated coil stroke system

[0034] 25 top disconnect tool

[0035] 26 tubing hanger

[0036] 27 bottom disconnect tool

[0037] 28 wear bushing

[0038] 30 torque system

[0039] 32 release system

[0040] 34 dual encapsulated coil stroke system

[0041] 35 inner mandrel for torque system

[0042] 37 keyway

[0043] 39 sleeve

[0044] 40 key

[0045] 42 grooves

[0046] 44 strap

[0047] 46 control lines

[0048] 48 slot connection

[0049] 50 torque sub

[0050] 52 outer tube

[0051] 54 cap

[0052] 60 cover plate

[0053] 62 helical anchor

[0054] 64 control line guide

[0055] 66 strap

[0056] 68 upper bushing

[0057] 70 helical anchor

[0058] 72 clamp

[0059] 74 clamp

[0060] 76 lower bushing

[0061] 78 anchor for lower bushing

[0062] 80 control line guide

[0063] 82 strap

[0064] 84 inner encapsulated coil

[0065] 86 outer encapsulated coil

[0066] 88 outer tube

[0067] 90 clamp

[0068] 92 clamp

[0069] 94 inner mandrel of dual encapsulated coil stroke system

[0070] 96 orientation key

[0071] 98 slots

[0072] 100 anchor for upper bushing

[0073] 102 sealing element

[0074] 200 resettable system

[0075] 202 outer tube

[0076] 204 collet retainer

[0077] 206 spacer

[0078] 208 collet profile

[0079] 210 collet

[0080] 212 bottom adapter

[0081] 214 guide

[0082] 216 inner mandrel for resettable system

[0083] 220 coil width

[0084] 225 coil thickness

[0085] 240 electrical control line

[0086] 241 electrical control line

[0087] 250 hydraulic control line

[0088] 251 hydraulic control line

[0089] FIG. 1 illustrates a cross-sectional view of a well system 10 including a travel joint with a dual encapsulated coil stroke system 34 in accordance with some embodiments of the present disclosure. A second trip completion in a well system 10 is represented on FIG. 1, in which a production rig 14 may be used to install a tubular string 12 in a wellhead 16. A bottom disconnect tool 27 may be previously installed in the wellbore 23, a top disconnect tool 25 may be installed in a second trip operation to reconnect with the bottom disconnect tool 27. The lower tubing 18 may be connected to the top disconnect tool 25. The lower tubing 18 may be connected to the travel joint with dual encapsulated coil stroke system 34. The intermediate tubing 12B may be connected to the travel joint 24. A packer 22 may be connected above the intermediate tubing 12B. The upper tubing 12A may be connected to the packer 22.

[0090] At the top of the wellhead 16, the upper tubing 12A may be connected with the tubing hanger 26 which may sit on a wear bushing 28. Between the packer 22 and the tubing hanger 26, may be installed any type of safety valves or gas lift mandrels. In a first trip operation, any type of flow control valves, isolation packers or chemical injection systems may be installed below the bottom disconnect tool 27. A central axis is shown travelling vertically down the center of the assembly and is generally shared by each component.

[0091] A travel joint 24 may be used to connect a bottom disconnect tool 27 (which may be positioned downhole within the wellbore 20) with a top disconnect tool 25, with a method that may include the steps of attaching a first end of a travel joint 24 to a tubing string 12, attaching a second end of the travel joint 24 to a lower tubing 18, and attaching a top disconnect tool 25 to the lower tubing 18. The method may further include the steps of running the travel joint 24 and the top disconnect tool 25 downhole until the top disconnect tool 25 makes contact with the bottom disconnect tool 27, and allowing a dual encapsulated coil stroke system 34 (shown and described below) within the travel joint 24 to stroke after the top disconnect tool 25 makes contact with the bottom disconnect tool 27.

[0092] FIG. 2 illustrates a cross-sectional view of the travel joint 24 of FIG. 1, where the section line cuts through the central axis shown in FIG. 1, in accordance with some embodiments of the present disclosure. In this embodiment, the travel joint 24 may connect between an intermediate tubing 12B and a lower tubing 18 and may contain a number of different systems which are connected together. Specifically, a torque system 30 is positioned on the up-hole side of the travel joint 24 and may connect with a release system 32 positioned in a central portion of the travel joint 24. Finally, a dual encapsulated coil stroke system 34 may be positioned on the down-hole side of the travel joint 24, extending downwardly from the release system 32 and mechanically attached to the release system 32. The dual encapsulated coil stroke system 34 may also be mechanically attached to an lower tubing 18 on the opposing end as the release system 32.

[0093] FIG. 3 illustrates a cross-sectional view of a torque system 30, and FIG. 4 illustrates a perspective view of a torque system in accordance with some embodiments of the present disclosure. A keyway 37 may be placed on the inner mandrel 35 in order to transfer torque to the key 40 and allow relative longitudinal movement between the inner mandrel 35 and the outer tube 52. Grooves 42 may be positioned on the inner mandrel 35 to organize the control lines 46. A slot connection 48 may be used to transfer torque from the sleeve 39 to a torque sub 50 and an outer tube 52.

[0094] The torque system 30 may be any keyed type or other design to keep the tool aligned during the stroke, the stroke is the relative axial movement between the outer tube 52 and the inner mandrel 35. The stroke will be linear, without relative rotations between the inner mandrel 35 and the outer tube 52. The torque system may transfer the torque applied to the inner mandrel 35 to the outer tube 52 through a key 40 installed in the outer tube 52 and a keyway 37 in the inner mandrel 35 where the keyway 37 may be oriented longitudinally. The torque system 30 may be used to protect the dual encapsulated coil stroke system 34, such that any torque applied to the tool will be transmitted through the torque system 30 and not through the dual encapsulated coil stroke system 34.

[0095] FIG. 5 illustrates a cross-sectional view of a dual encapsulated coil stroke system 34, in accordance with some embodiments of the present disclosure. The location of section plane A-A is also shown in this Figure, where it is cutting through a cover plate 60. An inner mandrel 94 may be positioned along the central axis and surrounded by an inner encapsulated coil 84 with an outer encapsulated coil 86 surrounding both the inner mandrel 94 as well as the inner encapsulated coil 84. When the dual encapsulated coil system is allowed to or forced to stroke, this may allow the inner encapsulated coil 84 to move freely and separately from the outer encapsulated coil 86. When the dual encapsulated coil system is allowed to or forced to stroke, this may allow the two coils 84 and 86 to move freely and separately from each other.

[0096] FIG. 6 illustrates a perspective cross-sectional view of a dual encapsulated coil stroke system 34, in accordance with some embodiments of the present disclosure. A helical anchor 62 may be used to secure the inner and outer coils 84 and 86 while reducing the stresses on them. The outer coil 86 may be secured at a first end with a clamp 92 while the opposing end of coil 86 may be secured with clamp 74. The inner coil 84 may be secured at a first end with a clamp 90 while the opposing end of coil 84 with a clamp 72. An upper bushing 68 may be used and may have a helical profile. Another helical anchor 70 may be placed on the opposing end as the helical anchor 62 and may be used to secure the opposing ends of the coils 84 and 86. A lower bushing 76 may also have a helical profile. The lower bushing 76 may be anchored to the outer tube 88 using an anchor 78 such that it cannot slide or rotate. A set of control lines 46 may travel along with either the inner coil 84, or the outer coil 86, or both coils. A first type of control lines 46 may be attached to the inner coil 84 while a second type of control lines 46 may be attached to the outer coil 86. In some embodiments, the first type of control lines 46 may be electrical while the second type of control lines may be hydraulic. In other embodiments, the first type of control lines 46 may be optical while the second type of control lines may be hydraulic. In other embodiments, the first type of control lines 46 may be optical while the second type of control lines may be electrical.

[0097] The travel joint 24 with dual encapsulated coil stroke system 34 may be a single piece assembly containing two coils 84 and 86 which may be manufactured with control lines 46, sometimes in flatpacks that may contain a plurality of lines, the lines may be hydraulic, electrical, or optical, or a mixture of these. Each flatpack may contain from two to six different lines, and each flatpack may have an odd or even number of lines. The encapsulated coils 84 and 86 may be coiled in opposing directions, to avoid the tangling of the control lines 46 during the stroke. In other words, one encapsulated coil 84 / 86 could wrap clockwise around the inner mandrel 94 while the other encapsulated coil 84 / 86 could wrap counterclockwise around the inner mandrel 94. The bottom end of both encapsulated coils 84 and 86 are anchored using preferably helical anchors 62 and 70 in the bottom side of the tool to lower anchor with a helical design, the helical design of the anchor reduces the stresses induced on the coils 84 and 86 during the stroke of the tool.

[0098] The helical anchor 70 may have two or more clamps 72 and 74 to keep the encapsulated coils 84 and 86 connected to it. The helical anchor 70 may be connected to an outer tube 88. An outer tube 88 may be connected to a lower tubing string in the bottom end of the tool. The top end of the encapsulated coils 84 and 86 may be anchored to a helical anchor 62 preferably with a helical design, the helical design of the anchor can reduce the stresses on the top end of the encapsulated coils 84 and 86, among other benefits. The helical anchor 62 on the top end of the encapsulated coils 84 and 86 may be connected to an inner mandrel 94. The inner mandrel 94 may be connected to the intermediate tubing 12B and moves axially downwards relative to the outer tube 52 when the travel joint 24 may be released. The flatpack guarantees the uniform distribution of stresses through the control lines 46 in a long space-out. The dual encapsulated coil stroke system 34 reduces the overall length of the tool compared to traditional travel joint systems that may use a single flatpack and thus has a longer space-out compared to bare control lines coiled over a traditional mandrel.

[0099] FIG. 7 illustrates a cross-sectional view of a dual encapsulated coil stroke system 34 as taken along section plane A-A, in accordance with some embodiments of the present disclosure. When in the position shown, the orientation key 96 may be aligned with one or more of the slots 98 positioned on the inner mandrel 94.

[0100] FIG. 8 illustrates a cross-sectional view of a dual encapsulated coil stroke system 34, in accordance with some embodiments of the present disclosure. A cover plate 60 may be positioned at the top of the orientation key 96 in the desired position. An upper bushing 68 may be anchored to the inner mandrel 94 using anchor 100 so that it cannot slide or rotate. The upper bushing 68 may slide through the outer tubing 88. The inner mandrel 94 may slide through the lower bushing 76. A sealing element 102 may be positioned to block tubing / annulus fluid communication through an open bottom end on the inner mandrel 94. Some embodiments may not use the sealing element 102 where the fluid communication with tubing / annulus is desired.

[0101] FIG. 9 illustrates a cross-sectional view of another embodiment for a travel joint 24, in accordance with some embodiments of the present disclosure. In this embodiment, an optional resettable system 200 may be connected to the dual encapsulated coil stroke system 34.

[0102] FIG. 10 illustrates a cross-sectional view of an optional resettable system 200, in accordance with some embodiments of the present disclosure. The collet 210 may have a collet profile 208 which provides a higher resistance to compression and release with a lower resistance to extend and reset the tool. The bottom adapter 212 would preferably be shaped and adapted to connect with the lower tubing 18. A guide 214 may be positioned on the bottom end of the inner mandrel 216 to facilitate the passage of fluids and intervention tools. Any number of collets 210 and guides 214 for collets 210 could be used depending on how much load is required by the user to release and reset the tool, with each one being uniquely designed for each situation.

[0103] FIG. 11 illustrates a cross-sectional view of an embodiment for the inner and outer encapsulated coils 84 and 86. Each of the coils 84 and 86 may contain a number of different control lines 46 which may be a series of electrical conductors encased within a plastic or potting material such that the geometry of the surrounding encasement which forms the coil 84 and 86 has a width 220 along with a thickness 225. Preferably, the coils 84 and 86 have a width 220 that is substantially larger than the thickness 225. In some embodiments, the width 220 of the coils 84 and / or 86 may be 2-5 times the size of the thickness 225. In some embodiments, the coils 84 and 86 may have a rectangular cross-section. In some embodiments, the encasement material surrounding the control lines 46 may have a rectangular cross-section. In some embodiments, the control lines 46 within both the inner coil 84 and outer coil 86 would be the same type (ex. electrical or hydraulic) but they would be placed on different coils depending on their property (ex. diameter, material, or bending properties). Thus, control lines 46 on the inner coil 84 may have similar small diameters (and / or bending strength) while control lines 46 on the outer coil 86 may be similar large diameters (and / or bending strength) when compared to the control lines on the inner coil 84.

[0104] FIG. 12 illustrates a cross-sectional view of another embodiment for the inner and outer encapsulated coils 84 and 86. Here the inner coil 84 contains a set of five control lines 46 where included within this assembly is an electrical control line 240 and electrical control line 241 where electrical control line 240 could be the same or different from control line 241. Additionally, outer coil 86 may contain a set of four control lines 46 where included within this assembly is a hydraulic control line 250 and hydraulic control line 251 where control line 250 could be different or the same as control line 251. In this embodiment, electrical control lines 240 and 241 are of a different type than hydraulic control lines 250 and 251, but these particular control line types are not required, as they could also be optical lines within a surrounding encasement just as the electrical or hydraulic or optical lines combined within the coils shown and described herein.

[0105] Disclosed herein are various embodiments for a system and method for using a travel joint 24 with dual encapsulated coil stroke system 34 to allow the long space-out of the upper completion in second trip operations to safely land the tubing hanger 26 in the wellhead. Some embodiments of the travel joint 24 with dual encapsulated coil stroke system 34 may have a stroke length of 1 to 20 meters. The dual encapsulated coil stroke system 34 may be used to install multiple completions strings like multi-lateral wells. The dual encapsulated coil stroke system 34 may run-in-hole in an extended configuration to land the tubing hanger in a second trip operation or may run-in-hole at half stroke as an integral part of the work string to compensate tubing contraction and elongation. The dual encapsulated coil stroke system 34 isolates the tubing from pressure communication with annulus. A remote command from surface may be used to release the stroke of the travel joint 24, allowing the upper part of the tool to stroke inwards up to total stroke length of the tool. The remote command can be through hydrostatic pressure in a control line or tubing, or through an electronic signal. The dual encapsulated coil stroke system 34 keeps the integrity of multiple electrical, hydraulic or optical lines in the travel joint during the stroke.

[0106] The travel joint 24 with dual encapsulated coil stroke system 34 may be an essential tool when using a disconnect system, especially on a second trip operation in ultra-deep rock salt formations to guarantee the tubing hanger landing and can be designed with a long space out from 1 to 20 meters depending on the completion requirement. This travel joint 24 keeps the integrity of multiple control lines 46 during and after the stroke of the tool. It also provides an alternate method of compensating for tubing contraction and elongation after the tubing hanger installation. It can be run as an integral part of the tubing string to in a first trip operation to compensate tubing contraction and elongation.

[0107] The illustrative embodiments contained herein are not in scale and are not a limitation of this disclosure. Some illustrations are purposedly changed to facilitate the understanding of the embodiment.

[0108] Embodiments of the present disclosure may be applicable to vertical, multilateral, horizontal, deviated, or otherwise nonlinear wellbores in any type of offshore or onshore subterranean formation, in ultra-deep or shallow wells. Embodiments may be applicable to injection or production wells, including hydrocarbon wells.

[0109] In an embodiment, the travel joint 24 with dual encapsulated coil stroke system 34 may be composed of three systems: torque system 30; release system 32 and dual encapsulated coil stroke system 34. The tool may be a single-piece connected to the string and run-in-hole in an extended configuration or at half stroke configuration.

[0110] The release system 32 may keep the tool in the extended configuration or at half stroke configuration depending on the completion design until a remote command is given to release the tool and allow the relative axial movement between the inner mandrel and the outer tube. The release command may be actuated through hydraulic pressure, electrical or electronic signal, and through axial load applied to the string.

[0111] The release through hydraulic pressure may be any pressure induced release method disclosed in U.S. Pat. No. 10,301,888, which is incorporated by reference herein in its entirety. To release through hydraulic pressure, in an embodiment a travel joint contain a bottom seal that is installed on the od of the inner mandrel and the id of the outer tube, when pressure is applied to the tubing, a pressure-induced axial load is generated and keep the tool in the extended position until the pressure is reduced to allow the relative axial downward movement between the inner mandrel and the outer tube.

[0112] The release may be designed to actuate with an electric or electronic device based on electric commands from a local pcb, that can be cabled or wireless. The release system may be actuated under downward force on the tubing string. The release through downward force on the tubing string may be the release method disclosed in U.S. Pat. No. 6,367,552, which is incorporated by reference herein in its entirety.

[0113] In an embodiment, the dual encapsulated coil stroke system 34 shown and described in this disclosure is built with two coils manufactured where either one or both contain a number of different types of control lines 46 such as control line flatpacks that may contain a plurality of line types and line sizes, the lines may be hydraulic, electrical, or optical. Each flatpack may contain from two to six or more different lines, and each flatpack may have an odd or even number of lines. An inner encapsulated coil 84 may be installed over an inner mandrel 94 and an outer encapsulated coil 86 may be installed over the inner encapsulated coil 84. An outer tube 88 may be installed over the outer encapsulated coil 86.

[0114] The encapsulated coils 84 and 86 may be coiled in opposed direction, to avoid the tangling of the flatpacks during the stroke. The bottom end of both encapsulated coils 84 and 86 may be anchored in the bottom side of the tool to with a helical anchor, where the helical design reduces the stresses induced on the flatpack during the stroke of the tool. The lower anchor may have two or more clamps to keep the encapsulated coils connected to it. The lower anchor may be connected to an outer tube 88. An outer tube 88 may be connected to a lower tubing string and with the disconnect tool below it. The top end of the coil flatpacks are anchored to upper anchor with a helical design, to reduce the stresses on the top end of the coil flatpacks.

[0115] The upper anchor on the top end of the encapsulated coils may be connected on an inner mandrel. The inner mandrel may be connected to the upper string and moves axially downwards relative to the outer tube 88 when the travel joint is released. In this disclosure the travel joint may be a sealing type, a dynamic seal may be installed on the outer tube id on the bottom end of the outer tube 88, to seal the od of the inner mandrel. The seal may continuously isolate the inner tubing from pressure communication with annulus when axial relative movement between the inner mandrel and the outer tube 88 occur during the stroke of the tool.

[0116] In an alternate embodiment, the dual encapsulated coil stroke system 34 may be used in multilateral wells to compensate the tubing movement. It may be a modular assembly divided in two pieces, with the lower piece containing the dual encapsulated coil stroke system 34 and the upper piece containing the torque system and the release system.

[0117] The stroke system may be integrated into the dual encapsulated coil stroke system. The key from the stroke system may be installed in the outer diameter of the upper anchor and a longitudinal keyway be included on the outer tube 88.

[0118] The system may include a variation with a resettable system. The resettable system may be designed with multiple collets that would allow the tool to be reset after the first release when extended to the initial configuration with application of tension load in the tool, the tool would be reused without a redress. The tool may be a non-sealing type travel joint, with the design of the tool allowing communication between annulus and tubing fluids.

[0119] The dual encapsulated coil system may be composed of an inner coil flatpack and outer coil flatpack. The outer coil flatpack may be installed over the inner coil flatpack, the coils are manufactured in opposed direction to avoid the tangling of the flatpacks during the stroke. The dual encapsulated coil stroke system 34 reduces the overall length of the tool compared to other travel joint systems that uses a single flatpack and allow longer space-out compared to other systems that uses bare control lines coiled over a mandrel.

[0120] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0121] Therefore, the present embodiments are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.

Examples

Embodiment Construction

[0015]Disclosed herein are various embodiments of a travel joint comprising a torque system adapted to attach to a tubular string, a release system attached to the torque system, a dual encapsulated coil stroke system attached to the release system and having an inner mandrel that is surrounded by an inner encapsulated coil, and an outer encapsulated coil surrounding the inner encapsulated coil.

[0016]Some travel joints further having a helical anchor which secures the inner encapsulated coil and the outer encapsulated coil to the inner mandrel. Some travel joints wherein the inner encapsulated coil and the outer encapsulated coil are coiled in opposing directions. Some travel joints further comprising a first set of control lines encapsulated within the inner encapsulated coil. Some travel joints further comprising a second set of control lines encapsulated within the outer encapsulated coil. Some travel joints wherein the first set of control lines are electrical and the second set...

Claims

1. A travel joint comprising:a torque system adapted to attach to a tubular string;a release system attached to the torque system; anda dual encapsulated coil stroke system attached to the release system and having an inner mandrel that is surrounded by an inner encapsulated coil; andan outer encapsulated coil surrounding the inner encapsulated coil.

2. The travel joint of claim 1 further comprising:a helical anchor which secures the inner encapsulated coil and the outer encapsulated coil to the inner mandrel.

3. The travel joint of claim 1 wherein:the inner encapsulated coil and the outer encapsulated coil are coiled in opposing directions.

4. The travel joint of claim 1 further comprising:a first set of control lines encapsulated within the inner encapsulated coil.

5. The travel joint of claim 4 further comprising:a second set of control lines encapsulated within the outer encapsulated coil.

6. The travel joint of claim 5 wherein:the first set of control lines are electrical, andthe second set of control lines are hydraulic.

7. The travel joint of claim 5 wherein:the first set of control lines are a different type than the second set of control lines.

8. The travel joint of claim 5 wherein:the first set of control lines are electrical, andthe second set of control lines are optical.

9. The travel joint of claim 1 further comprising:an orientation key positioned underneath a cover plate.

10. The travel joint of claim 9 wherein:the orientation key aligns with a slot positioned on the inner mandrel.11-12. (canceled)13. The travel joint of claim 1 further comprising:an upper bushing anda lower bushing.

14. The travel joint of claim 13 wherein:the upper bushing is anchored to the inner mandrel so that the upper bushing cannot slide or move relative to the inner mandrel.

15. The travel joint of claim 14 wherein:the inner mandrel slides through the lower bushing.

16. A method for connecting a top disconnect tool with a downhole bottom disconnect tool using a travel joint comprising the steps of:attaching a first end of a travel joint to an upper tubing;attaching a second end of the travel joint to a lower tubing;attaching a top disconnect tool to the lower tubing;running the travel joint and the top disconnect tool downhole until the top disconnect tool makes contact with a bottom disconnect; andallowing a dual encapsulated coil stroke system within the travel joint to stroke after the top disconnect tool makes contact with the bottom disconnect.

17. The method of claim 16 wherein:the dual encapsulated coil stroke system comprises:an inner mandrel that is surrounded by an inner encapsulated coil; andan outer encapsulated coil surrounding the inner encapsulated coil.

18. The method of claim 16 wherein:the step of allowing a dual encapsulated coil stroke system to stroke comprises allowing an inner encapsulated coil to move freely and separately from an outer encapsulated coil.

19. The method of claim 16 wherein:the dual encapsulated coil stroke system comprisesan upper bushing which is anchored to an inner mandrel so that the upper bushing cannot slide or move relative to the inner mandrel, anda lower bushing which allows the inner mandrel to slide therethrough.

20. The method of claim 16 further comprising:aligning an orientation key with a slot positioned on an inner mandrel.

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