A well tool device and a bypass plug kit

Abstract

A well tool device comprising a tubular housing (21) with an axial through running boring (26), the well tool device further comprises a closing sleeve (7) with an open frangible ball seat (1) and a first breaking mechanism (20), and a plug holding sleeve (19) with a solid frangible plug (2) and a second breaking mechanism (14), said plug holding sleeve (19) is provided downstream of the closing sleeve (7). The closing sleeve (7) is equipped with first fluid communication apertures (4) for fluid communication through a bypass channel (6) with second fluid communication apertures (5) downstream of the solid plug (2), and said closing sleeve (7) comprises a fluid channel (10) arranged to be opened up for fluid communication between the through running boring (26) and a piston (11) on the closing sleeve (7). The open frangible seat (1) is arranged for receipt of a drop ball (3) to close of the ball seat (1), wherein pressure builds up and forces the ball seat (1) to be shattered by the first breaking mechanism (20) and allowing fluid to flow through said fluid channel (10).

Description

[0001] A well tool device and a bypass plug kit.

[0002] Field of the invention

[0003] The present invention relates to a well tool device comprising a tubular housing with an axial through running boring, and a bypass plug kit for insertion in the housing.

[0004] The present invention relates to a well tool device for opening and closing a fluid bore in a well. In particular, the present invention relates to a well tool device having a temporary open state, a temporary closed state, and a permanent open state.

[0005] Background of the invention

[0006] In different types of well operations, it is a need for well tool devices having a valve function, i.e. , the well tool device needs to be reconfigured between an open state and a closed state.

[0007] Typically, the closed state is used for pressure testing purposes to ensure that the well integrity is intact. The open state is typically during production, to allow hydrocarbon fluids to be transported from the well to the topside of the well. During the installation of the completion string or tubing, it is preferred that the tubing is open, so well fluid can flow into the tubing during the lowering of the tubing into the well.

[0008] When the tubing is landed in the well head and the pressure control equipment is installed above the tubing / well head, it is desired to replace the heavy well fluid with a lighter completion fluid before the production packer is installed. In such a case, completion fluid is pumped down into the tubing and return fluid is received through the annulus. Again, during such operations, the tubing must be open. In some operations, the open state is also used for pressure testing purposes.

[0009] Disclosure of the state of art

[0010] NO332526B1 discloses a device for use in a system for carrying out tests of a well, pipe or the like, where a plug of a removable material is inserted in a pipe through the well to carry out the tests. The pipe's wall parts comprising a channel that establishes a fluid connection between the well space above and the well space below the plug, which channel comprises an axial chamber in which a piston is arranged and can be adjusted by axial movement from a first position where there is fluid connection through the channel and a second position where the fluid connection is permanently closed.

[0011] NO343059B1 corresponding to US2020115989A1 and NO343864B1 corresponding to US2021040816A1 disclose a well tool device for opening and closing a fluid bore in a well. The well tool device has a temporary open state, a temporary closed state, and a permanent open state.

[0012] Mousa, A., Completion Barrier Glass Plug with Integrated Bypass Sleeve, Society of Petroleum Engineers, 31 October-3 November 2022, Abu Dhabi, UAE, SPE-211582- MS describes a barrier glass plug with bypass capability. The plug allows self-filling of the tubing while running in hole and circulating of fluid to displace the wellbore.

[0013] Objects of the present invention

[0014] It is an object to provide a well tool device for use in oil and gas well completion activities.

[0015] The well tool device provides means to run in the completion string in open ended, so that the completion string filles itself with well fluid from below while Running in Hole (RIH).

[0016] The well tool device provides means to close off the completion string inside to enable setting of a pressure set production packer and to pressure up against the closed bypass plug to pressure test the completion above the well tool device with the bypass plug.

[0017] The well tool device provides means to open the completion string to full bore after the production packer is set and the completion is tested, so that the well can be produced.

[0018] It is also an object to provide a bypass plug kit for insertion in the housing of the well tool device.

[0019] Summary of the invention

[0020] According to a first aspect of the invention, a well tool device comprising a tubular housing with an axial through running boring is provided, the well tool device further comprises: a closing sleeve, an open frangible ball seat and a first breaking mechanism, a plug holding sleeve with a solid frangible plug and a second breaking mechanism, said plug holding sleeve is provided downstream of the closing sleeve, said closing sleeve is equipped with first fluid communication apertures for fluid communication through a bypass channel with second fluid communication apertures downstream of the solid frangible plug, and a fluid channel arranged to be opened up for fluid communication between the through running boring and a piston on the closing sleeve, said open frangible ball seat is arranged for receipt of a drop ball to close off the ball seat, wherein pressure builds up and forces the ball seat to be shattered by the first breaking mechanism and allowing fluid to flow through said fluid channel.

[0021] The open frangible ball seat and the first breaking mechanism can be arranged in the closing sleeve.

[0022] The fluid channel can at least partly be comprised in the closing sleeve.

[0023] The piston can be arranged to force the closing sleeve upstream in the through running boring and the first fluid communication apertures out of alignment with the bypass channel, closing fluid communication through said bypass channel.

[0024] The well tool device can comprise an upper atmospheric chamber and a lower atmospheric chamber, said upper atmospheric chamber and lower atmospheric chamber are separated by the piston, and the fluid channel is running from the through running boring to the lower atmospheric chamber.

[0025] The fluid channel can be a radial channel running to said lower atmospheric chamber.

[0026] The piston can be an external flange on the closing sleeve.

[0027] Further, a check valve channel can be running between the upper atmospheric chamber and the lower atmospheric chamber, said channel is equipped with a check valve. The check valve can be a plug arranged to pop out if pressure in the upper atmospheric chamber is higher than the pressure in the lower atmospheric chamber.

[0028] The plug can be covered with or made of a low friction material.

[0029] The first breaking mechanism can in one embodiment comprise one or more breaking pins covered by a cap isolating the pin from the ball seat.

[0030] The solid frangible plug can be arranged to be shattered by the second breaking mechanism when fluid pressure reaches a predetermined threshold, to fully open the through running boring.

[0031] The second breaking mechanism can in one embodiment comprises a load ring supporting the solid frangible plug, said load ring is axially movable within the through running boring between a first position in where the solid frangible plug is with a distance to a breaking pin and a second position in where the solid frangible plug is forced against the breaking pin.

[0032] The load ring can be resting on a shear ring with an annular shear lip to prevent axial movement in the first position until the shear lip is subjected to a force higher than a predetermined force, wherein the annular shear lip of the shear ring extends radially inward in the through running boring, and the breaking pin is resting on the shear ring, and said breaking pin is accommodated in a pocket on an outside of the load ring.

[0033] The closing sleeve may comprise an upper sleeve and a lower sleeve with the first fluid communication apertures, wherein the ball seat is mounted between the upper sleeve and the lower sleeve.

[0034] The open frangible ball seat can be a donut shaped disc made of brittle glass.

[0035] Further, the solid frangible plug can be a disc shaped plug made of brittle glass.

[0036] The closing sleeve can comprise an engagement connection, such as a profile or flange, for attachment to a shifting tool in case the closing sleeve needs to be mechanically shifted. The housing may further comprise a release profile for triggering a release mechanism on a shifting tool to release the shifting tool from the closing sleeve when the closing sleeve is fully closed.

[0037] According to a second aspect of the invention, a bypass plug kit is provided, comprising a closing sleeve with an open frangible ball seat and a first breaking mechanism, and a plug holding sleeve with a solid frangible plug and a second breaking mechanism, said plug holding sleeve is interconnected with the closing sleeve, wherein the bypass plug kit is arranged to be inserted into a housing.

[0038] The bypass plug kit is preferable arranged to be inserted into the housing from below before a lower crossover is screwed onto the housing.

[0039] The bypass plug kit can be prevented from sliding axially back out of the housing by segments in a groove inside the housing, wherein the segments are secured radially by a ring held in place by an end insert having set screws.

[0040] Description of the figures

[0041] Embodiments of the present invention will now be described, by way of example only, with reference to the following figures, wherein:

[0042] Figure 1 shows a well tool device according to the invention, in a Run in Hole state.

[0043] Figure 2 shows the well tool device according to the invention, after a drop ball has been dropped and landed in a ball seat.

[0044] Figure 3 shows an enlarged view of the well tool device in fig. 2.

[0045] Figure 4 shows an enlarged view of the well tool device in fig. 3.

[0046] Figure 5 shows the well tool device according to the invention, after the ball seat is shattered and with a closed bypass channel.

[0047] Figure 6 shows an enlarged view of the well tool device in fig, 5.

[0048] Figure 7 shows the well tool device according to the invention, after a solid bypass plug has been shattered.

[0049] Figure 8 shows an enlarged view of the well tool device, showing a check valve between an upper atmospheric chamber and a lower atmospheric chamber.

[0050] Figure 9 shows a bypass plug kit according to the invention.

[0051] Description of preferred embodiments of the invention The well tool device according to the invention comprises a housing 21 equipped with an upper and a lower crossover 22,23 screwed into the housing 21 in each end. The crossovers 22,23 have threads that fit with the tubing it is supposed to be mounted in. As an improvement to the design in the figures the upper crossover 22 and the housing 21 can be manufactured as one piece. This will remove a possible leakage point and reduce the number of parts, thus simplifying the process of final assembly.

[0052] The present invention can be used in a vertical part of the well, in a horizontal part of the well or in the transition between vertical and horizontal. Hence, “downstream” must be understood to be similar to “below”. Correspondingly, “upstream” must be understood to be similar to “above”.

[0053] The well tool device further comprises a bypass plug kit 50 (fig, 9) that is designed to be inserted into the housing 21 from below before the lower crossover 23 is screwed to the housing 21. The bypass plug kit 50 has two main components, comprising a closing sleeve 7 with an open frangible ball seat 1 and a first breaking mechanism 20, and a plug holding sleeve 19 with a solid frangible plug 2 and a second breaking mechanism 14. The plug holding sleeve 19 is interconnected with the closing sleeve 7, which is axially displaceable relative to the plug holding sleeve 19. The plug holding sleeve 19 comprises grooves that together with the housing 21 provides a bypass channel 6. The bypass plug kit 50 further comprises external packers mating with internal grooves in the housing.

[0054] The bypass plug kit is for instance prevented from sliding axially back out of the housing 21 by segments 12 in a groove 27 inside the housing 21 (see for instance fig. 3 and 6). The segments 12 are secured radially by a ring 13 held in place by an end insert 25 having set screws 28.

[0055] The closing sleeve can comprise two connected sleeves 7a, 7b (fig. 3), to enable mounting of the frangible ball seat 1 , but for the purpose of describing the function it can be considered as one sleeve. The closing sleeve 7 is arranged to move relative to the housing and relative to the plug holding sleeve 19 to close a bypass channel 6.

[0056] As an alternative, the frangible ball seat 1 together with the first breaking mechanism

[0057] 20 can be arranged in a separate sleeve above or below the closing sleeve 7. A further alternative can be to arrange the frangible ball seat 1 directly in the housing

[0058] 21 between an internal slanted ledge in the housing and a support sleeve or ring and then arrange the first breaking mechanism 20 in said support sleeve or ring.

[0059] The frangible ball seat 1 is in all embodiments preferably arranged above the solid frangible plug 2.

[0060] The bypass channel 6 comprises one or more channels running external on the closing sleeve 7 and / or the plug holding sleeve 19 and within the housing 21 between first fluid communication apertures 4 in the closing sleeve 7 and second fluid communication apertures 5 in the plug holding sleeve 19. The second fluid communication apertures in the plug holding sleeve 19 are located downstream of the solid plug 2.

[0061] The first fluid communication apertures 4 in the closing sleeve 7 and the second fluid communication apertures 5 in the plug holding sleeve 19 can also be referred to as upper bypass ports 4 and lower bypass ports 5.

[0062] The closing sleeve 7 comprises the first breaking mechanism 20 for breaking the frangible ball seat 1 , and the plug holding sleeve 19 comprises the second breaking mechanism 14 for breaking the solid frangible plug 2.

[0063] The open frangible ball seat 1 can be a donut shaped disc made of brittle glass. The solid frangible plug 2 can be a disc shaped plug made of brittle glass.

[0064] The first breaking mechanism 20 (fig. 3 and 4) can in one embodiment comprise one or more breaking pins covered by a cap 29 isolating the pin from the seat 1 . When the ball seat 1 is closed by a drop ball 3 and fluid pressure has reached a predetermined threshold, the ball seat 1 is shattered by the breaking pin 20.

[0065] The solid frangible plug 2 is arranged to be shattered by the second breaking mechanism 14 when fluid pressure reaches a predetermined threshold, to fully open the through running boring 26.

[0066] The second breaking mechanism 14 (fig. 3) can in one embodiment comprises a load ring 30 supporting the solid frangible plug 2, said load ring is axially movable within the through running boring 26 between a first position in where the solid frangible plug 2 is with a distance to a breaking pin 31 and a second position in where the solid frangible plug 2 is forced against the breaking pin 31 .

[0067] Further, the load ring 30 can be resting on a shear ring 32 with an annular shear lip 32a to prevent axial movement in the first position until the shear lip 32a is subjected to a force higher than a predetermined force, wherein the annular shear lip 32a of the shear ring 32 extends radially inward in the through running boring 26. The breaking pin 31 is resting on the shear ring 32 and the breaking pin 31 can be accommodated in a pocket on an outside of the load ring 30.

[0068] Fig. 1 shows the well tool device when Run in Hole (RIH), where the sleeve is open for fluid bypass past the plug 2 through the bypass channel 6.

[0069] In fig. 2 a drop ball 3 has been dropped and landed in the open ball seat 1 and is closing of fluid communication to the bypass channel 6.

[0070] In fig. 5 the frangible ball seat 1 has been shattered so that the bypass channel 6 is closed. This is done by increasing the pressure above the ball seat 1 with the drop ball 3 above a predefined pressure where the ball seat 1 shatters by the first breaking mechanism 20 and allows for well fluid / pressure below the piston area on the closing sleeve 7.

[0071] Fig. 7 shows that the plug 2 has been shattered and the well tool is permanently fully open.

[0072] The well tool device comprises an upper atmospheric chamber 8 and a lower atmospheric chamber 9, wherein the upper atmospheric chamber 8 and the lower atmospheric chamber 9 is separated by a piston 11 , and a radial fluid channel 10 is running from the through running boring 26 to the lower atmospheric chamber 9.

[0073] The opening to the fluid channel 10 is located between two packers 24a, 24b, for instance O-rings, sealing of the ball seat 1 in the closing sleeve 7.

[0074] The closing of the closing sleeve 7 is initiated by shattering the ball seat 1 by the first breaking mechanism 20 so that well pressure enters the radial channel 10 sealed off radially outside the ball seat 1 . When the ball seat 1 is removed the well pressure will enter this channel 10 and the hydrostatic pressure from the well will act on the lower side of the piston 11 on the closing sleeve, which for instance can be a flange. On the upper side of the piston 11 is the air-filled atmospheric chamber 8. Due to the differential pressure across the piston 11 , the closing sleeve 7 will shift upwards and close the bypass channel 6.

[0075] To open the solid frangible plug, the pressure above the plug 2 is increased to above a predefined limit and the plug breaking mechanism 14 will shatter the glass plug 2.

[0076] Shifting the closing sleeve 7 upstream instead of downstream to close the bypass channel 6 enables mechanical shifting of the sleeve with a wireline shifting tool as a contingency in case the closing mechanism does not work.

[0077] The well tool device can comprise check valve channel 18 (fig. 8) running between the upper atmospheric chamber 8 and the lower atmospheric chamber 9, wherein said channel 18 is equipped with a check valve.

[0078] In one embodiment, said check valve can be a plug 17 arranged to pop out if pressure in the upper atmospheric chamber 8 is higher than the pressure in the lower atmospheric chamber 9. The plug 17 can be covered with or made of a low friction material, such as Polytetrafluoroethylene (PTFE).

[0079] The axial channel 18 with the plug 17 makes it possible to shift the sleeve mechanically (with wireline shifting tool) in case there has been a leak into the atmospheric chamber 8. Without this feature there could possibly be a volume of fluid in the chamber that is trapped and will prevent the sleeve from shifting up. The low friction plug 17 is a cost effective and reliable solution for evacuating liquid from the chamber, other solutions such as a small check valve could also be used.

[0080] The closing sleeve 7 can thus comprise an engagement connection 15 (fig. 5), such as a profile or flange, for attachment to a shifting tool in case the closing sleeve 7 needs to be mechanically shifted.

[0081] Further, the housing 21 can comprise a release profile 16 (fig. 5) for triggering a release mechanism on a shifting tool to release the shifting tool from the closing sleeve 7 when the closing sleeve 7 is fully closed. The mechanism with the moving parts etc. is designed so that it can be produced as a bypass plug kit 50. This bypass plug kit is relative to the complete tool very small and light, which makes it easy and cheap to ship. The housing 21 is a component that can be made after manufacturing specification / drawings in a lot of machine shops around the world. The bypass plug kit 50 is designed so that it does not require any special skills to insert it and mount it in a purpose-built housing.

[0082] A more general advantage of the tool compared to other similar bypass plugs is that it has relative few parts, the both the plug breaking mechanism and the glass seat breaking mechanism is easy and reliable. It shears at an accurate pressure and has few moving parts.

Claims

Claims1 . A well tool device comprising a tubular housing (21 ) with an axial through running boring (26), the well tool device further comprises: a closing sleeve (7), an open frangible ball seat (1 ) and a first breaking mechanism (20), a plug holding sleeve (19) with a solid frangible plug (2) and a second breaking mechanism (14), said plug holding sleeve (19) is provided downstream of the closing sleeve (7), said closing sleeve (7) is equipped with first fluid communication apertures (4) for fluid communication through a bypass channel (6) with second fluid communication apertures (5) downstream of the solid frangible plug (2), and a fluid channel (10) arranged to be opened up for fluid communication between the through running boring (26) and a piston (11 ) on the closing sleeve (7), characterized in that said open frangible ball seat (1) is arranged for receipt of a drop ball (3) to close off the ball seat (1 ), wherein pressure builds up and forces the ball seat (1 ) to be shattered by the first breaking mechanism (20) and allowing fluid to flow through said fluid channel (10).

2. The well tool device according to claim 1 , wherein the open frangible ball seat (1) and the first breaking mechanism (20) are arranged in the closing sleeve (7).

3. The well tool device according to claim 1 or 2, wherein the fluid channel (10) is at least partly comprised in the closing sleeve (7).

4. The well tool device according to claim 1 , wherein the piston (11) is arranged to force the closing sleeve (7) upstream in the through running boring (26) and the first fluid communication apertures (4) out of alignment with the bypass channel (6), closing fluid communication through said bypass channel (6).

5. The well tool device according to claim 1 , comprising an upper atmospheric chamber (8) and a lower atmospheric chamber (9), said upper atmospheric chamber (8) and lower atmospheric chamber (9) are separated by the piston (11), and the fluid channel (10) is running from the through running boring (26) to the lower atmospheric chamber (9).

6. The well tool device according to claim 5, wherein the fluid channel (10) is a radial channel running to said lower atmospheric chamber (9).

7. The well tool device according to claim 1 , wherein the piston (11 ) is an external flange on the closing sleeve (7).

8. The well tool device according to claim 5, wherein a check valve channel (18) is running between the upper atmospheric chamber (8) and the lower atmospheric chamber (9), said channel (18) is equipped with a check valve.

9. The well tool device according to claim 8, wherein said check valve is a plug (17) arranged to pop out if pressure in the upper atmospheric chamber (8) is higher than the pressure in the lower atmospheric chamber (9).

10. The well tool device according to claim 9, wherein the plug (17) is covered with or made of a low friction material.11 . The well tool device according to claim 1 , wherein the first breaking mechanism (20) comprises one or more breaking pins covered by a cap (29) isolating the pin from the ball seat (1).

12. The well tool device according to claim 1 , wherein the solid frangible plug (2) is arranged to be shattered by the second breaking mechanism (14) when fluid pressure reaches a predetermined threshold, to fully open the through running boring (26).

13. The well tool device according to claim 1 , wherein the second breaking mechanism (14) comprises a load ring (30) supporting the solid frangible plug (2), said load ring is axially movable within the through running boring (26) between a first position in where the solid frangible plug (2) is with a distance to a breaking pin (31 ) and a second position in where the solid frangible plug (2) is forced against the breaking pin (31 ).

14. The well tool device according to claim 13, wherein said load ring (30) is resting on a shear ring (32) with an annular shear lip (32a) to prevent axial movement in the first position until the shear lip (32a) is subjected to a force higher than a predetermined force, wherein the annular shear lip (32a) of the shear ring (32)extends radially inward in the through running boring (26), and the breaking pin (31 ) is resting on the shear ring (32), and said breaking pin (31) is accommodated in a pocket on an outside of the load ring (30).

15. The well tool device according to claim 1 , wherein the closing sleeve (7) comprises an upper sleeve (7a), and a lower sleeve(7b) with the first fluid communication apertures (4), wherein the ball seat (1 ) is mounted between the upper sleeve (7a) and the lower sleeve (7b).

16. The well tool device according to claim 1 , wherein the open frangible ball seat (1 ) is a donut shaped disc made of brittle glass.

17. The well tool device according to claim 1 , wherein the solid frangible plug (2) is a disc shaped plug made of brittle glass.

18. The well tool device according to claim 1 , wherein the closing sleeve (7) comprises an engagement connection (15), such as a profile or flange, for attachment to a shifting tool in case the closing sleeve (7) needs to be mechanically shifted.

19. The well tool device according to claim 18, wherein the housing (21) comprises a release profile (16) for triggering a release mechanism on a shifting tool to release the shifting tool from the closing sleeve (7) when the closing sleeve (7) is fully closed.

20. A bypass plug kit (50) comprising a closing sleeve (7) with an open frangible ball seat (1 ) and a first breaking mechanism (20), and a plug holding sleeve (19) with a solid frangible plug (2) and a second breaking mechanism (14), characterized in that said plug holding sleeve (19) is interconnected with the closing sleeve (7), wherein the bypass plug kit (50) is arranged to be inserted into a housing (21 ).21 . The bypass plug kit (50) according to claim 20, wherein the bypass plug kit (50) is arranged to be inserted into the housing (21 ) from below before a lower crossover (23) is screwed onto the housing (21 ).

22. The bypass plug kit (50) according to claim 21 , wherein the bypass plug kit (50) is prevented from sliding axially back out of the housing (21) by segments (12) in a groove (27) inside the housing (21 ), wherein the segments (12) are secured radially by a ring (13) held in place by an end insert (25) having set screws (28).

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