Apparatus and method for deploying a component in a well

Abstract

The embodiments of the present disclosure relate to an apparatus and method for deploying multiple downhole components with one conveyancing trip. In some embodiments of the present disclosure, the downhole components may be set and released into a profile that is pre-installed, for example by way of a threaded profile sub within the string of pipe within the well. In some embodiments of the present disclosure, the downhole components may be one or more individual profiles that can be set, sealed and released at a desired location within a well that is lined or not.

Description

APPARATUS AND METHOD FOR DEPLOYING A COMPONENT IN A WELLTECHNICAL FIELD

[0001] This disclosure generally relates to operations that occur within a well. In particular, this disclosure relates to an apparatus and a method of deploying and retrieving one or more downhole tools within a well.BACKGROUND

[0002] Wells are drilled into subterranean geologic formations to access and produce a desired product from the geologic formation. The life of a well includes various stages, such as: exploration for geologic formations that contain the desired product, planning a well, drilling the well, working over the well, producing the desired products and abandoning the well.

[0003] Once drilled, a well may require one or more downhole tools or components in order to facilitate and / or enhance further well operations, such as production or injection of the desired products. Non-limiting examples of such desired products include: oil, gas, geothermally -heated fluids and the like.

[0004] Inter-connected tubulars can be inserted into the drilled well. Each tubular may be referred to as pipe, casing, tubing and / or liner and the inter-connected tubulars may be referred to as a pipe string, a casing string, a tubing string and / or a liner string. Sections of tubulars can be secured in place within the well, for example by cement. Once secured, portions of the tubulars can be perforated in order to establish fluid communication between inside the tubular and the geological formation that contains the desired product. In some instances, portions of the tubular are inserted into the well already perforated but covered with a slideable sleeve, also referred to as a frac sleeve.

[0005] Improvements in well technology may extend the life of a well, which ultimately may result in more desired products being produced. However, the lifecycle of deployed downhole tools is often not as long as the extended life of the well.As such, downhole tools may need to be maintained and / or replaced. Typically downhole tools are conveyed through by coiled tubing, wireline, e-line or combinations thereof. However, deploying a downhole tool takes time and it can be expensive, where the costs are calculated on a per-trip basis. Furthermore, while downhole tools can be deployed by being incorporated into the pipe string as it is assembled at the surface, that approach can result in much higher pipe string assembly costs and increased friction within the wellbore fluids as the pipe string is positioned into the well. As such, it may be desirable to enhance the efficiency of deploying and retrieving of downhole tools.SUMMARY

[0006] The embodiments of the present disclosure relate to an apparatus and a method of deploying components, such as downhole tools and / or devices, into a well by assembling one or more devices onto a single deployment apparatus, which may also be referred to as a bottom hole assembly (BHA).

[0007] Some embodiments of the present disclosure relate to an apparatus that can carry one or more components. The apparatus is configured for conveying multiple components and for deploying each component at a desired location in a well. The apparatus comprises an inner mandrel that comprises a receiver and an arming mechanism; and an outer mandrel that carries the one or more components. Upon a downhole event occurring at or proximal the receiver, the arming mechanism is configured to arm a first of the multiple components for setting in a pre-installed profile at the desired location in the well. When the first of the multiple components is set, the inner mandrel is configured to arm a second of the multiple components for setting in a second pre-installed profile at a second desired location in the well. Optionally, the apparatus can repeatedly cycle through sequences to arm and set the next component carried on the outer mandrel until all components are armed and set.

[0008] Some embodiments of the present disclosure relate to a method for conveying, setting, sealing and releasing a component within a pre-installed profile patch at a desired location within a well.

[0009] Some embodiments of the present disclosure relate to a method for deploying a component at a desired location in a well. The method comprises the steps of: providing a specific shape on an inner surface of the well at the desired location; positioning the component proximal the specific shape; arming the device to release the component from a carrying apparatus; setting the component into the specific shape; and releasing the component into the device.

[0010] In some embodiments of the present disclosure, an apparatus and a method is provided for retrieving components that are deployed and set within a profile patch at a desired location within the well.

[0011] Some embodiments of the present disclosure relate to an apparatus that can carry multiple profile patches - as an example of a component - for deployment at a desired location in a well. In some embodiments of the present disclosure, the apparatus comprises an inner mandrel and an outer mandrel. In some embodiments of the present disclosure, the inner mandrel comprises three seats and an associated set of ports, pistons and setting dogs. When a surface-home object is received at a first of the three seats, the first seat shifts from a first operational position to a second operational position and the object is released for landing in a second of the three seats. Landing of the object in the second seat causes the second seat to shift to a second operational position and the object is released for landing in a third of the three seats. When the first two seats are in the second operational position the associated sets of ports are exposed and configured to transfer a fluid pressure from a bore of the inner mandrel onto the associated piston faces in order to shift the setting dogs and to set, seal and release the profile at the desired location within the well. When the setting dogs are shifted, due to the fluid pressure acting on the associated pistons, landing of the object in the third seat and the fluid pressure causes the third seat to shift to a second operational position.

[0012] Some embodiments of the present disclosure relate to a method for conveying, setting, sealing and releasing a profile patch at a desired location within a well.

[0013] Some embodiments of the present disclosure relate to an apparatus and a method for deploying a profde patch within a well, where such profde patch defines a specific shape for receiving a device in order to isolate one or more perforations or ports inside an existing well. The profile patches provide a way of sealing above and below ports / perforations to force fluid flow through the profile patch that can then receive a frac sleeve, coiled tubing straddle tool, flow control device, or another downhole device to regulate the fluid flow through the profile patch. The profile patch can also receive a downhole monitoring device or a well-integrity device / plug to prevent flow outward through the profile patch or downward past the profile patch in the wellbore. The profile patches may have a relatively large flow area or the profile patches may have a restricted flow area to create a pressure drop when fluids flow goes outward through the patch.

[0014] Some embodiments of the present disclosure relate to an apparatus and a method of retrieving one or more components from a well. A mechanism may be engaged that will pull into the first component and then release the locking mechanism. The first component is pulled into the second component, which releases the locking mechanism on the second component. This cycle of engaging and releasing may continue until all desired components are retrieved.

[0015] Without being bound by any particular theory, the embodiments of the present disclosure may provide a way to deploy and retrieve one or more components in a well in a single trip into the well, which decreases the number of trips required and the associated costs.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These and other features of the present disclosure will become more apparent in the following detailed description in which reference is made to the appended drawings.

[0017] FIG. 1 shows a side elevation, mid-line cross-sectional view of an apparatus in a first operational position, according to embodiments of the presentdisclosure, with an upper panel showing the apparatus in use with a coiled tubing system and a lower panel with a closer view of box A, shown in the upper panel.

[0018] FIG. 2 shows a side elevation, mid-line cross-sectional view of the apparatus of FIG. 1 in a second operational position, according to embodiments of the present disclosure.

[0019] FIG. 3 shows a side elevation, mid-line cross-sectional view of the apparatus of FIG. 1 in a further operational position, according to embodiments of the present disclosure.

[0020] FIG. 4 shows a side elevation, mid-line cross-sectional view of the apparatus of FIG. 1 in a further operational position, according to embodiments of the present disclosure.

[0021] FIG. 5 shows a side elevation, mid-line cross-sectional view of the apparatus of FIG. 1 in a further operational position, according to embodiments of the present disclosure.

[0022] FIG. 6 shows a side elevation, mid-line cross-sectional view of the apparatus of FIG. 1 in a further operational position, according to embodiments of the present disclosure.

[0023] FIG. 7 shows a side elevation, mid-line cross-sectional view of the apparatus of FIG. 1 in a further operational position, according to embodiments of the present disclosure.

[0024] FIG. 8 shows a side elevation, mid-line cross-sectional view of the apparatus of FIG. 1 in a further operational position, according to embodiments of the present disclosure.

[0025] FIG. 9 shows a side elevation, mid-line cross-sectional view of the apparatus of FIG. 1 in a further operational position, according to embodiments of the present disclosure.

[0026] FIG. 10 shows a side elevation view of a well system, according to embodiments of the present disclosure.

[0027] FIG. 11 shows a side elevation view of a further well system, according to embodiments of the present disclosure.

[0028] FIG. 12 shows a side elevation view of a well system, according to embodiments of the present disclosure.

[0029] FIG. 13 shows a lower panel that provides side elevation view of a well system and an upper panel that provides a mid-line cross-sectional and closer view of box C of the lower panel, according to embodiments of the present disclosure.

[0030] FIG. 14 shows a side elevation view of a well system, according to embodiments of the present disclosure.

[0031] FIG. 15 shows a side elevation view of a well system, according to embodiments of the present disclosure.

[0032] FIG. 16 shows a side elevation view of a well system, according to embodiments of the present disclosure.

[0033] FIG. 17 shows a side elevation view of a well system, according to embodiments of the present disclosure.

[0034] FIG. 18 shows a side elevation, mid-line cross-sectional view of a further apparatus in a first operational position, according to embodiments of the present disclosure, with an upper panel showing the apparatus in use within a cased well or an open-hole well and a lower panel with a closer view of box B, shown in the upper panel.

[0035] FIG. 19 shows a side elevation, mid-line cross-sectional view of the further apparatus of FIG. 18 in a further operational position, according to embodiments of the present disclosure.

[0036] FIG. 20 shows a side elevation, mid-line cross-sectional view of the further apparatus of FIG. 18 in a further operational position, according to embodiments of the present disclosure.

[0037] FIG. 21 shows a side elevation, mid-line cross-sectional view of the further apparatus of FIG. 18 in a further operational position, according to embodiments of the present disclosure.

[0038] FIG. 22 shows a side elevation, mid-line cross-sectional view of the further apparatus of FIG. 18 in a further operational position, according to embodiments of the present disclosure.

[0039] FIG. 23 shows a side elevation, mid-line cross-sectional view of the further apparatus of FIG. 18 in a further operational position, according to embodiments of the present disclosure.

[0040] FIG. 24 shows a side elevation, mid-line cross-sectional view of the further apparatus of FIG. 18 in a further operational position, according to embodiments of the present disclosure.

[0041] FIG. 25 shows a side elevation, mid-line cross-sectional view of the further apparatus of FIG. 18 in a further operational position, according to embodiments of the present disclosure.

[0042] FIG. 26 shows a side elevation, mid-line cross-sectional view of the further apparatus of FIG. 18 in a further operational position, according to embodiments of the present disclosure.

[0043] FIG. 27 shows three panels that each depict the steps of a method according to embodiments of the present disclosure.DETAILED DESCRIPTION

[0044] The embodiments of the present disclosure relate to an apparatus, and a method for deploying and retrieving one or more downhole components into and from a desired position within a well. The embodiments of the present disclosure providedeploying one or more downhole components on a single conveyancing trip. In some embodiments of the present disclosure, the one or more downhole components are deployed by being set and sealed into a pre-installed profde with a specific shape that is defined on an inner surface of the wellbore. Profiles may be pre-installed by being incorporated into the pipe string at the surface or the profiles may be profile patches that are deployed at a desired location within the well according to embodiments of the present disclosure.

[0045] Embodiments of the present disclosure will now be described by reference to the figures, which show representations of the apparatus, systems and methods according to the present disclosure.

[0046] Referring to FIG. 1, an apparatus 10 is shown. The apparatus 10 is configured to carry and deploy two or more devices (FIG. 1 shows three devices 102, 104, 106, but this is a non-limiting example of the number of two or more devices) within a well lined with casing 2. As will be appreciated by those skilled in the art, while FIG. 1 shows a well lined with casing 2, the well need not be lined with casing or otherwise. The devices 102, 104, 106 may also be referred to herein as downhole tools and / or downhole devices that each are configured to perform a well operation at a desired location within the well. As will be appreciated by those skilled in the art, there may be two, three or more components that can be carried by the apparatus 10 and each device may be deployed at a different desired location within the well. Some nonlimiting examples of the components include, but are not limited to: a profile patch according to embodiments of the present disclosure, flow control devices, downhole monitoring devices, frac sleeves, annular isolation barriers / packers, liner hangers, liner hanger packers, seal assemblies, seal assembly receptacles, bridge plugs, and other well integrity devices, setting / activation devices for other downhole devices installed on the liner including but not limited to annular isolation barriers / packers, liner hangers, liner hanger packers, seal assemblies, seal assembly receptacles, bridge plugs, and other well integrity devices. The devices 102, 104, 106 are carried by the apparatus 10 and the apparatus 10 is configured to deploy each device 102, 104, 106 at a desired location within the well where such desired location is defined by a specific profile that is defined on the inner surface of the well. For example, when the well is lined with atubular (such as casing or liner) that tubular will comprise multiple profiles. Each profile defines a specific shape that is configured to receive and retain a respective device until such time that the device is retrieved, according to embodiments of the present disclosure. In other examples, a profile patch can be set, sealed and released at the desired location within the well, according to embodiments of the present disclosure. The profile patch will also define a specific shape that is configured to receive and retain a respective device on the inner surface of the well.

[0047] For clarity, as dictated by the context the term “component” refers to a downhole profile patch or a downhole device that can be deployed and retrieved according to the embodiments of the present disclosure.

[0048] For clarity, the terms “deploy” and “deployed” are used herein to refer to a component being positioned at a desired position within a well so that the component can perform a desired function. Some non-limiting examples are when the component is a profile that is incorporated into a pipe string and positioned in the well, when the component is a profile patch that is set, sealed and released at a desired location in the well and when the component is a device it can be armed, set and released into a profile or profile patch.

[0049] For clarity, the term “retrieve” and “retrieved” are used herein to refer to a component (such as a profile, a profile patch or a device) that is released and recovered from the desired position where it was deployed. The releasing may occur by reversing one or more steps that occurred when the component was deployed. The recovery may occur by re-loading the component on an apparatus for conveying the component back to the surface.

[0050] The apparatus 10 has a downhole end 10A and an uphole end 10B with a longitudinal axis of the apparatus 10 defined therebetween. The uphole end 10B is configured to be operatively coupled to a conveyancing system 108. The conveyancing system 108 is configured to convey the apparatus 10 through the well between the surface and desired locations within the well. Non-limiting examples of a suitable conveyancing system 108 include, but are not limited to: coiled tubing, wireline,wireline tractor, drill pipe, jointed tubing, e-line, e-coiled tubing or combinations thereof.

[0051] The apparatus 10 comprises an inner mandrel 13 and an outer mandrel 15. The inner mandrel 13 (which may also be referred to as the running tool mandrel 13) is positioned within the outer mandrel 15 (which is referred to as the device mandrel). The apparatus 10 defines an inter-mandrel space 5 between an outer surface of the inner mandrel 13 and an inner surface of the outer mandrel 15. In some circumstances, the inner mandrel 13 may be longitudinally moveable (i.e. along the longitudinal axis of the apparatus 10) within the outer mandrel 15. In some embodiments of the present disclosure, the inner mandrel 13 may be configured to deliver fluids and objects from the surface to a desired location within the well. In some embodiments of the present disclosure, the outer mandrel 15 may be configured to deliver fluids from the surface, within the inter-mandrel space 5 when the inner mandrel 13 is present or otherwise.

[0052] The inner mandrel 13 may carry a receiver assembly 11 at the downhole end 10A. The receiver assembly 11 comprises an arming cage 12, a receiver 14, and an arming mechanism 16. The arming cage 12 is fixed at the downhole end of the inner mandrel 13 while the receiver 14 is moveably coupled to the inner mandrel 13 and the arming mechanism 16 is pivotably coupled to the received 14. As but one non-limiting example, the receiver 14 may be positioned within the bore of the inner mandrel 13 and the arming mechanism 16 may be positioned outside of the inner mandrel 13. The receiver 14 may be coupled to the arming mechanism by a peg 17 that is connected at one end to the receiver 14 within the inner mandrel 13 and an opposite end that is connected to a pivot 19, such as a hinge. The pivot 19 is connected to a first end of the arming mechanism 16 so that the arming mechanism 16 is pivotally coupled to the receiver 14. The peg 17 is positioned within a slot 21 that is defined by the inner mandrel 13. The length of the slot 21 is predetermined to as to limit the distance that the receiver 14 can move relative to the inner mandrel 13 in the downhole direction (i.e. towards end 10A and towards the cage 12). In another embodiment of the present disclosure, the receiver 14 comprises a mechanical sleeve (not shown) that can interactwith and arm the arming sleeve 20 and then the mechanical sleeve can be released from the arming sleeve 20.

[0053] The inner mandrel 13 further includes a run-in dog 18 and a c-ring 22 are is positioned on the outer surface of the inner mandrel 13 and they extend into the inter-mandrel space 5 that is defined between the outer surface of the inner mandrel 13 and an inner surface of the outer mandrel 15. The inner mandrel 13 may have a run-in dog 18 and a c-ring 22 for each device 102, 104, 106 that the apparatus 10 is carrying. The upper panel of FIG. 1 shows three devices 102, 104, 106 and the lower panel (being a zoomed in view of BOX A of the upper panel) shows a first device 102 only.

[0054] The outer mandrel 15 is configured to carry the devices 102, 104, 106 on the outer surface of the outer mandrel 15. The outer mandrel 15 may be separated into different sections (with FIG. 1 showing the non-limiting example of sections I, II and III), with each section comprising an associated device (e.g. section I has a first device 102, section II has a second device 104 and section III has a third device 106). Each section also comprises (moving from the downhole end to the uphole end) an arming sleeve 20, a locking dog 24, an arming dog 26, an arming sleeve spring 28, a lower collet support 30, an upper collet support 32, , a collet 36 (shown unsupported in FIG. 1 upper panel), an upper collet support point 38, a collet c-ring 40, a releasing dog 42, a release dog spring 44, a bottom seal 46, a flow control mechanism 48 (as but one example of a downhole tool / device) that includes a secondary spring 50. As such, each section can be defined as being between an adjacent section’s respective arming sleeve 20 and device.

[0055] The receiver 14 can move upon the occurrence of a surface borne, downhole event. Until the occurrence of the surface-home, downhole event the receiver 14 may be held in place by one or more breakable pins (not shown) or other known mechanisms and, optionally, a second end of the arming mechanism 16 may be positioned so as to abut an arming sleeve 20 of the outer mandrel 15. Non-limiting examples of surface home, downhole events are delivery of a fluid at a high fluid flow rate and / or high pressure to the receiver 14 or a surface-home object 300 (see FIG. 2) is delivered to the receiver 14 or an electronic signal sent from the surface or an onboardcontroller recognizes a desired location within the well and causes the receiver 14 to move. Non-limiting examples of a surface-home object 300 are a dart, a ball and the like. When the surface-borne, downhole event is delivery of a high-pressure fluid, the receiver 14 is configured to act like a piston face, where a pressure differential is created with a higher pressure uphole of the receiver 14 and a lower pressure is downhole of the receiver 14. This pressure differential can cause the receiver 14 and the pivotally coupled arming mechanism 16 to move towards the cage 12. As will be understood by those skilled in the art, when the receiver 14 is configured to receive the surface-borne object 300, the surface-borne object 300 will move from the surface, through the well and occupy a seated position within (or upon) the receiver 14 to form a seal and, therefore, a piston face. When the surface-borne object 300 is seated, together the object 300 and the receiver 14 form a piston face that is moveable when a pressure differential is established with a higher pressure up hole of the receiver 14 and a lower pressure downhole of the receiver 14. The pressure differential causes the receiver 14 and the pivotally coupled arming mechanism 16 to move towards and into the cage 12.

[0056] FIG. 1 shows the receiver 14 in a first position, with the receiver 14 held in the first position, uphole of the cage 12. The first position may also be referred to as a run-in-hole (RIH) position. In the first position, the arming mechanism 16 is in a position that is not parallel to the outer surface of the inner mandrel 13 so that the second end of the arming mechanism 16 is abuttingly engaged with the arming sleeve 20 of the outer mandrel 15. FIG. 2 shows the receiver 14 having an object 300 seated therein and having moved in a second position by sliding downhole into the cage 12. In the second position, the arming mechanism 16 has also moved downhole and into the cage 12, with the cage 12 pushing the arming mechanism 16 into a position that is substantially parallel to the outer surface of the inner mandrel 13.

[0057] In the second position, the arming mechanism 16 is no longer abutting the arming sleeve 20 and the arming sleeve spring 28 can exert a sufficient biasing force on the arming sleeve 20, which causes the arming sleeve 20 to shift towards the downhole end 10A of the apparatus 10. Moving the arming sleeve 20 downhole allows the arming dog 26 to move to a retracted position (because in the first position the arming dogs 26 are supported in an extended position by the arming sleeve 20).Because the arming dog 26 is in the retracted position, the collet 36 can slide (under the biasing force of the spring 28) to a second position, which once the collet 36 is released into the profde, the collet 36 can engage the locking dogs 24 to hold the collet 36 in the second position with assistance from the collet c-ring 40. Furthermore, when the receiver 14 is in the second position, it forms a seal with the cage 12, which can prevent the flow of fluids within the inner mandrel 13 past the downhole end 10A of the apparatus 10. Similarly, fluids moving within the inter-mandrel space 5 cannot flow past the downhole end of the outer mandrel 15, except via the flow control mechanism 48.

[0058] The apparatus 10 can then be pulled in the uphole direction to a desired location within the well so that the releasing dogs 42 can extend outwardly from the outer surface of the outer mandrel 15 to engage into a seal profde 112 that defines a specific shape on the inner surface of the casing 2. For clarity, the term “profile” is used herein to refer to an object that is positionable at a desired location within the well (whether lined or not) and the object has a specific shape is defined on the inner surface of the well that is configured to mate with (receive) and retain a downhole tool at the desired location. As but one example, the desired location in the well may be adjacent or proximal to a perforated section of the well and the downhole tool may be a flow control device (such as flow control device 48 shown in FIG. 1) that regulates the flow of fluids into or out of the well.

[0059] FIG. 3 shows the collet 36 engaged into the profile 112 of the casing 2 at the same time the releasing dogs 42 are engaged which allows the collet 36 to now be able to shift downhole to a next position.

[0060] FIG. 4 shows the collet 36 engaged with / into the profile 112 that is preinstalled in the casing 2 and the collet 36 has shifted downwards into the supported and locked position, which holds the device 102 in the desired position. On the downhole end, the collet 36 is stopped from moving down by the locking dogs 24, and on the uphole end the collet 36 is stopped from moving up by the collet c-ring 40. Additionally, the lower collet support 34 and upper collet support 38 can prevent the collect 36 from compressing and releasing from the profile.

[0061] FIG. 5 shows the initial retraction of the run-in dog 18 that is now held in a retracted position by the inner mandrel’s 13 c-ring 22. The arming sleeve 204B of the section is released at the same time allowing the next device 104 to lock into the next uphole profde that is defined on the inner surface of the casing 2.

[0062] In this fashion, the apparatus 10 can carry multiple devices downhole, and when the first section I of the apparatus 10 is downhole of a desired profile that is defined on the inner surface of the casing 2, a surface-home, downhole event can cause the apparatus 10 to move from the first position to the second position, which results in the device 102 of the first section I being deployed at the desired position within the well and the arming sleeve 20 of the second section II moving to the second position (under the biasing force of the arming spring 28 of section II) to initiate the same cycle of movements of components of the apparatus 10 to deploy the second device 104 in a desired position of the well. The same cycle can be repeated until all of the multiple devices upon the apparatus 10 are deployed in the desired location within the well.

[0063] As shown in FIG. 6, the apparatus 10 can also be used to retrieve one or more of the deployed devices. The inner mandrel 13 is moved beyond the first deployed device and downhole of the arming sleeve 20 of the first section I. The inner mandrel 13 further comprises a retrieval device 301 that is positioned on the outer surface of the inner mandrel 13. The retrieval device 301 has a downhole end with a ramped surface 302 that can engage the inner surface of the arming mechanism 16 and move the arming mechanism 16 from the position of being substantially parallel to the outer surface of the inner mandrel 13. Next the inner mandrel 13 can be pulled uphole so that the arming mechanism 16 engages and moves the arming sleeve 20 of the first section I. This allows the locking dog 24 to retract and the collet 36 can move inwardly to disengage the profile on the inner surface of the casing 2 (see FIG. 7 and FIG. 8).

[0064] As shown in FIG. 9, the device 102 of the first section I can then abut and move the arming sleeve 20 of the second section II, which similarly causes the components within the second section II to move and release the device 104 back onto the outer mandrel 15.

[0065] FIG. 10 shows a wellbore 400 that has been drilled into a geologic formation 450. The wellbore 400 with multiple profdes 402 installed at desired positions within the wellbore 400. The profiles 402 are without devices deployed therein. The profiles 402 may be installed by being threaded into the string of casing, tubing or pipe as the string is connected at the surface and deployed into the well 400. In some embodiments of the present disclosure, the profile 112 may be defined by a surface of a device (not shown) that is already installed as part of the tubing string. Non-limiting examples of these types of profile-defining devices include, but are not limited to: a ported profile device, a solid non-ported profile device, a frac sleeve, an annular isolation barrier / packer, a liner hanger, a liner hanger packer, a seal assembly, a seal assembly receptacle, a casing collar, a flow control device, a downhole monitoring device, a downhole device containing a mandrel, or any other well integrity device. The device containing the profile may have a larger flow area than the tubing string or the device may have a restricted flow area to create pressure drop when fluids flow goes outward through the device.

[0066] FIG. 11 shows a device 404 deployed within each of the profiles 402, according to the embodiments of the present disclosure.

[0067] FIG. 12 shows a wellbore 400 that contains a string of tubulars with perforated sections 406 or ports that provide fluid communication between the wellbore and the surrounding geologic formation 450.

[0068] FIG. 13 includes a lower panel that shows the wellbore 400 from FIG.12 with one or more profiles 408 now installed across each set of ports / perforations 406 in the well casing 2, according to the embodiments of present disclosure. The upper panel of FIG. 13 shows a closer view of box C in the lower panel with one or more ports 407 in a desired position adjacent or proximal to the ports / perforations 406. In some embodiments of the present disclosure, the profile 408 has an annular isolation barrier 410, which may comprise an uphole wedge 410B positioned uphole of the ports / perforations 406 and a downhole wedge 410A positioned downhole thereof. The annular isolation barrier 410 contributes to forming a metal-to-metal seal 412 that seals off a position uphole and a position downhole of the ports 406 so that fluid flowingthrough the wellbore 400 has to pass through the profile 408. As will be appreciated by those skilled in the art, the profile 408 may also be installed by being incorporated into the pipe string by threaded connections as the pipe string is joined at the surface and positioned into the well.

[0069] FIG. 14 shows the same wellbore 400 from FIG. 13, with a device 404 now deployed and installed in each of the profiles 408.

[0070] FIG. 15 shows a wellbore 400 that contains perforations or ports 406 to provide fluid communication with the geologic formation 450. FIG. 16 shows the same wellbore 400 of FIG. 15 with tubing / casing / pipe installed and profiles 402 threaded onto the tubing. Also threaded onto the tubing are annular isolation barriers 410 to isolate groups of perforations / ports.

[0071] FIG. 17 shows the wellbore 400 of FIG. 16 with devices deployed in the profiles 402, according to the embodiments of the present disclosure.

[0072] As will be appreciated by those skilled in the art, the devices described herein above may include profiles that can be deployed at a desired position within a well, where such profiles are configured to receive and retain a further deployed device.

[0073] FIG. 18 shows an example of an apparatus 500 that is configured to deploy one or more profiles 502 at a desired location within a well. As but one example, a desired location may be adjacent or proximal a portion of the well that has already been perforated.

[0074] As shown in the upper panel of FIG. 18, the apparatus 500 has a downhole end 500A and an uphole end 500B for defining a longitudinal axis of the apparatus 500 therebetween. The apparatus 500 may be positioned within a wellbore 4 that is either lined with casing or not via the same types of conveyancing system 108 described herein above. The non-limiting example of FIG. 18 shows the apparatus 500 as comprising three sections X, Y, Z, but as will be appreciated by those skilled in the art, the apparatus 500 may have more or less sections.

[0075] As shown in the lower panel of FIG. 18 (which is a closer view of box B of the upper panel), section Y is described as an example of the components within a given section of the apparatus 500.

[0076] Each section comprises an inner mandrel 504 (which may also be referred to as a setting tool mandrel) and an outer mandrel 506 (which may also be referred to as a profile mandrel). The inner mandrel 504 may be positioned within the outer mandrel 506 to define an inter-mandrel space 503 therebetween. Each mandrel 504, 506 may extend the entire length of the apparatus 500. Depending on the circumstances, the inner mandrel 504 may be longitudinally moveable within the outer mandrel 506. In some embodiments of the present disclosure, the inner mandrel 504 may be configured to deliver fluids and objects from the surface to a desired location within the well. In some embodiments of the present disclosure, the outer mandrel 506 may be configured to deliver fluids from the surface, within the inter-mandrel space 503 when the inner mandrel 504 is present or otherwise

[0077] Towards the uphole end, the section Y comprises a top setting dog 532, a top setting port ball seat 534, a top setting port 536, a top setting piston 538, a top setting adapter 540, a top setting dog 542, a top setting wedge 544 and a set of seals 546.

[0078] Towards the downhole end, the section Y comprises a bottom setting dog 510, a patch setting seat dog 512 (which may also be referred to as a profile setting seat dog), a patch setting ball seat 514 (which may also be referred to as a profile setting ball seat), a bottom setting seat dog 518, a bottom setting piston 520, a bottom setting port 522, a bottom setting port ball seat 524, a bottom setting adapter 526, a bottom setting wedge 528 and a set of seals 530.

[0079] The profile mandrel 506 is held in place by the top and bottom setting dogs 542, 510. The top and bottom setting port ball seats 534, 524 isolate the setting ports 536, 522, which prevents the apparatus 500 from being set until the setting ports 536, 522 have shifted. A final ball seat has a higher shift pressure to allow the Profile to be set before the ball fully releases. The profile has a top and bottom setting wedgeto extrude the profile into the casing or open hole and create a seal. The seal is created between the profile and the casing above and below the ports / perforations to force the fluid flow through the profile.

[0080] The apparatus 500 can change its operational position based upon a surface borne, downhole event. Such events may be the same as described herein above for the apparatus 10. As but one non-limiting example, the function of the apparatus 500 will be described based upon the surface borne, downhole event being delivery of a surface-bome object 300A, such as a ball, dart or the like, to the apparatus 500. As shown in FIG. 19, when the apparatus 500 has been positioned within the well at a desired location (e.g. adjacent or proximal perforations in the unlined well or preinstalled ports in the lined well) the object 300A can be delivered to land upon the top setting ball seat 534. When landed, together the object 300A and the seat 534 can provide a fluidic seal across the inner surface of the inner mandrel 504. Such that, when pressurized fluids are delivered from the surface to the landed object 300A and the seat 534, the seat 534 can be shifted from a first operational position, where the seat 534 covers the ports 536, to a second operational position, further downhole from the first operational position. In the second operational position, the ports 536 are revealed and exposed to the bore of the inner mandrel 504 (see FIG. 20). In the second operational position, the top setting dog 532 can retract to release the object 300A from the seat 534 so that the object 300A can travel within the bore of the inner mandrel 504 further downhole to land on the bottom setting port ball seat 524 (see FIG. 21).

[0081] After the delivery of further pressurized fluids from the surface to the landed object 300A and the bottom setting port ball seat 524, the seat 524 can move from a first operational position, where the seat 524 covers the bottom setting ports 522, to a second operational position. In the second operational position of the seat 524, the ports 522 are exposed to the bore of the inner mandrel 504 (see FIG. 22). In the second operational position, the bottom setting seat dogs 518 can retract to release the object 300A from the seat 524 so that the object 300A can travel within the bore of the inner mandrel 504 further downhole to land on the profile setting ball seat 514 (see FIG. 23).

[0082] When both sets of ports 536, 522 are opened and the object 300A is in the seat 514, some of the pressurized fluid within the bore of the inner mandrel 504 may flow outwards through the ports 536, 522 and act on the top setting piston 528 and the bottom setting piston 520, respectively. The pressure acting on the pistons 528, 520 will cause the pistons 528, 520 to generate a piston force that acts upon the top setting dogs 542 and the bottom setting dogs 510, respectively. The dogs 542, 510 are configured to direct the piston force into a setting force that acts upon the top setting wedge 544 and the bottom setting wedge 528, respectively. The wedges 544, 528 each respond to the setting force by setting the outer mandrel 506 against the inner surface of the well, in the desired location, with the seals 546, 530 positioned to seal the set outer mandrel 506 against the inner surface of the well (see FIG. 24).

[0083] The continued delivery of pressurized fluids from the surface to the landed object 300A and the seat 514, causes the seat 514 to move downhole from a first operational position to a second operational position. In the second operational position, the top setting dogs 542 and the bottom setting dogs 510 retract so as to release that portion of the outer mandrel 506 that comprises the profile of section Y in the set and sealed position at the desired location within the well. In the second operational position, the patch setting seat dogs 512 can retract, releasing the object 300A from the seat 514 (see FIG. 25).

[0084] As shown in FIG. 26, the inner mandrel 504 can now be pulled in the uphole direction, leaving the set, sealed and released section Y with the desired profile in the desired location of the well so the inner mandrel 504 can move into the next uphole section X, which contains the same components as section Y in order to cycle through the same set of steps in order to set, seal and release the profile of section X in the desired location within the well.

[0085] Some embodiments of the present disclosure relate to a method 700 of deploying one or more downhole tools / devices each at a desired location within a well in one conveyancing trip (see left panel of FIG. 27). The method 700 can start once profiles are pre-installed at desired locations within a lined well. The method 700 comprises a step of conveying 702 an apparatus from surface that carries at least twodevices thereupon to a desired position where the first device to be set is positioned downhole of the desired matching profile. The method further comprises a step of arming 704 the apparatus by one or more of an increased flow rate and / or fluid pressure within the well, dropping an object into the well to land upon a portion of the apparatus, conducting an electronic signal to the apparatus or initiating a local arming signal by a controller that is also deployed onboard of the apparatus. The step of arming 704 will cause the device to be released and set into the matching profile. The step of releasing and setting 706 the device comprises the steps of shifting an arming sleeve, for example by applying a biasing force, after a release mechanism is engaged, thereby allowing a locking mechanism (such as a collet or dog) to shift down to the next position. The locking mechanism is still held in place until the releasing mechanism to engage into the matching seal profile.

[0086] Next a step of moving 706 the apparatus in the uphole direction may occur, which causes releasing dogs of the apparatus to engage into the seal profile at the same time the locking collet / dogs engage into the locking profile allowing the locking mechanism to shift down into the locked position. Seals are then engaged into seal profiles to isolate ports at the desired location. The force applied in the step of moving 706 may be increased until released by a releasable component such as a shearable, expandable or compressible component of the apparatus are exposed to a predetermined force, which results in those components mechanically failing or releasing and a step of fully releasing 708 the device from the apparatus. An optional step of cycling 710 through the applicable prior-steps of the method 700 may be performed in order to deploy a second device to set in a second profile at a second desired location within the well.

[0087] Some embodiments of the present disclosure relate to a method 800 for installing one or more profile patches at a desired location adjacent or proximal to perforations or ports within a well (see middle panel of FIG. 27). After well operations, such as perforation operations, stimulation operations are completed on the well, a step of conveying 802 an apparatus that carries the one or more profile patches into a desired location within the well. Next a step of creating 804 a surface-borne event that can actuate a setting mechanism of the apparatus for performing a step ofsetting 805 a profile patch at a desired location within the well. For example, the surface-home event may be a mechanically-based signal (i.e. direct physical contact between two or more components), an electronic-based signal (i.e. based upon an electronic signal sent from the surface and / or based upon an electronic signal generated based upon a detected position of the apparatus relative to the surface), a fluid-based signal (i.e. based on fluid pressure and / or fluid flow rates) or any combination thereof. As but one non-limiting example of the step of setting 805, a mechanical signal may used by a step of introducing a surface-borne object into the well so that the surface-borne object will land in a first seat of the apparatus. A step of delivering 806 pressurized fluid is also performed, which causes the first seat of the apparatus to initiate moving 808 from a first operational position to a second operational position. In the second operational position, a first set of ports may be exposed and the surface-borne object is released from the first seat for moving and landing 810 in a second seat of the apparatus. The delivering step 806 may be continued (either at the same or a different flow rate and / or pressure) to cause the second seat of the apparatus to initiate moving 812 from a first operational position to a second operational position. In the second operational position a second set of ports may be exposed and the surface-borne object is released from the second seat for moving and landing 814 in a third seat of the apparatus. The delivering step 806 may be continued (either at the same or a different flow rate and / or pressure) to cause pressurized fluid to move through the first and second set of ports and a step of applying 816 a force to respective piston faces of the apparatus. The piston faces will move resulting in a step of applying 818 a setting force on respective sets of dogs of the apparatus. The setting force causes a step of setting and sealing 820 the profile in the desired location of the well. The delivering step 806 may also cause the third seat of the apparatus to initiate moving 822 from a first operational position to a second operational position. When in the second operational position, the third seat will perform a step of releasing 824 the surface-bom object and releasing 826 the set and sealed profile at the desired location of the well. The method 800 may further comprise a step of moving 828 the apparatus uphole and optionally a step of cycling 830 through the applicable prior-steps of the method 800 in order to set, seal and release a second profile at a second desired location within the well.

[0088] As will be appreciated by those skilled in art, the method 800 can also be completed by the surface-borne object landing in only a signal seat that is held in various operational positions based upon a set of variable releasable components, such as shearable, expandable or compressible components. For example, the landed object and seat may move from a first operational position to a second operational position when exposed to a first fluid pressure or flow rate and then the landed object and seat may move from the second operational position to a third operational position when exposed to a second fluid pressure (or flow rate) that is higher than the first and so on.

[0089] As will be appreciated by those skilled in the art, optionally the step of setting 805 is done via an electronic-based signal or a fluid-based signal (shown as 805A in FIG. 27) the method may avoid steps 806 through 818 described above and the step of setting 805 may be followed by the step of sealing 818 the profile at the desired location and the step of releasing 826 the set and sealed profile at the desired location of the well. When in the second operational position, the associated ports may be exposed to the fluid within the bore of the inner mandrel, which as described above will result in the profile patch being set at the desired location.

[0090] Some embodiments of the present disclosure relate to a method 900 of retrieving and / or replacing a deployed device (including a deployed profile) within a well (see right panel of FIG. 27). When a device has been deployed at a desired location within a well and it is desired to retrieve such device, the method 900 comprises a step of conveying 902 an apparatus into the well at a position that is downhole of the device to be retrieved. Next a step of moving 904 the apparatus in the uphole direction in order to perform a step of engaging 906 the device. The step of engaging 906 will compress a biasing member by moving an arming sleeve of the apparatus. The compressing of the biasing member will cause a step of releasing 908 one or more retaining devices (such as dogs and / or collets) to shift and release from the profile in which the device is set. Next the retaining devices will perform a step of shifting 910 into a released position thereby engaging the released device to an outer surface of the apparatus. Next a step of moving 912 is performed to position the apparatus uphole adjacent or proximal the next device that is desired to be retrieved.Optionally a step of cycling 914 through the applicable prior steps of the method 900 can be performed in order to retrieve a second device that is desired to be retrieved.

[0091] In order to replace any devices by setting new devices in profiles positioned at a desired location of the well, the steps of method 700 may be employed.

[0092] Without being bound by any particular theory, the embodiments of the present disclosure relate to an apparatus and methods for deploying multiple downhole tools / devices with one conveyancing trip. In some embodiments of the present disclosure, the downhole tools / devices may set and released into a profile that is preinstalled, for example by way of a threaded profile sub within the string of pipe within the well. In some embodiments of the present disclosure, the downhole tools / devices may be one or more individual profiles that can be set, sealed and released at a desired location within a well that is lined or not.

Claims

I claim1. An apparatus for conveying one or more devices for deploying each device in a well, the apparatus comprising:(a) an inner mandrel that comprises a receiver and an arming mechanism(b) an outer mandrel that carries the one or more devices,wherein upon a downhole event occurring at the receiver, the arming mechanism is configured to arm a first of the one or more devices for setting in a pre-installed profile at a first desired location in the well, and whereinwhen the first of the one or more devices is set in the preinstalled profile, a second of the one or more devices becomes armed for setting in a second pre-installed profile at a second desired location in the well.

2. The apparatus of claim 1, wherein the apparatus is configured to retrieve one or more of the one or more devices from each respective desired location within the well.

3. The apparatus of claim 1, wherein the one or more devices are two or more devices.

4. An apparatus for conveying one or more profile patches and for deploying each profile patch within a well, the apparatus comprising:(a) an inner mandrel, with a shiftable seat, and an associated set of ports, a piston and a setting dog, wherein the shiftable seat is configured to releasably land a surface-borne object for shifting the shiftable seat from a first position to a second position, wherein when in the second position the associated ports enter into fluid communication with a bore of the inner mandrel; and(b) an outer mandrel that is configured to carry the one or more profile patches on an outer surface thereof, wherein when the ports enter into fluid communication with the bore of the inner mandrel, the outer mandrel is configured to set, seal and release one of the one or more profile patches at a desired location within the well.

5. The apparatus of claim 4, wherein the one or more profile patches are two or more profile patches.

6. A method for deploying a device at a desired location in a well, the method comprising steps of:(a) providing a specific shape on an inner surface of the well;(b) positioning the device proximal the specific shape;(c) arming the device to release from a carrying apparatus;(d) setting the device into the specific shape; and(e) releasing the device into the specific shape.

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