CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of an earlier filing date from U.S. Application Serial No. 63/057,591 filed July 28, 2020, the entire disclosure of which is incorporated herein by reference.

BACKGROUND

[0002] In the resource recovery industry, frac and gravel packs are a well-known means to protect a subsurface formation from collapse and to filter out unwanted particulates from a production borehole. So too are the apparatus for depositing sand or gravel that will make up the gravel pack. Referring to Figure 1, a prior art system 10, which happens to be configured as a gravel pack system but could be configured as a frac/frac pack system, or a cement system is illustrated that is and has been commercially available from Baker Hughes. The portion of Figure 1, other than the crossover tool depicted therein, is a slurry extension available under product number H484220008 (available from Baker Hughes). One of ordinary skill in the art is well familiar with the system.

[0003] Broadly, still referring to Figure 1, a crossover tool 10 is used to deposit gravel in an annular space and then a closure sleeve 12 is moved to a closed position in a seal bore 14 of a top sub 16 around the crossover tool 10. Due to particulates deposited in the immediate vicinity 18 of the crossover tool and seal bore 14, seals 20 on the closure sleeve 12 can sometimes be damaged such that differential pressure may not be completely manageable thereacross. This can be commercially undesirable in some situations. Therefore, the art would be benefited by a system that can accomplish the task of creating a gravel pack without damaging seals of the closure sleeve such that differential pressure can be maintained.

SUMMARY

[0004] An embodiment of slurry outlet system including a top sub, a closure sleeve movable relative to the top sub between a closed position and an open position, a seal mounted on one or the other of the top sub or the closure sleeve, a protector sleeve disposed to cover the seal until displaced by one or the other of the top sub or the closure sleeve that does not include the seal during movement to the closed position. [0005] An embodiment of a method for pressure sealingly closing a slurry outlet system including bringing a closure sleeve into proximity with a top sub of the slurry outlet system, displacing a protector sleeve, with the closure sleeve, off a seal disposed about the closure sleeve and simultaneously making sealing contact between the top sub and the seal.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The following descriptions should not be considered limiting in any way.

With reference to the accompanying drawings, like elements are numbered alike:

[0007] Figure 1 is a cross sectional view of a prior art slurry outlet system;

[0008] Figure 2 is a cross sectional view of an embodiment of a slurry outlet system as disclosed herein;

[0009] Figure 3 is an enlarged view of a portion of Figure 2 taken at the circumscribed area in Figure 2 and in an open position of the system;

[0010] Figure 3a is the illustration of Figure 3 with a biasing arrangement added;

[0011] Figure 4 is the same view as Figure 3 but in the closed position of the system;

[0012] Figure 5 is a schematic representation of an engagement arrangement for components of the system disclosed herein;

[0013] Figure 6 is a cross sectional view of another embodiment of a slurry outlet system described herein;

[0014] Figure 7 is a cross sectional view of another embodiment of a slurry outlet system described herein;

[0015] Figure 8 is a cross sectional view of another embodiment of a slurry outlet system described herein; and

[0016] Figure 9 is a cross sectional view of another embodiment of a slurry outlet system described herein in an open position;

[0017] Figure 10 is Figure 9 in a clsed position; and

[0018] Figure 11 is a schematic view of a wellbore wherein the a slurry outlet system as described herein is disposed.

DETAILED DESCRIPTION

[0019] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. [0020] Referring to Figures 2 - 4, a slurry outlet with seal protection system 30 is illustrated. The system 30, which may be a gravel pack system frac/frac pack system, or a cement system (it will be appreciated that a crossover tool is illustrated disposed in the system but the crossover tool may be easily swapped for a frac/frac pack service tool or a cementing service tool as is familiar to one of ordinary skill in this art) may include many similar components to that of the prior art system 10 but with several significant departures. Specifically, a top sub 32 (“top sub” being broadly meant as one of more actual components of the system functioning as a seal bore, a seal housing, a seal assembly housing, etc. which can be one piece or a number of pieces secured together) of system 30 carries a number of seal(s) 34 at an inside diameter surface 36 thereof and, in some variations, a number of wiper(s) 38 as well. The wiper 38 may be helpful in that if a small amount of debris clings to the outer surface of a closure sleeve, the wiper 38 will wipe that off prior to the closure sleeve interacting with the seals 34, thereby ensuring that the seals are not contaminated with and/or damaged by any particulate matter that could compromise seal integrity. It is to be appreciated that all known types of seals could be employed such as O-ring seals, bonded seals, a seal stack or non-elastomeric seals (including metal seals), etc., the representations in the Figures being general to each of these. It is further to be understood that more than one of the above mentioned seals may be used together in some embodiments.

[0021] Further, a movable protector sleeve 40 is initially disposed to cover and protect the seals 34 and wiper 38 from damage including due to contamination by particulate materials that might otherwise damage the seals 34 upon moving the system 30 to the closed position. The seals remain protected by the protector sleeve 40 both during slurry flow and during shifting of a closure sleeve 50. As illustrated in Figure 3, the protector sleeve 40 is disposed radially inwardly of the top sub 32 and with an outside surface 42 of the protector sleeve 40 in contact with the seals 34 and wiper 38. In one embodiment, the protector sleeve 40 is a part of a seal protection subsystem 44 that further includes a protector sleeve pocket 46. The pocket 46 is a segregated volume that will not admit particulate matter from the slurry outlet or other expected wellbore particulate or debris. The pocket 46 is maintained in this condition by a tight fit between a pocket barrier 47 and the protector sleeve 40. The term “tight fit” as used herein means that the gap presented between two components is smaller than the average size of the proppant used in a gravel slurry or particulate used in a cement slurry. Ensuring a gap has a size smaller than the particulate means that no particulates can penetrate the area. No particles penetrating the area means that there will be no impediment to the protector sleeve 40 when it is time to remove the protector sleeve 40 from the seals 34. The seal protection subsystem 44 further includes a release member 48 such as, for example, a shear screw or detent. The release member 48 prevents movement of the protector sleeve until a threshold selected force is placed on the protector sleeve 40. The seal protection subsystem 44 may be configured as a telescopic unit as illustrated, in some variations. The pocket 46 is receptive to the protector sleeve 40 when that sleeve 40 is urged into the pocket by the closure sleeve 50 (refer to Figures 2 and 4). While urging the protector sleeve 40 directly with the closure sleeve 50 is efficient and effective, it is also contemplated that the protector sleeve 40 may be shifted by another component either once contact between closure sleeve 50 and protector sleeve 40 is made or once the closure sleeve 50 is sufficiently close to the protector sleeve 40. “Sufficiently close” in this context means that the gap presented between two components is smaller than the average size of the proppant used in a gravel slurry or particulate used in a cement slurry. Ensuring a gap has a size smaller than the particulate means that no particulates can penetrate the area.

[0022] In variations, a biasing arrangement 49 may be provided in the pocket 46 (see FIG. 3a) to ensure that if the closure sleeve 50 reverses direction for any reason, the protector sleeve 40 will responsively re-cover the seals 34 and wiper 38. The biasing arrangement may be a spring, such as a coil spring, a gas chamber, an elastomeric member, etc. Alternatively to the biasing arrangement, or in addition thereto, the protector sleeve 40 may include an engagement feature 54 that latches with a catch 56 on the closure sleeve 50 to ensure the protector sleeve 40 will follow the closure sleeve 50 (see Figure 5).

[0023] Notably, the closure sleeve 50 includes only a seal-less uninterrupted outer surface 52 on an end thereof that is to interact with the top sub 32 and the protector sleeve 40. The lack of seals in this area reduces the ability of the closure sleeve 50 to carry particulates with it during its transition from the open position of the system 30 to the closed position of the system 30.

[0024] Considering the positions illustrated in Figure 3 and 4 simultaneously, which show the same portion of the system 30 in the open and closed positions respectively, it is evident that the sleeve 50 displaces the sleeve 40 through contact therewith and hence there is no opening for particulate matter to contaminate the seals 34.

[0025] In the prior art system 10, since seals are present on the closure sleeve 12, the trapping of particulates thereat and the direct damage to the seals during stroking of the sleeve 12 was a distinct possibility. With the particular combination of features disclosed herein however, the direct damage to the seals and the trapping of particulate material that may possibly contaminate or cause damage to the seals has been substantially reduced or eliminated.

[0026] In another embodiment, referring to Figure 6, it will be recognized that top sub 32 is unchanged from embodiments above but that the seal protector subsystem (44 above) has been substituted by a different protector sleeve 140. In this embodiment, the protector sleeve 140 extends a longer distance and bridges a volume that becomes a pocket 146 where particulate matter is excluded. The embodiment includes an upset 147 that provides a stop in both the uphole and downhole directions of movement of the protector sleeve 140. A release member 148 is still employed for the protector sleeve 140, in an alternate location to the foregoing embodiment, and retains the function of securing the protector sleeve 140 until a threshold selected force is applied thereto to release the release member 148. In other respects, the embodiment is similar to the foregoing embodiments.

[0027] In yet another embodiment, referring to Figure 7, a protector sleeve 240 includes a ramped section 250 that is configured to displace particulate. This is due to the potential for particulate to collect in a space 252 where the protector sleeve 240 will move when the seals 34 are uncovered. It will be appreciated in this embodiment that the particulate free pocket of the foregoing embodiments is not present. Rather the space where the pocket would be in this embodiment, space 252, a is actually open to particulate incursion. Because of the potential for particulate incursion, there is a possibility that the protector sleeve 240 may encounter particulates that hinder its movement toward the left of Figure 7 during actuation. The ramped section 250 will help to displace aggregated particulates radially inwardly and therefore out of the way of the protector sleeve 240. In other respects, the embodiment is similar to the foregoing embodiments.

[0028] In yet another embodiment, referring to Figure 8, it will be appreciated that the protector sleeve 240 is the same as in Figure 7. The addition in this embodiment is an anchor sleeve 260. The anchor sleeve allows for easy testing for movement of the protector sleeve 240 during manufacture and then later securing of the protector sleeve 240 by insertion of the anchor sleeve 260 and a release member 262. The release member 262 is releaseable upon impetus as described above and the protector sleeve 240 will move leftwardly in Figure 8 while displacing any aggregated particulate with the ramped section 250 as discussed above. In other respects, the embodiment is similar to the foregoing embodiments.

[0029] The system 30 operates very similarly to the system 10 of the prior art with the departures being discussed above. Accordingly, since the departures of system 30 from system 10 have been described and illustrated, further disclosure is not necessary for one of ordinary skill in the art to make and use what is taught herein.

[0030] In another embodiment, a slurry outlet system 400, referring to Figures 9 and 10, is illustrated. The system 400 includes a top sub 402 that is a seal bore. Specifically, this top sub differs from those of the foregoing embodiments as it does not house the seals that the above disclosed embodiments do. In this embodiment, a seal 404 (same as above in number and character and further may include a wiper 405) is disposed instead on closure sleeve 406. In keeping with the foregoing embodiments, a protector sleeve 408 is disposed to protect the seal 404 and hence is located in this embodiment upon the closure sleeve 406 immediately radially outwardly of the seal 404. Protector sleeve 408 then translates with the closure sleeve 406 to protect the seal 404 throughout the movement of the closure sleeve when moving from the open position to the closed position. Upon reaching proximity to the closed position, which is illustrated in Figure 10, the protector sleeve 408 is shouldered against the top sub 402 which prevents further movement of protector sleeve 408 and allows closure sleeve 406 and specifically the seal 404 to slide telescopically through the protector sleeve 408 into sealing contact with the top sub 402. The seal 404 is protected from debris similarly to the foregoing embodients with the same benefits from achieving that condition. Also similar to foregoing embodiments, the protector sleeve 408 may be biased by a biasing arrangement 410 such as a spring to automatically close if the closure sleeeve 406 reverses direction. In variations, the protector sleeve may also include a release arrangement 412 such as a shear screw.

[0031] Further disclosed herein is a wellbore system 500 as schematically illustrated in Figure 11. The wellbore system 500 includes a borehole 360 disposed in a subsurface formation 362. A gravel pack system, frac/frac pack system, or a cement system 30 or 400 is a part of a string 364 and disposed in the borehole 360.

[0032] Set forth below are some embodiments of the foregoing disclosure:

[0033] Embodiment 1: A slurry outlet system including atop sub, a closure sleeve movable relative to the top sub between a closed position and an open position, a seal mounted on one or the other of the top sub or the closure sleeve, a protector sleeve disposed to cover the seal until displaced by one or the other of the top sub or the closure sleeve that does not include the seal during movement to the closed position.

[0034] Embodiment 2: The system as in any prior embodiment, wherein the seal is mounted upon the closure sleeve. [0035] Embodiment 3: The system as in any prior embodiment, wherein the protector sleeve is disposed radially outwardly of the seal.

[0036] Embodiment 4: The system as in any prior embodiment, wherein the closure sleeve includes a plurality of seals.

[0037] Embodiment 5: The system as in any prior embodiment, further including a wiper.

[0038] Embodiment 6: The system as in any prior embodiment, wherein the top sub contacts the protector sleeve.

[0039] Embodiment 7: The system as in any prior embodiment, further including a crossover tool disposed radially inwardly of the top sub in a gravel packing, fracing or frac packing position of the system and removed therefrom after completion of a gravel packing, fracing or frac packing operation.

[0040] Embodiment 8: The system as in any prior embodiment, further including a cementing tool disposed radially inwardly of the top sub in a cementing position of the system and removed therefrom after completion of a cementing operation.

[0041] Embodiment 9: The system as in any prior embodiment, wherein the seal is one or more of an o-ring, a bonded seal, metal seal, a seal stack or non-elastomeric seals.

[0042] Embodiment 10: The system as in any prior embodiment, wherein the top sub includes a seal bore for interacting with the seal on the closure sleeve, that is a seal less uninterrupted surface.

[0043] Embodiment 11: The system as in any prior embodiment, further comprising a biasing arrangement disposed to bias the protector sleeve.

[0044] Embodiment 12: The system as in any prior embodiment, further comprising a release member attached to the protector sleeve.

[0045] Embodiment 13: The system as in any prior embodiment, wherein the release member is a shear screw.

[0046] Embodiment 14: A method for pressure sealingly closing a slurry outlet system including bringing a closure sleeve into proximity with a top sub of the slurry outlet system, displacing a protector sleeve, with the closure sleeve, off a seal disposed about the closure sleeve and simultaneously making sealing contact between the top sub and the seal.

[0047] Embodiment 15: The method as in any prior embodiment, further including wiping the top sub prior to making sealing contact with the seal.

[0048] Embodiment 16: The method as in any prior embodiment, wherein the urging of the protector sleeve includes causing the release of a release member. [0049] Embodiment 17: A wellbore system including a borehole in a subsurface formation, a string including a slurry outlet system as in any prior embodiment.

[0050] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).

[0051] The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and / or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

[0052] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.