COMPLETION COMPONENT

Description

The present invention relates to a completion component for providing an annular barrier in a well between a first well tubular metal structure and an inner face of a borehole or a second well tubular metal structure for providing zone isolation between a first zone and a second zone of an annulus. Moreover, the present invention also relates to a downhole system and a cementing method of providing cement in an annulus between the well tubular metal structure and a wall of a borehole or a second well tubular metal structure.

Packers or similar annular barriers expanded in a well to provide a barrier between a casing or tubing and the borehole or another tubing are often provided with a valve assembly for providing several means of fluid communication, e.g. when run in hole. The space underneath the expandable sleeve may thus be in fluid communication with the annulus to prevent collapse, and when the annular barrier is arranged at the intended location, the fluid communication needs to be shifted so that the space is in fluid communication with the inside of the tubing to pressurise and expand the expandable sleeve. After expansion, the valve assembly shifts again to ensure that the space is pressure-compensated with the highest pressure in the annulus. These valve assemblies are costly as they are to shift the fluid communication several times, and as they need to be tested and designed for each borehole size. Thus, there is a need for a simpler solution to decrease the cost for manufacturing.

It is an object of the present invention to wholly or partly overcome the above disadvantages and drawbacks of the prior art. More specifically, it is an object to provide an improved completion component that provides a simpler solution for shifting of fluid communication than that of the known packers or annular barriers to decrease manufacturing cost without decreasing the reliability of the completion component.

The above objects, together with numerous other objects, advantages and features, which will become evident from the below description, are accomplished by a solution in accordance with the present invention by a completion component for providing an annular barrier in a well between a first well tubular metal structure and an inner face of a borehole or a second well tubular metal structure for providing zone isolation between a first zone and a second zone of an annulus, comprising:

• • a tubular metal part for mounting as part of the first well tubular metal structure, the tubular metal part having an axial extension and an outer face,
  • an expandable sleeve surrounding the tubular metal part and having a first end part and a second end part, an outer face facing towards the inner face of the borehole or the second well tubular metal structure, and an inner face facing the outer face of the tubular metal part,
  • an annular space between the expandable sleeve and the tubular metal part, and
  • an expansion opening in the tubular metal part through which fluid may enter the annular space in order to expand the expandable sleeve,
    wherein the first end part of the expandable sleeve is fixedly fastened with the tubular metal part, and the second end part is slidable along the axial extension, and
    wherein the completion component further comprises a first connection part having a first condition in which the first connection part is fixedly arranged along the axial extension, and a second condition in the first connection part is slidable along the axial extension, the second end part of the expandable sleeve abutting and being slidable in relation to the first connection part.

The expandable sleeve may be an expandable metal sleeve so that when the sleeve is expanded, the annular barrier becomes a permanent annular barrier.

By a first connection part having the first condition in which the first connection part is fixedly arranged along the axial extension, and the second condition in which the first connection part is slidable along the axial extension, expansion of the expandable metal sleeve is obtained, and subsequently the completion component is opened for access to the annulus for cementing above the completion component, which thus functions as a port collar and also a plug so that the cement stays at the intended position during curing. Thus, a very simple completion component is obtained instead of using very costly and complex valve assemblies.

Furthermore, the second end part of the expandable sleeve is slidable and can move during expansion so that the thinning effect occurring during expansion is reduced compared to the expandable metal sleeve ends being fixed during expansion. In addition, the expansion fluid can act on the second end part so as to provide a compression force thereon to reduce the thinning effect even more, whereby the expandable metal sleeve may be expanded to a larger outer diameter than if both ends of the expandable metal sleeve were fixed to the tubular metal part or without the compression force.

In addition, the first connection part may be annular and circumferent the tubular metal part and part of the second end part of the expandable sleeve.

Moreover, the second end part of the expandable sleeve may be slidable in relation to the first connection part.

Furthermore, the first connection part in the first condition may be fixedly arranged by means of a breakable element which is breakable at predetermined differential pressure between the pressure in the annular space and the first zone.

Additionally, the first connection part may be fixedly arranged along the axial extension by means of a breakable element such as a shear pin.

Also, fluid may be allowed to enter the expansion opening in the first condition to expand the expandable sleeve.

Further, the second end part may be slidable in relation to the first connection part in a first direction towards the first end part of the expandable sleeve.

In addition, the second end part may comprise a sleeve end part which is slidable in relation to the first connection part in the first direction towards the first end part of the expandable sleeve.

Moreover, the first connection part may be slidable in the first direction after breaking the breakable element for creating an aperture between the first connection part and the tubular metal part or an end piece fastened to the tubular metal part.

Furthermore, the first connection part may be slidable in a second direction opposite the first direction after breaking the breakable element for creating an aperture between the first connection part and the second end part of the expandable sleeve.

Additionally, the fluid entering the expansion opening in order to expand the expandable sleeve may be cement so that the cement also enters the aperture in order to provide cement in the first zone.

Also, the first end part of the expandable sleeve may be fixedly fastened with the tubular metal part via a second connection part.

Moreover, the expandable sleeve may comprise an intermediate part between the first end part and the second end part, the second end part of the expandable sleeve having a first thickness, and the intermediate part having a second thickness being smaller than the first thickness.

Furthermore, as the first thickness of the second end part is larger than the second thickness, the second end part may provide a piston effect in that the second end part has a first piston face facing the expansion opening so that the fluid entering the expansion opening pushes on the first piston face to provide a compression force on the expandable sleeve during expansion of the expandable sleeve.

In addition, a sealing element may be arranged between the second end part and the first connection part.

Further, the sealing element may be a unidirectional or bidirectional seal.

Thus, the sealing element may not be an elastomeric seal.

Furthermore, the expandable sleeve may be an expandable metal sleeve and may have sealing elements arranged on the outer face of the expandable metal sleeve.

Moreover, no sealing element may be provided between the second end part and the outer face of the tubular metal part.

Additionally, the first connection part may comprise a first fluid channel which in the first condition provides fluid communication between the expansion opening and the annular space.

Furthermore, the first connection part may, after breaking the breakable element, be slidable in the second direction in relation to the tubular metal part or in relation to an end piece fastened to the tubular metal part, closing the fluid communication between the expansion opening and the annular space.

Also, a first sealing element may be provided between the first connection part and the tubular metal part or an end piece fastened to the tubular metal part at one side of the expansion opening, and a second sealing element may be provided between the first connection part and the tubular metal part or an end piece fastened to the tubular metal part at the other side of the expansion opening.

In addition, the first sealing element and the second sealing element may provide a bidirectional seal.

The completion component may further comprise a locking element for locking the first connection part in the second condition.

Also, the locking element may fit into a groove.

Moreover, the first connection part may be slidable in a second direction opposite the first direction after breaking the breakable element for creating an aperture between the first connection part and the second end part of the expandable sleeve, providing annulus compensation through the aperture after expansion.

Further, after expansion, annulus compensation may also be provided by arranging a unidirectional seal between the second end part of the expandable sleeve and the first connection part.

Additionally, the first connection part may further comprise a first compensation channel which in the second condition provides fluid communication between the annular space and the annulus surrounding the expandable sleeve.

Furthermore, the first compensation channel may have a first end in fluid communication with the annular space and a second end arranged between two sealing elements in the first condition for sealing off fluid communication between the annulus and the annular space.

Also, the first and second sealing elements may be provided in the end piece fastened to the tubular metal part and facing the first connection part.

Moreover, the end piece may have a second compensation channel which in the second condition is arranged opposite the second end of the first compensation channel. The first connection part is pressure-balanced in the second condition in the first compensation channel, and the second compensation channel is aligned, providing fluid communication between the annular space and the annulus.

In addition, the completion component may further comprise an annular protection element arranged to circumferent the tubular metal part and arranged between the expansion opening and the second end part of the expandable sleeve, the annular protection element comprising a flow channel providing fluid communication between the expansion opening and the annular space in the first condition.

Furthermore, a sealing element may be arranged between the annular protection element and the tubular metal part.

Additionally, the annular protection element may be made of PEEK, PTFE or similar material.

Moreover, the annular protection element may be fastened to the first connection part in the first condition in a first position by means of a second breakable element, and the annular protection element has an inner diameter being less than an inner diameter of the first connection part so that part of an end face of the annular protection element is exposed to the fluid entering the expansion opening to the effect that if the expandable sleeve bursts during expansion, the fluid from the expansion opening presses onto the annular protection element, breaking the breakable element and moving the annular protection element to a second position as the flow channel restricts the flow of fluid and creates higher pressure on the exposed end side than in the annular space.

In addition, the annular protection element may have moved to the second position in which the annular protection element abuts the second end part of the expandable sleeve, the annular protection element preventing any flow of fluid from the expansion opening to the annular space. When expanding several expandable sleeves of completion components, the pressure in the well tubular metal structure is increased, but if an expandable sleeve bursts, the pressure then drops, and the other expandable sleeves can no longer be expanded in the known solutions. However, by having the annular protection element, the completion component comprising a burst expandable sleeve can be shut off so that the other completion components can be expanded.

Further, a sliding sleeve may be arranged opposite the expansion opening to cover or uncover the expansion opening.

Also, the completion component may be an annular barrier.

Additionally, the completion component may be a port collar, i.e. a cementing port through which cement can flow when opened.

Moreover, the expandable sleeve of the annular barrier may be an expandable metal sleeve.

The present invention also relates to a downhole system comprising a completion component and a well tubular metal structure.

Furthermore, the downhole system may comprise a first completion component and a second completion component.

In addition, the first completion component and the second completion component may then function as a backup to each other.

Also, the downhole system may comprise a flow line fluidly connecting the first completion component and the second completion component.

Further, the downhole system may comprise a protection valve assembly arranged between the first completion component and the second completion component so that the flow line extends through the protection valve assembly.

Additionally, the first completion component and the second completion component may be arranged so that the second connection part of the first completion component is arranged closer to the second connection part of the second completion component than to the first connection part of the first completion component.

Moreover, the first connection parts may be provided with unidirectional sealing elements, allowing fluid communication from the annulus to the annular space but not from the annular space to the annulus.

Finally, the present invention relates to a cementing method of providing cement in an annulus between the well tubular metal structure and a wall of a borehole or a second well tubular metal structure, comprising:

• • mounting a tubular metal part of a completion component as part of the well tubular metal structure,
  • lowering the well tubular metal structure into the borehole,
  • expanding the expandable sleeve by pressurising the well tubular metal structure with cement until the predetermined pressure differential is reached,
  • providing an aperture, and
  • letting cement out through the aperture and into the annulus.

The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which:

FIG. 1 shows a cross-sectional view of a completion component in a first condition and an initial position of a first connection part,

FIG. 2 shows a cross-sectional view of the completion component of FIG. 1 in the first condition of the first connection part, where the expandable sleeve has been expanded,

FIG. 3 shows a cross-sectional view of the completion component of FIG. 1 in a second condition of the first connection part,

FIG. 4 shows a cross-sectional view of another completion component in a first condition and an initial position of a first connection part,

FIG. 5 shows a cross-sectional view of the completion component of FIG. 4 in the first condition of the first connection part, where the expandable sleeve has been expanded,

FIG. 6 shows a cross-sectional view of the completion component of FIG. 4 in a second condition of the first connection part,

FIG. 7 shows a cross-sectional view of part of yet another completion component in the first condition and initial position of the first connection part,

FIG. 8 shows a cross-sectional view of the completion component of FIG. 7 in the first condition of the first connection part, where the expandable sleeve has been expanded,

FIG. 9 shows a cross-sectional view of the completion component of FIG. 7 in a second condition of the first connection part,

FIG. 10 shows a cross-sectional view of part of yet another completion component in the second condition of the first connection part, where movement of the first connection part from the first condition to the second condition provides an aperture between the expandable sleeve and the first connection part,

FIG. 11 shows a cross-sectional view of part of yet another completion component in the first condition and initial position of the first connection part,

FIG. 12 shows a cross-sectional view of the completion component of FIG. 11 in the first condition of the first connection part, where the expandable sleeve has been expanded,

FIG. 13 shows a cross-sectional view of the completion component of FIG. 11 in a second condition of the first connection part,

FIG. 14 shows a cross-sectional view of part of another completion component in the first condition and initial position of the first connection part,

FIG. 15 shows a cross-sectional view of the completion component of FIG. 14 in the first condition of the first connection part, where the expandable sleeve has burst, and the annular protection element has moved,

FIG. 16 shows a cross-sectional view of a downhole system comprising two completion components,

FIG. 17 shows a cross-sectional view of another downhole system comprising two completion components,

FIG. 18A shows a cross-sectional view of part of another completion component in the first condition and initial position of the first connection part,

FIG. 18B shows the completion component of FIG. 18A in the second condition of the first connection part,

FIG. 19 shows a cross-sectional view of part of yet another completion component having an anti-rotation element arranged to prevent rotation of the first connection part during deployment, and

FIG. 20 shows a cross-sectional view of part of yet another completion component having another anti-rotation solution.

All the figures are highly schematic and not necessarily to scale, and they show only those parts which are necessary in order to elucidate the invention, other parts being omitted or merely suggested.

FIG. 1 shows a completion component 1 for providing an annular barrier 2 in a well 50 between a first well tubular metal structure 3 and an inner face 4 of a borehole 5 or a second well tubular metal structure (not shown) for providing zone isolation, as shown in FIG. 2, between a first zone 101 and a second zone 102 of an annulus 105. The completion component 1 comprises a tubular metal part 6 for mounting as part of the first well tubular metal structure 3. The tubular metal part 6 has an axial extension L and an outer face 7. The completion component 1 further comprises an expandable sleeve 8 surrounding the tubular metal part 6 and having a first end part 14, a second end part 15, an outer face 9 facing towards the inner face 4 of the borehole 5 or the second well tubular metal structure, and an inner face 10 facing the outer face 7 of the tubular metal part 6. The completion component 1 comprises an annular space 11 between the expandable sleeve 8 and the tubular metal part 6 and an expansion opening 12 in the tubular metal part 6 through which fluid may enter the annular space in order to expand the expandable sleeve 8. The first end part 14 of the expandable sleeve 8 is fixedly fastened with the tubular metal part 6, and the second end part 15 is slidable along the axial extension L. The completion component 1 further comprises a first connection part 16 having a first condition in which the first connection part 16 is fixedly arranged along the axial extension L and a second condition in which the first connection part 16 is slidable along the axial extension L, the second end part 15 of the expandable sleeve 8 abutting and being slidable in relation to the first connection part 16.

The completion component 1 of FIGS. 1-3 functions as a port collar, i.e. a cementing port through which cement can flow when the completion component 1 is “open”, providing access from the expansion opening 12 to the surrounding annulus 105. In FIG. 1, the completion component 1 is in its initial position as RIH (Run in Hole). The completion component 1 comprises a sliding sleeve 41 which is open, exposing the expansion opening 12 so that fluid from within the tubular metal part 6 and the well tubular metal structure 3 can flow in through the expansion opening 12 and into the annular space 11. As the expandable metal sleeve 8 is expanded by means of the fluid, the expandable metal sleeve 8 shortens in length, and the second end part 15 of the expandable metal sleeve 8 moves away from the first connection part 16 in a first direction D1 towards the first end part 14 of the expandable sleeve 8, as shown in FIG. 2, and the first zone 101 is isolated from the second zone 102. By further pressurisation, the fluid provides a force on the second end part 15 in the form of a sleeve end part 25 breaking a breakable element 17, such as a shear pin 17A, which is breakable at predetermined differential pressure between the pressure in the annular space 11 and the first zone 101, and the first connection part 16 slides along the axial extension L away from the second end part 15 in a second direction D2, providing an aperture 18, as shown in FIG. 3. When the completion component 1 functions as a port collar, the fluid is cement, or at least the fluid is changed to cement after expansion or provision of the aperture 18 so that the cement is allowed to flow into the first zone 101 of the annulus 105 to cement above the expandable metal sleeve 8 and provide a cement plug. The first connection part 16 is sliding along the axial extension L on a polished surface 38 on the tubular metal part 6 in the form of a cladding being subsequently polished. Between the tubular metal part 6 and the first connection part 16, a sealing element 23 is arranged. The first end part 14 of the expandable metal sleeve 8 is fixedly connected to the tubular metal part 6 by means of a second connection part 16B which is welded to the tubular metal part 6, and the first end part 14 is welded to the second connection part 16B. The second end part 15 is welded to the sleeve end part 25, and the sleeve end part 25 thus forms part of the second end part 15. The first connection part 16 slides until the aperture 18 occurs, and the seal is lost inside the annular space 11. Higher pressure during cementing may further increase the aperture 18. The completion component 1 may have annular sealing elements arranged on the outer face 7 of the expandable sleeve 8 for providing a better seal against the inner wall of the borehole 5 or a second well tubular metal structure. The expandable sleeve 8 is an expandable metal sleeve to form a permanent annular barrier when expanded.

By having a first connection part 16 with the first condition in which the first connection part 16 is fixedly arranged along the axial extension L, and the second condition in which the first connection part 16 is slidable along the axial extension L, expansion of the expandable metal sleeve 8 is obtained, and subsequently the completion component 1 is opened for access to the annulus 105 for cementing above the completion component 1, which thus functions as a port collar and also a plug so that the cement stays at the intended position during curing. Thus, a very simple completion component 1 is obtained compared to the known very costly and complex valve assemblies.

In FIG. 4, the completion component 1 is in its initial position and provides a combined annular barrier and port collar, where the second end part 15 of the expandable metal sleeve 8 abuts the first connection part 16 in a slidable manner, with a sealing element 23 arranged therebetween. The first connection part 16 is in its first condition fixed to the tubular metal part 6 by means of a breakable element 17 in the form of a shear pin 17A and via an end piece 19 which is fastened to the tubular metal part 6 by means of welding. The completion component 1 may further comprise a sliding sleeve 41 so that the expansion opening 12 can be closed or opened by sliding the sliding sleeve 41 along the axial extension L, exposing or covering the expansion opening 12. The expandable metal sleeve 8 is expanded by allowing fluid to enter the expansion opening 12 and flow further into the annular space 11, as shown in FIG. 5, causing the second end part 15 and the sleeve end part 25 to slide in the first direction towards the first end part 14 of the expandable metal sleeve 8. The expanded expandable metal sleeve 8 provides an annular barrier 2 isolating the first zone 101 from the second zone 102. By continuing to allow fluid to enter the expansion opening 12 and the annular space 11, differential pressure across the first connection part 16 is created, and the breakable element 17 is broken, allowing the first connection part 16 to move in the first direction, creating an aperture 18 allowing fluid within the annular space 11 to escape in order to provide cement in the first zone 101 of the annulus 105. If the shear pin 17A breaks prematurely before expansion, the expandable metal sleeve 8 cannot move before the pressure is intentionally increased. The first connection part 16 may move with the expandable sleeve 8 during expansion, and then the expandable metal sleeve 8 may not be fully expanded but may still provide a sufficient plug during curing of the cement.

The completion component 1 may also be an annular barrier without port collar functionality. In FIG. 7, a cross-sectional view of part of the completion component 1 in the form of an annular barrier is shown. The expandable sleeve 8 comprises an intermediate part 21 between the first end part 14 and the second end part 15, and the second end part 15 of the expandable sleeve 8 has a first thickness t1, and the intermediate part 21 has a second thickness t2 being smaller than the first thickness t1. As the first thickness t1 of the second end part 15 is larger than the second thickness t2, the second end part 15 provides a piston effect in that the second end part 15 has a first piston face 22 facing the expansion opening 12 so that the fluid entering the expansion opening 12 pushes on the first piston face 22 to provide a compression force on the expandable sleeve 8 during expansion of the expandable sleeve 8. When expanding the expandable metal sleeve 8, the expandable metal sleeve 8 is slightly thinning during expansion, but by providing the compression force, this thinning is substantially minimised, if not fully eliminated. Thus, the expansion fluid can act on the second end part 15 to provide a compression force on the second end part 15 to reduce the thinning effect even more, whereby the expandable metal sleeve 8 may be expanded to a larger outer diameter than if both ends of the expandable metal sleeve 8 were fixed to the tubular metal part 6 or without the compression force. The overlap of the second end part 15 and the first connection part 16 can be made larger than shown so that the expandable metal sleeve 8 can be expanded to an even larger outer diameter. Further, by having this design the completion component 1 can be designed to fit both a smaller and a larger-diameter borehole 5 than the known solutions. Thus, if facing an unexpected larger local diameter in the borehole 5, the expandable metal sleeve 8 will not burst as the expandable metal sleeve 8 does not thin as much as in the known solutions.

As can be seen in FIG. 7, a sealing element 23 is arranged between the second end part 15 and the first connection part 16. The sealing element 23 may be a unidirectional or bidirectional seal. The first connection part 16 comprises a first fluid channel 24 which in the first condition provides fluid communication between the expansion opening 12 and the annular space 11. No sealing element is provided between the second end part 15 and the outer face of the tubular metal part 6 so that fluid from the expansion opening 12 may enter the annular space 11 through the first fluid channel 24 and in between the second end part 15 and the tubular metal part 6. Furthermore, if the expandable metal sleeve 8 unintentionally bursts, the very small gap between the second end part 15 and the outer face of the tubular metal part 6 provides a large pressure drop so that the pressure inside the first well tubular metal structure 3 is not sufficient to hinder expansion of other expandable sleeves or similar activities. A first sealing element 26 is provided between the first connection part 16 and the tubular metal part 6 or an end piece 19 fastened to the tubular metal part 6 at one side of the expansion opening 12, and a second sealing element 27 is provided between the first connection part 16 and the tubular metal part 6 or an end piece 19 fastened to the tubular metal part 6 at the other side of the expansion opening 12. In the initial position of the completion component 1, the fluid channel 24 bridges over the first sealing element 26. In FIG. 8, the expandable metal sleeve 8 has been expanded so that the second end part 15 has slid in relation to the first connection part 16 in the first direction D1. If fluid is continuously let into the annular space 11, the breakable element 17 will break, and the first connection part 16 after breaking the breakable element 17 will slide in the second direction D2 in relation to the tubular metal part 6 or an end piece 19 fastened to the tubular metal part 6, as shown in FIG. 9, so that the fluid channel 24 is arranged between the first and second sealing elements 26, 27, closing the fluid communication between the expansion opening 12 and the annular space 11. The first sealing element 26 and the second sealing element 27 provide a bidirectional seal in order to close the fluid communication. The completion component 1 further comprises a locking element 28 for locking the first connection part 16 in the second condition. The locking element 28 may fit into a groove 29 of a part 37 of the end piece 19 fastened to the tubular metal part 6.

The completion component 1 shown in FIGS. 7 and 8 may also be designed so that the first connection part 16 is slidable in the second direction D2 opposite the first direction D1 after breaking the breakable element 17 for creating an aperture 18 between the first connection part 16 and the second end part 15 of the expandable sleeve 8, providing annulus compensation through the aperture 18 after expansion, as shown in FIG. 10, instead of stopping in the position shown in FIG. 9. After expansion, annulus compensation may also be provided by arranging a unidirectional seal 23C and not an elastomeric seal between the second end part 15 of the expandable sleeve 8 and the first connection part 16 in the embodiment shown in FIG. 9.

In FIG. 11, the completion component 1 is an annular barrier, and the first connection part 16 of the completion component 1 further comprises a first compensation channel 30 which in the second condition provides fluid communication between the annular space 11 and the annulus surrounding the expandable sleeve 8, as shown in FIG. 13. In FIG. 11, the first connection part 16 is in its first condition where the first compensation channel 30 has a first end 31 in fluid communication with the annular space 11 and a second end 32 arranged between two sealing elements sealing off fluid communication between the annulus and the annular space 11. The first and second sealing elements 26, 27 may be provided in the end piece 19 fastened to the tubular metal part 6 and facing the first connection part 16. In FIG. 12, the expandable metal sleeve 8 has been expanded, and the second end part 15 has moved in the first direction D1. The end piece 19 has a second compensation channel 33 which in the second condition is arranged opposite the second end 32 of the first compensation channel 30, as shown in FIG. 13. The first connection part 16 is thus pressure-balanced in the second condition in that the first compensation channel 30 and the second compensation channel 33 are aligned, providing fluid communication between the annular space 11 and the annulus 105. The end piece 19 has a flange 37 projecting radially outwards so as to prevent the first connection part 16 from sliding further and thus to ensure that the second compensation channel 33 is aligned with the first compensation channel 30. By having such flange stopping the first connection part 16, it is ensured that even if the shear pin breaks prematurely, the seal between the second end part 15 and the first connection part 16 is intact until the expandable metal sleeve 8 is expanded sufficiently to move the second end part 15 past the first connection part 16. In such a case, the expandable metal sleeve 8 may not be fully expanded to abut the inner wall of the borehole 5 but does provide some limitation on fluid passing.

When expanding the expandable metal sleeve 8, the expandable metal sleeve 8 may burst if the inner diameter of the borehole 5 or the second well tubular metal structure is larger than expected, e.g. due to an unexpected wash-out or a similar unforeseen enlargement. As the expandable metal sleeve 8 has not been designed to expand to such a large diameter, this may cause the expandable metal sleeve 8 to burst during expansion. When expanding several expandable metal sleeves 8, the other expandable metal sleeves 8 cannot be expanded if the burst expandable metal sleeve 8 causes the pressure of the fluid to drop. Therefore, as shown in FIG. 14, the completion component 1 may further comprise an annular protection element 34 arranged to circumferent the tubular metal part 6 and arranged between the expansion opening 12 and the second end part 15 of the expandable sleeve 8. The annular protection element 34 comprises a flow channel 35 providing fluid communication between the expansion opening 12 and the annular space 11 in the first condition. A sealing element 39 is arranged between the annular protection element 34 and the tubular metal part 6. The annular protection element 34 is made of PEEK, PTFE or similar material. The annular protection element 34 is fastened to the first connection part 16 in the first condition in a first position by means of a second breakable element 36. The annular protection element 34 has an inner diameter ID1 being less that an inner diameter ID2 of the first connection part 16 so that part of an end face 45 of the annular protection element 34 is exposed to the fluid entering the expansion opening 12 so that if the expandable sleeve 8 bursts during expansion, the fluid from the expansion opening 12 presses onto the end face of the annular protection element 34, breaking the breakable element 17 and moving the annular protection element 34 to a second position, as shown in FIG. 15, since the flow channel 35 restricts the flow of fluid and creates higher pressure on the exposed end side than in the annular space 11. When the annular protection element 34 has moved to the second position in which the annular protection element 34 abuts the second end part 15 of the expandable sleeve 8, the annular protection element 34 prevents any flow of fluid from the expansion opening 12 to the annular space 11. Thus, when expanding several expandable sleeves 8 of completion components 1, the pressure in the well tubular metal structure 3 can still be increased even if one expandable sleeve 8 bursts as the annular protection element 34 prevents pressure drops, and the other expandable sleeves 8 can still be expanded.

The first connection part 1 is annular and circumferents the tubular metal part 6 and part of the second end part 15 of the expandable sleeve 8. The second connection part 16B is annular and circumferents the tubular metal part 6 and part of the first end part 14 of the expandable sleeve 8. The sleeve end part 25 is also annular and circumferents the tubular metal part 6.

In FIG. 16, a downhole system 100 comprises a first well tubular metal structure 3 and a first completion component 1, 1A and a second completion component 1, 1B, where each of their tubular metal parts 6 is mounted as part of the first well tubular metal structure. The first and second completion components 1, 1A, 1B are arranged so that the first completion component 1A is arranged opposite the second completion component 1B in that the second connection part 16B of the first completion component 1A is arranged next to the second connection part 16B of the second completion component 1B. The first completion component 1A is fluidly connected to the second completion component 1B by a flow line 43 extending through a protection valve assembly 42. Initially, the first and second completion components 1A, 1B are connected to the bore within the first well tubular metal structure 3 through an expansion opening 12. Upon activation, i.e. pressurising the first well tubular metal structure and letting the fluid in through the expansion openings 12, the first and second completion components 1A, 1B are thus fluidly connected. After expansion, they are connected to the confined space 5 in the annulus between the expandable metal sleeves 8 so that if the pressure in the first zone is higher than the pressure inside the completion components 1A, 1B, the pressure will propagate through the unidirectional seals 23C into the first completion component 1A, into the flow line 43 between them and into the second completion component 1B and vice versa; if the pressure in the second zone is higher than the pressure inside the completion components 1A, 1B, the pressure will propagate through the unidirectional seals 23C into the second completion component 1B, into the flow line 43 between them and into the first completion component 1A. In order to provide this pressure compensation, the first connection parts 16 are provided with the unidirectional seals 23C allowing fluid communication from the annulus 105 to the annular space 11 but not from the annular space 11 to the annulus 105.

In FIG. 17, the downhole system 100 has another valve assembly 42B having a filter 51 in communication with the confined space before and during expansion of the expandable sleeves 8 of the completion components 1A, 1B and after expansion connects the annular space 11 in the first and second completion components 1A, 1B so that the flow line 43 connects the completion components 1A, 1B in the same way as in FIG. 16. The valve assembly 42B is fluidly connected to the expansion opening 12 so that expansion of the completion components 1A, 1B occurs via the valve assembly 42B and the flow line 43. The valve assembly 42B may comprise an overpressure valve in the opening in fluid communication with the confined space, should the pressure rise in the confined space after the expandable metal sleeves 8 have been expanded so that the higher pressure in the confined space is pressure-equalised into the completion components 1A, 1B.

The completion component 1 comprises in FIGS. 18A and 18B another locking arrangement for locking the first connection part 16 in the second condition. The end piece 19 comprises a projection 28B as shown in FIG. 18A functioning as the locking element for locking the first connection part 16 in the second condition when sliding to fit into the groove 29 in the first connection part 16, as shown in FIG. 18B. The part 37 of the end piece 19 fastened to the tubular metal part 6 is forced to bend by an inclined face 53 of the first connection part 16 when the first connection part 16 moves past the part 37.

During deployment of the well tubular metal structure 3 with the completion component 1, the well tubular metal structure 3 is often rotated as it is run in hole. In order to prevent the first connection part 16 from rotating during deployment, the completion component 1 may further comprise an anti-rotation element 54 as shown in FIG. 19. The anti-rotation element 54 is arranged in a first groove 56 extending along the axial extension L in the first connection part 16 and a second groove 55 extending into the end piece 19 and also along the axial extension L, as illustrated with dotted lines. In FIG. 20, another anti-rotation solution is shown, where the breakable element 17 is engaging both into the first connection part 16 and the end piece 19, as illustrated with dotted lines.

The invention further relates to a cementing method of providing cement or even a cement plug in an annulus between the well tubular metal structure and a wall of a borehole or a second well tubular metal structure. The cementing method comprises mounting a tubular metal part of a completion component as part of the well tubular metal structure, lowering the well tubular metal structure into the borehole, expanding the expandable sleeve by pressurising the well tubular metal structure with cement until the predetermined pressure differential is reached, providing an aperture allowing fluid communication between the expansion opening and the annulus, letting cement out through the aperture and into the annulus. In that way, a one-run cementing method is provided as both the annular barrier provided a lower stop for the cement, and the cementing job can be performed in one continuous run. The fluid expanding the expandable metal sleeve may be any kind of liquid such as salt water arranged in front of wiper dart dividing the liquid and the subsequent cement.

By “fluid” or “well fluid” is meant any kind of fluid that may be present in oil or gas wells downhole, such as natural gas, oil, oil mud, crude oil, water, etc. By “gas” is meant any kind of gas composition present in a well, completion or open hole, and by “oil” is meant any kind of oil composition, such as crude oil, an oil-containing fluid, etc. Gas, oil and water fluids may thus all comprise other elements or substances than gas, oil and/or water, respectively.

By “annular barrier” is meant an annular barrier comprising a tubular metal part mounted as part of the well tubular metal structure and an expandable metal sleeve surrounding and connected to the tubular metal part defining an annular barrier space.

By “casing” or “well tubular metal structure” is meant any kind of pipe, tubing, tubular, liner, string, etc., used downhole in relation to oil or natural gas production.

Although the invention has been described above in connection with preferred embodiments of the invention, it will be evident to a person skilled in the art that several modifications are conceivable without departing from the invention as defined by the following claims.