Select Port Injection Collar Device and Method of Use

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to and claims priority from earlier filed U.S. Provisional Patent Application No. 63/714,114, filed Oct. 30, 2024, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to a device and method for controlling the flow of injected chemicals inside an oil well or gas well. This disclosure relates to a select port chemical injection collar device used in wellbore operations and a method for using a single device to selectively inject fluids into a production tubing string, well annulus, or a downhole apparatus, such as a downhole pump.

2. Description of Related Art

Subsurface wells, used for extraction of fluid or gaseous media from a subsurface formation reservoir, typically contain a tubular pipe string extending to or through the reservoir. The tubular pipe string may be permanently set in place by anchors or cementing. Through the casing, additional tubular strings may be nested (e.g., a production tubing string). Nested tubing string may have an internal diameter or various staggered diameters sufficient to provide the desired pressure, velocity, and volume of media to the surface for collection. Tubing strings are most often comprised of lengths of metal pipe or “joints” of a certain diameter and wall thickness. The pipe is of nominal length and most often enlarged or “upset” on each end, as well as threaded externally for connection to a threaded coupling or collar. A collar is a larger diameter short piece of cylindrical metal of sufficient thickness and diameter to accommodate internal threads sized to fit the threaded ends of the tubing joints. The production tubing string comprises lengths of tubing joints connected with collars to achieve the desired depth of the production tubing string. An oil well or gas well relies on inflow and internal flow of petroleum products to and through the production tubing string. When natural reservoir inflow to a well is reduced or internal flow within well production tubing string is reduced, often the operator employs a wellbore treatment such as chemical injection. This is accomplished by pumping fluids such as acids, solvents, cleaners, or stimulation fluids from a surface storage supply into the well to improve well production.

Current methods include introducing treatment chemicals in various forms at the top surface of the well and releasing or pumping in volume in order to reach and treat a problem area. This method often proves wasteful and inefficient.

Other current methods involve the use of small flexible tubing strings placed within a well at specific depths for the direct delivery of treatment chemicals to predetermined locations within the wellbore. These “capillary strings” may be installed internally and/or externally in the production tubing string. Capillary strings convey the treatment chemical directly to the installed depth and may be terminated with various means.

A typical external production tubing string termination method utilizing a capillary string for chemical delivery includes the use of a side pocket mandrel. Side pocket mandrels are installed in the tubing string at a predetermined location along the length of the production tubing string and may serve as a termination point for the capillary tubing string. The side pocket connection or “lug” may be formed integral to a downhole tool or fixed to a length of tubing called a “tubing sub” by permanent means such as welding. Prior art side pocket lugs include threaded connections for connection of bottom hole tools, such as a chemical injection valve, that are connected to the capillary tubing string. Current lugs are configured for fluids or chemicals to flow either into or outside of the production tubing string and into the media stream or reservoir. With current devices, the fluid flow path must be selected at the time of manufacture of the side pocket lug before installation into a well. As a result, the current art requires a different piece of equipment for each type of installation, such that the particular equipment will allow for injecting chemical specifically into either the production tubing string, the well annulus, or a downhole apparatus, such as a downhole pump.

Another problem seen with current devices is the common practice of welding a side pocket lug to an outside wall of a tubing string which, while practical, often results in problems such as leaks, premature corrosion, metallurgy changes, and misalignment. Due to the nature of the welded joint design of a welded lug arrangement, space exists between the tubing joint outer wall and the interior surface of the side pocket lug, which space cannot be sealed in a practical manner. This space often provides a reservoir for highly caustic or powerful chemicals to pool, resulting in premature corrosion. This condition results in side pocket mandrel lug failure, which may lead to production tubing string failure. These and other problems lead to reduced well efficiency and lost production.

Another possible failure scenario exists with current devices and methods due to the close proximity of the installed device, in the side pocket mandrel connection, with the interior wall of the well casing. Installed devices, such as a chemical injection valve, are often damaged during installation or removal of the production tubing string in the well. With current devices, a chemical injection valve is typically installed on top of the side pocket mandrel connection, leaving the chemical injection valve completely exposed within the well casing and production tubing string annulus. Ideally, the diameter of the installed chemical injection valve is smaller than the diameter of the side pocket mandrel lug. However, this smaller diameter reduces fluid flow capacity through the valve compared to the well operator's desired flow rate. Therefore, a larger diameter chemical injection valve often is installed to achieve the desired chemical flow rate. This increases the likelihood of an interference issue—the production tubing string may drift and collide with the interior surface of the well casing as it travels within the well during installation or removal, causing damage, fractures, or misalignment of the installed chemical injection valve in the side pocket mandrel lug. This results in leakage of chemicals or other inoperable conditions, increasing well servicing costs and lost well production.

In view of the foregoing, it is apparent that a need exists in the art for a select port injection collar device and method of use which overcomes, mitigates or solves the above problems in the art. It is a purpose of this invention to fulfill this and other needs in the art which will become more apparent to the skilled artisan once given the following disclosure.

OBJECTS AND SUMMARY OF THE INVENTION

It is an object of the present invention to overcome the above-described drawbacks associated with current devices and methods used to inject chemicals directly into the production tubing string at a selected depth, without obstructing production flow. To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described, the present disclosure describes a select port injection collar device and method for injecting fluids selectively into a well annulus, tubing collar bore, or through the outlet of the collar fluid flow-through chamber to a downhole apparatus, such as a downhole pump.

In oil and gas well construction, tubing collars are installed at every joint connection along a tubing string. The disclosed injection collar device is a specialized tubing component that provides a fixed chemical injection point downhole. The disclosed device is configured to receive and releasably retain chemical injection valve cartridges. By connecting a surface chemical supply to a chemical injection valve cartridge housed in an internal chamber of the collar device, treatment fluids can be accurately delivered into a wellbore, improving flow assurance, protecting equipment, and enhancing production efficiency.

The disclosed collar device comprises an internal chamber containing connection means for attachment of downhole tools such as a chemical injection valve cartridge. Internal cavities and passages for fluid flow and discharge are provided with communication to multiple discharge ports which may be deselected or plugged by means of pipe plugs (e.g., a threaded plug or any other member, such as a stopper, cap, etc., arranged and configured to permanently or temporarily seal off, close or block an opening or port). The installer or operator can select the flow path or paths of treatment chemicals through the disclosed device via their selection of discharge ports to be isolated.

The disclosed collar device includes a chamber designed to meet the specifications of a side pocket mandrel. This collar is adapted to replace any tubing collar in a production tubing string and may be positioned at any desired depth. The disclosed collar includes multiple ports for injecting chemicals through one of three fluid flow paths formed integrally within the collar. The discharge ports of the disclosed injection collar may be internally threaded to accept a plug member. The plug members are insertable and removable by an operator or installer to select a desired treatment fluid flow path, thereby eliminating the need for multiple devices to accommodate different flow path scenarios.

Further, the disclosed collar device with an integral collar fluid flow-through chamber comprises a unique chemical injection valve arranged and configured as a modular cartridge, herein referred to as a chemical injection valve cartridge, that provides many advantages over current designs. The injection valve cartridge eliminates potential failures due to possible collision or interference issues within a well annulus during removal or installation of the production tubing string into the well. The disclosed device incorporates integral guide and protection features in the collar fluid flow-through chamber, which is configured as a housing for the injection valve cartridge, to protect the chemical injection valve cartridge from physical damage, thereby increasing reliability by decreasing the risk of damage to the injection valve cartridge. Additionally, the chemical injection valve cartridge receptacle or cavity formed in the disclosed collar device provides for increased flow capacity. The increased diameter and space of the cartridge receptacle allow for connection of larger internal injection valve components. Furthermore, the modular chemical injection valve cartridge design can be custom designed and configured with multiple features such as redundant check valves and as an integral point of injection anti-syphon valve. Finally, the valve cartridge design is arranged and configured for adjusting closed and cracking pressure by means of a pressure adjustment screw, shims, or spacers.

These, together with other objects of the invention, along with various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages, and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there are described illustrative embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the present invention, and together with the description, serve to explain the principles of the invention. It is to be expressly understood that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. In the drawings:

FIG. 1 is a sectional side view of a select port injection collar device constructed in accordance with the teachings of the present disclosure.

FIG. 2 is a sectional side view of a select port injection collar device constructed in accordance with the teachings of the present disclosure.

FIG. 3 is a sectional side view of a select port injection collar device constructed in accordance with the teachings of the present disclosure.

FIG. 4 is a sectional side view of a select port injection collar device constructed in accordance with the teachings of the present disclosure.

FIG. 5 is a sectional side view of a select port injection collar device constructed in accordance with the teachings of the present disclosure.

FIG. 6 is a sectional side view of a select port injection collar device constructed in accordance with the teachings of the present disclosure.

FIG. 7 is a front view of a select port injection collar device constructed in accordance with the teachings of the present disclosure.

FIG. 8 is a sectional side view of a spring retainer constructed in accordance with the teachings of the present disclosure.

FIG. 9 is a sectional side view of a spring retainer constructed in accordance with the teachings of the present disclosure.

FIG. 10 is a top view of a spring retainer constructed in accordance with the teachings of the present disclosure.

FIG. 11 is an exploded side view of a chemical injection valve cartridge constructed in accordance with the teachings of the present disclosure.

FIG. 12 is an exploded sectional side view of a chemical injection valve cartridge constructed in accordance with the teachings of the present disclosure.

FIG. 13 is a sectional side view of a chemical injection valve cartridge constructed in accordance with the teachings of the present disclosure.

FIG. 14 is a side perspective view of a select port injection collar device constructed in accordance with the teachings of the present disclosure.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Exemplary embodiments of injection collar devices in accordance with the present disclosure are discussed herein. Many other uses of the present invention will become obvious to one skilled in the art upon acquiring a thorough understanding of the present invention. Once given the below disclosures, many other features, modifications and variations will become apparent to the skilled artisan in view of the teachings set forth herein. Such other features, modifications and variations are, therefore, considered to be a part of this invention.

Turning to FIG. 1, the illustrated select port injection collar device 20 comprises a tubular member 21, such as the illustrated tubing collar 21, wherein the tubing collar 21 comprises a tubing collar bore 22 having an inlet end 30 and an outlet end 29, said tubing collar bore being configured to receive reservoir fluids therethrough. The collar 21 further comprises one or more collar bore ports 32 formed through a collar wall 36 for directing injected fluids into the collar bore 22. The illustrated select port injection collar device 20 further comprises a chemical injection valve cartridge 23. A tubing connector 31 connects a capillary line 24 to the chemical injection valve cartridge 23. The illustrated chemical injection valve cartridge 23 is received in a cavity or cartridge receptacle 54 formed in a collar fluid flow-through chamber 26. The flow-through chamber 26 comprises an internal cartridge receptacle 54 connected to an internal spring receptacle 55, which is connected to an outlet discharge port 56.

FIG. 1 depicts a chemical injection valve cartridge assembly 23 installed in the cartridge receptacle 54. The disclosed chemical injection valve cartridge 23 is arranged and configured such that the injection valve cartridge is releasably attachable, removable, and the cartridge is configured as a replaceable insert. The disclosed chemical injection valve cartridge can be removed and replaced without replacing the entire tubing collar with integral fluid flow-through chamber 26. This arrangement allows the chemical injection valve cartridge assembly 23 to be custom designed and changed to a user's specifications.

As illustrated in FIGS. 2-7, the collar fluid flow-through chamber 26 comprises multiple fluid flow passages. The primary fluid flow passage 39 extends through the length of the flow-through chamber 26. The primary fluid flow passage 39 directs injected fluid through the length of the fluid flow-through chamber and through any connected tubing or apparatus, such as to a downhole pump (not depicted). FIG. 1 depicts a tubing connector assembly 28 configured for connection to tubing called a tail pipe. The tubing connector assembly 28 is configured to connect to an outlet discharge port 56 of the flow-through chamber 26, and the tubing connector assembly 28 allows fluid to flow through the connector assembly and into any connected tubing or apparatus. The tubing connector assembly 28 may connect the flow-through chamber 26 to a tail pipe (not shown), which tail pipe can connect directly to the inlet of a downhole apparatus or which tail pipe can deliver injected fluids indirectly to a downhole apparatus, such as a pump. This creates a primary fluid flow passage that allows injected fluids to flow through the collar fluid flow-through chamber 26 and through the tubing connector assembly 28 and into any connected tubing or apparatus, such as to a downhole pump. Alternatively, a plug member 27, as illustrated in FIGS. 4-5, can be inserted or installed into the outlet discharge port 56 to plug and seal off the outlet discharge port and change the fluid flow path of the injected fluid into either the well annulus (see FIG. 5) or into the collar tubing bore (see FIG. 4).

The collar fluid flow-through chamber 26 of the disclosed device is arranged and configured as an integral chamber formed inside a 36 of a tubing collar 21. The flow-through chamber 26 further comprises one or more secondary fluid flow passages 37 (see FIG. 7) that each extend between a collar bore port 32 and an annulus port 38. The bore ports 32 allow injected fluids to flow into the tubing collar bore and the annulus ports 38 allow injected fluids to flow into a well annulus.

As illustrated in FIG. 7, the secondary fluid flow passages 37 may obliquely intersect the primary fluid flow passage 39. In FIG. 7, two secondary fluid flow passages 37 are illustrated. Whereas two or four secondary fluid flow passages 37 may be the most common design of the disclosed injection collar device, the present disclosure anticipates one or more secondary fluid flow passages 37 formed in the flow-through chamber 26. The flow-through chamber 26 has one or more apertures 38 on its top surface defined as annulus ports 38. The apertures in the flow-through chamber 26 top surface create the fluid flow path into the well annulus. Thereby, the flow-through chamber 26 is arranged and configured to provide three separate fluid flow paths into either the annulus, tubing collar bore, or through the outlet of the flow-through chamber to a downhole apparatus, such as a downhole pump.

Turning to FIG. 3, a method and configuration for creating a primary fluid flow passage through the collar fluid flow-through chamber 26 to a downhole apparatus, such as a downhole pump, is illustrated. In this drawing, socket head pipe plugs 27 seal off the one or more annulus ports 38 and the one or more collar bore ports 32 of the flow-through chamber 26. The primary fluid flow passage 39 extends through the fluid flow-through chamber formed in the tubing collar wall 36 from the inlet face 57 to the outlet face 58 of the flow-through chamber 26. When the annulus ports 38 and the collar bore ports 32 are sealed off by plug members 27, the primary fluid flow passage 39 directs injected fluid through the flow-through chamber 26, through a tubing connector assembly 28, and through a tail pipe or any other connected tubing or apparatus.

In FIG. 4, the collar fluid flow-through chamber 26 is arranged to direct fluid flow into the collar bore 22. Here, socket head pipe plugs 27 seal off the outlet discharge port 56 and the one or more annulus ports 38. This forces chemical to flow through the flow-through chamber 26 and through the collar bore ports 32 and into the tubing collar bore 22 and directly into the production flow stream.

In FIG. 5, the flow-through chamber 26 is arranged to direct fluid flow into the annulus of a well. Here, socket head pipe plugs 27 seal off the collar bore ports 32 and the outlet discharge port 56. This forces chemical to flow through the flow-through chamber 26 and out of the annulus ports 38, establishing a fluid flow path into the annulus of the well.

The drawings illustrate pipe plugs 27 configured as threaded socket head pipe plugs. Additionally, the drawings illustrate the chamber with receptacles configured to receive and releasably retain the pipe plugs 27. As will be understood by those skilled in the art, the plug members 27 may be defined as a threaded plug or any other plug member, such as a stopper, cap, etc., arranged and configured to temporarily or permanently seal off, close, or block an opening or port. Likewise, the plug receptacles can be configured in any way to receive and retain—releasably, permanently, or temporarily—the plug members. In other embodiments anticipated by the present disclosure, the flow-through chamber may be configured to only provide one fluid flow passage for injecting chemical into one of the following: production tubing string, annulus, or downhole pump. Alternatively, in other embodiments anticipated by the present disclosure, the flow-through chamber may be configured to provide two or more fluid flow passages for injecting chemical.

Turning to FIGS. 6-7, FIG. 6 is a sectional side view of a select port injection collar device 20 illustrating a sectional view through one of the secondary fluid flow passages 37. A front view, shown in FIG. 7, shows two secondary fluid flow passages 37, two annulus ports 38, and two collar bore ports 32. As illustrated in FIG. 7, the secondary fluid flow passages 37 may obliquely intersect the primary fluid flow passage 39. As shown in FIG. 1, the secondary fluid flow passages 37 may be formed to intersect a spring receptacle 55. In certain embodiments, the spring 52 disposed in the spring receptacle 55, must be removed to insert a plug member to seal off the collar bore ports. In other embodiments, the secondary fluid flow passages 37 may be disposed at wider angles such that the spring 52 does not have to be removed from the spring receptacle 55 when inserting or removing a plug member to seal off or open the collar bore ports.

In FIGS. 11-13, the chemical injection valve cartridge 23 comprises a cartridge housing 37 that connects to a cartridge retainer 51 to retain the cartridge components inside the chemical injection valve cartridge assembly 23. A sealing member 40, such as an O-ring, may be disposed around the cartridge housing 37, as depicted in FIG. 1. The illustrated chemical injection valve cartridge assembly 23 comprises a primary check valve and a secondary check valve. The check valves allow chemical to flow into the flow-through chamber 26, while preventing backflow of well fluids into the capillary line 24. In the attached figures, the primary check valve and secondary check valve are depicted as ball-and-spring check valves, but other check valves known to those skilled in the art may be used (e.g., flapper check valve, wafer check valve, dart check valve, etc.). The illustrated secondary or backup check valve 41 is disposed inside the cartridge housing, which cartridge housing comprises a ball seat 59. A resilient member, such as a conical spring 42, holds the check ball 41 under tension against the ball seat 59 in the cartridge housing 37. The spring 42 is held in place by a spring retainer 43. The spring retainer 43 comprises a slot 44 arranged to prevent the check ball 41 from obstructing the chemical injection valve 23 in the event of a spring malfunction. A primary valve seat 46 is disposed against the spring retainer 43. FIG. 1 depicts a seal 45 that passes around the top circumference of the primary valve seat 46. Additionally, FIGS. 11 and 12 depict a seal, such as an O-ring 48 and two backup O-rings 47. The O-ring 48 and two backup O-rings 47 may pass around the middle circumference of the primary valve seat 46. A primary check valve 49 is disposed against the primary valve seat 46. A ball stand 50 holds the check ball 49 in the correct position relative to the primary valve seat 46, limits movement of the check ball 49, and provides proper alignment and stability during operation of the injection valve 23. A cartridge retainer 51 connects with the cartridge housing 37 to retain all the components inside the chemical injection valve cartridge 23.

This chemical injection valve cartridge assembly 23 is a releasably attachable, removable, and replaceable cartridge. The cartridge assembly can be modified as needed and the cartridge assembly can be quickly installed or uninstalled in the cartridge receptacle 54 of the flow-through chamber 26. The drawings illustrate threaded connections for installing and uninstalling the cartridge assembly. Other methods of connection known by those skilled in the art may be utilized to install and uninstall the cartridge assembly 23 in the cartridge receptacle 54 of the flow-through chamber 26.

As illustrated in FIGS. 8-10, the chemical injection valve cartridge assembly may include a spring retainer 43 for holding the spring 42 in place in the cartridge. In one embodiment anticipated by the present disclosure, the spring retainer 43 comprises a non-circular slot 44 arranged to prevent a check ball 41 from obstructing the chemical injection valve 23 in the event of a spring malfunction. Rather than designing the slot 44 as a circular aperture, which would allow the check ball to fall through and obstruct or plug the chemical injection valve 23 in the case of a spring failure, the disclosed spring retainer 43 may include a non-circular slot 44 configured to ensure that the check ball 41 does not obstruct or plug the chemical injection valve 23 if the spring 42 fails.

Additionally, as illustrated in FIG. 1, a spring receptacle 55 for receiving a spring 52 is formed in the flow-through chamber 26. As depicted in FIG. 1, a spring 52 and shim spacers 53 may be disposed in the spring receptacle 55. The shim spacers 53 provide a means of adjusting pressure. Shim spacers 53 may be added or deleted as needed to increase or decrease the set pressure.

It is important to note that the construction and arrangement of the elements of the invention provided herein are illustrative only. Although only a few exemplary embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible in these embodiments (such as variations in orientation of the components of the system, sizes, structures, shapes and proportions of the various components, etc.) without materially departing from the novel teachings and advantages of the invention.

Many other uses of the present invention will become obvious to one skilled in the art upon acquiring a thorough understanding of the present invention. Once given the above disclosures, many other features, modifications and variations will become apparent to the skilled artisan in view of the teachings set forth herein. Such other features, modifications and variations are, therefore, considered to be a part of this invention, the scope of which is to be determined by the following claims.