(12) Umted States Patent
`(10) Patent N0.:
`US 6,902,006 132
`
`Myerley et al.
`(45) Date of Patent:
`Jun. 7, 2005
`
`U5006902006B2
`
`(54) LOCK OPEN AND CONTROL SYSTEM
`ACCESS APPARATUS AND METHOD FOR A
`DOWNHOLE SAFETY VALVE
`
`(75)
`
`Inventors: Thomas S. Myerley, Broken Arrow,
`OK (US); Scott C. Strattan, Tulsa, OK
`(U5); Van J- MCViCker> Btekeh Att0W>
`OK (US)
`(73) Assigneer Baker Hughes Incorporated, Houston,
`TX (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 58 days.
`
`(21) Appl. No.: 10/263,946
`
`(22)
`
`Filed:
`
`Oct. 3, 2002
`
`(65)
`
`Prior Publication Data
`
`US 2004/0065442 A1 APR 8, 2004
`(51)
`Int. Cl.7 ................................................ E21B 43/12
`
`(52) US. Cl. ........................ 166/373: 166/332.8
`(58) Field of Search
`166/332 8 332 4
`""""""166/318 ”323 373 '3’74 3'75’
`’
`’
`’
`’
`
`(56)
`
`.
`References Clted
`U.S. PATENT DOCUMENTS
`2 974 922 A
`3/1961 Keithahn
`4,420,041 A
`12/1983 Patel
`4,437,516 A
`3/1984 Cockrell
`4,566,541 A *
`1/1986 Moussy et a1.
`
`............. 166/318
`
`4,574,889 A
`4,577,694 A
`4,585,067 A
`4,624,315 A
`4513:3243?) 2
`53109005 A
`5:564:675 A
`6,059,041 A
`6 125 930 A
`6:575:249 B2 *
`6,619,388 B2 *
`2001/0007284 A1
`
`3/1986 Pringle
`3/1986 Bfakhage; JR
`4/1986 Blizzard et 211.
`11/1986 Dickson et a1.
`15/133? film;
`t
`1
`5/1994 13:31sz 6 ‘1'
`10/1996 Hill, Jr. et 211.
`5/2000 Scott
`10 2000 M0 es
`6/2003 Deayton ....................... 166/373
`9/2003 Dietz et a1.
`.............. 166/3328
`7/2001 French et a1.
`
`* cited by examiner
`
`Primary Examiner—David Bagnell
`Assistant Examiner—Matthew J. Smith
`(74) Attorney, Agent, or Firm—Steve Rosenblatt
`
`(57)
`
`ABSTRACT
`
`.
`.
`.
`A lock open devrce for a flapper IS dlsclosed. The tool
`engages in the sub-surface safety valve (SSSV) body and
`tetates the flapper t0 the Open Pesttieth Without Shifting the
`flow tube. The flapper base IS preferably held by a shearable
`thread and has a groove for engagement by the tool. The tool
`jars down on the flapper base to shear the thread and force
`the held open flapper into a retaining groove. Optionally, a
`penetrating tool can be connected so that, in a single trip, the
`flapper can be locked open and the pressurized control
`system can be accessed. Shearing the thread allows the flow
`tube spring to bias the held open flapper into its retaining
`groove‘
`
`20 Claims, 22 Drawing Sheets
`
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`Jun.7,2005
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`Jun.7,2005
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`US 6,902,006 B2
`
`1
`LOCK OPEN AND CONTROL SYSTEM
`ACCESS APPARATUS AND METHOD FOR A
`DOWNHOLE SAFETY VALVE
`
`FIELD OF THE INVENTION
`
`The field of this invention is lock open devices for
`sub-surface safety valves (SSSV) and related techniques for
`gaining access to the pressurized control system for subse-
`quent operation of an inserted replacement.
`BACKGROUND OF THE INVENTION
`
`SSSVs are normally closed valves that prevent blowouts
`if the surface safety equipment fails. Conditions can arise
`where the SSSV fails to function for a variety of reasons.
`One solution to this situation has been to lock open the
`SSSV and to gain access into the pressurized control system
`that is used to move the flow tube to push the flapper into an
`open position against the force of a closure spring that urges
`the valve into a closed position. Thereafter, a replacement
`valve is delivered, normally on wireline, and latched into
`place such that the newly formed access to the control
`system of the original valve is now straddled by the replace-
`ment valve. This allows the original control system to be
`used to operate the replacement valve.
`There have been several variations of lock open devices
`in the past. US. Pat. No. 4,577,694 assigned to Baker
`Hughes teaches the use of a flapper lock open tool (FLO)
`which delivers a band of spring steel
`to expand when
`retaining sleeves on the FLO tool are retracted. The tool
`latches inside the SSSV and with the flow tube in the
`
`flapper-closed position the band is released. This design
`offered the advantages of the lockout device not being
`integral to the SSSV. Instead it was only introduced when
`needed through a wireline. Another advantage was that the
`release of the band did no damage to the SSSV or the FLO
`tool. The band expanded into a recessed area so as to allow
`full-bore through-tubing access. The flow tube did not have
`to be shifted so that no spring forces acting on the flow tube
`had to be overcome to actuate the FLO tool. Subsequently,
`when the SSSV was retrieved to the surface, the band was
`easily removed by hand without special tools. The FLO tool
`had safety features to prevent premature release or incorrect
`placement. The FLO tool did not require fluid communica-
`tion with the control system, as its purpose was solely
`flapper lock out.
`The FLO tool did have some disadvantages. One was that
`the band could become dislodged under high gas flow rates.
`The tool was complicated and expensive to manufacture.
`The expanding ring presented design challenges and
`required stocking a large variety to accommodate different
`conditions. The running method required two wireline trips
`with jar-down/j ar-up activation.
`US. Pat. No. 4,574,889 assigned to Camco, now
`Schlumberger, required latching in the SSSV and stroking
`the flow tube down to the valve open position. The flow tube
`would then be outwardly indented in the valve open position
`so that the indentations would engage a downwardly ori-
`ented shoulder to prevent the flow tube from moving back to
`the valve closed position. This design had some of the
`advantages of the Baker Hughes FLO design and could
`accomplish the locking open with a single wireline trip. The
`disadvantages were that
`the flow tube was permanently
`damaged and that the flow tube had to be forced against a
`closure spring force before being dimpled to hold that
`position. This made disassembly of the SSSV with the flow
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`tube under spring pressure a potentially dangerous proposi-
`tion when the valve was later brought to the surface.
`
`US. Pat. No. 5,564,675 assigned to Camco, now
`Schlumberger, also involved forcibly pushing the flow tube
`against the spring to get the flapper into the open position.
`In fact, the flow tube was over-stroked to push the actuator
`piston out of its bore in the pressurized control system, at
`which point
`the piston would have a portion splay out
`preventing its re-entry into the bore, thereby holding the
`flow tube in the flapper open position. This design had the
`safety issues of disassembly at the surface where the flow
`tube was under a considerable spring force. Additionally,
`fluid communication into the control system was not an
`option when locking open using this tool.
`
`US. Pat. No. 6,059,041 assigned to Halliburton uses a
`tool that forces the flow tube down to get the flapper in the
`open position. It then releases a band above the flow tube
`that lodges on a downwardly oriented shoulder to hold the
`flapper open. This system has the risk of a flow tube under
`a spring force causing injury when later disassembled at the
`surface. This tool is fluid activated and must overcome the
`
`spring force to get the flow tube to the flapper open position.
`Finally, the tool is fluid pressure actuated, which will require
`a long fluid column to eventually communicate with the
`formation, a particular disadvantage in gas wells.
`
`Also of interest in the area of lock open devices for SSSVs
`are US. Pat. Nos. 4,624,315; 4,967,845 and 6,125,930
`(featuring collet fingers on the end of the flow tube that
`engage a groove in the SSSV body).
`
`The present invention addresses these shortcomings by
`providing a technique to use a tool to get the flapper open
`without shifting the flow tube. In the preferred embodiment
`the flapper base is shifted with the flapper in the open
`position to trap the flapper in the open position. The closure
`spring that normally biases the flow tube into the flapper
`closed position is employed after the flapper base is liberated
`to bias the held-open flapper into its retaining grove. The
`lock open feature can be combined with stroking an oriented
`penetrating tool into the control system conduit for access to
`operate a subsequently installed valve to replace the locked
`open SSSV. The penetration step is not required to obtain the
`lock open state. Optionally the flapper base can be retained
`in its normal operating position by a shearable thread to
`allow taking advantage of a metal-to-metal sealing feature of
`the thread. These and other advantages of the present
`invention will become more readily apparent to those skilled
`in the art from a review of the description of the preferred
`embodiment and the claims appended below.
`
`SUMMARY OF THE INVENTION
`
`A lock open device for a flapper is disclosed. The tool
`engages in the sub-surface safety valve (SSSV) body and
`rotates the flapper to the open position, without shifting the
`flow tube. The flapper base is preferably held by a shearable
`thread and has a groove for engagement by the tool. The tool
`jars down on the flapper base to shear the thread and force
`the held open flapper into a retaining groove. Optionally, a
`penetrating tool can be connected so that, in a single trip, the
`flapper can be locked open and the pressurized control
`system can be accessed. Shearing the thread allows the flow
`tube spring to bias the held open flapper into its retaining
`groove.
`
`MEGCO EX. 1012
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`MEGCO Ex. 1012
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`

`US 6,902,006 B2
`
`3
`DETAILED DESCRIPTION OF THE DRAWINGS
`
`FIGS. 1a—le are a section view of the SSSV in the closed
`
`position;
`FIGS. 2a—Ze are a section view of the SSSV with the lock
`
`5
`
`open tool latched;
`FIGS. 3a—3e show the collets freed at the base of the tool
`
`to push the flapper into the fully open position;
`FIGS. 4a—4e are a section view showing the flapper base
`engaged by the tool just before the threads shear;
`FIGS. 5L1—56 are a section view with the flapper base
`sheared and the flow tube spring acting on the flapper base
`to retain the flapper in the lock open recess;
`FIGS. 6a—6e show the SSSV in section with the lock open
`tool removed;
`FIGS. 7a—7c shows the addition of the penetrating tool
`above the lock open tool;
`FIG. 8 is the penetrating tool after rotation;
`FIG. 9 is the penetrating tool after penetration;
`FIG. 10 shows the flapper in the normal operating closed
`position with an enlarged hinge diameter; and
`FIG. 11 is the view of FIG. 10 with the enlarged hinge
`diameter forced down into interference with an adjacent
`reduced bore diameter.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENT
`
`The sub-surface safety valve is illustrated in the closed
`position for the flapper 12, in FIG. 1. Spring 16 bearing on
`shoulder 18 biases the flow tube 14 upwardly. Flapper 12 is
`secured to flapper base 20 at pivot 22. Spring 24 biases
`flapper 12 to the closed position shown in FIG. 1d. Flapper
`base 20 is secured by sleeve 26 to body 28. That connection
`is preferably by a thread 30. Thread 30 is designed to release
`under a predetermined force applied to flapper base 20.
`Other retainers that selectively release such as shear pins or
`collets can be used instead of thread 30 as contemplated in
`alternative forms of the present invention. Apiston 32 sees
`pressure from a control line extending from the surface (not
`shown) and connected to port 34. Piston 32 engages groove
`36 to push the flow tube 14 down against the force of spring
`16. Grooves 38 and 40 are for locating the lock open tool T
`as shown in FIG. 2b. FIG. 1d shows an enlargement of the
`area around thread 30.
`FIGS. 2a—Ze illustrate the initial insertion of the tool T.
`
`Tool T has a mandrel 42 made up of a top sub 44 connected
`to segment 46 at thread 48. Segment 50 is connected to
`segment 46 at thread 52 with the connection held locked by
`screws 54. Segment 56 is held to segment 50 at thread 58
`with the connection locked by screws 60. Segment 56
`further comprises a tapered shoulder 62. Collet retainer 64
`is secured by thread 66 to segment 56 by screws 67. Collet
`retainer 64 comprises an extension segment 68 that defines
`an annular groove 70 in which the lower ends 71 of the
`collets 82 are disposed. The outer assembly 72 fits over the
`mandrel 42 and comprises a top sub 74 retained to segment
`46 of mandrel 42 by a shear pin or pins 76. Segment 75 is
`retained to top sub 74 at thread 77. Projections 79 and 81
`latch respectively into grooves 38 and 40 of body 28 due to
`the flexible nature of segment 75. Segment 78 is retained to
`segment 75 by a shear pin or pins 80. Collets 82 are secured
`to segment 78 by shear pin or pins 84. Collets 82 have an
`internal shoulder 86 for jarring down and an external shoul-
`der 88 to engage groove 90 on flapper seat 20. Flapper seat
`20 can be made of several interconnected parts. Spring 16
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`bears on flapper seat 20 for reasons to be explained below.
`Insertion of tool T results in a partial rotation of the flapper
`12 toward the fully open position. The flapper is in the fully
`open position when in alignment with groove 92 in body
`28as shown in FIGS. 3d—3e.
`
`The significant components now having been described,
`the operation of the tool will be reviewed in detail. The tool
`T is lowered into the valve 10 until projections 79 and 81
`spring into grooves 38 and 40 for latching contact. This
`position is shown in FIGS. 2a—2b. The collets 82 still have
`their lower ends 71 held by collet retainer 64, but
`the
`insertion itself has resulted in partial rotation of flapper 12
`towards its fully open position. Actuating the mandrel 42
`downwardly with a wireline operated jarring tool
`(not
`shown) connected to top sub 44 forces down the mandrel 42.
`Initially, shear pin or pins 76 break as the mandrel moves
`with respect to the outer assembly 72, which is supported to
`body 28 at grooves 38 and 40. Downward movement of the
`mandrel 42 moves collet retainer 64 away from lower ends
`71 of collets 82, allowing them to spring radially outwardly
`so that shoulder 88 engages groove 90 in flapper seat 20.
`This is shown in FIG. 3d. The mandrel 42 continues moving
`down until shoulder 51 on segment 50 engages shoulder 53
`on segment 78 of the outer assembly 72. At this time shear
`pin or pins 80 will break after the application of a prede-
`termined force. When shear pin or pins 80 break, segment 78
`of the outer assembly 72 is driven down until lower end 83
`engages shoulder 86 on collets 82. By this time the collets
`82 have pushed the flapper 12 into the fully open position so
`that it is in alignment with groove 92 in body 28. Movement
`of the lower end 83 of segment 78 breaks shear pin or pins
`84, as shown in FIG. 4d. When a predetermined force is
`applied to shoulder 86 from lower end 83 the thread 30
`holding flapper base 20 to sleeve 26 shears or otherwise fails
`and the flapper base 20 is driven down, now also with the
`help of spring 16 until the flapper 12 has entered groove 92.
`Spring 16 retains flapper 12 in groove 92. Collets 82 insure
`the alignment of flapper 12 with groove 92 as the flapper is
`driven down from the force of the jarring tool on the wireline
`(not shown) acting on mandrel 42 and from spring 16. The
`tool T can now be removed by an upward force on the
`wireline (not shown) and the flapped remains locked in
`groove 92 under the force of spring 16, as shown in FIGS.
`6a—6e. The downward movement of flapper base 20 can be
`purely translation, as described for
`the preferred
`embodiment, or rotation or a combination of both move-
`ments to get the flapper 12 into groove 92.
`Referring to FIGS. 7a—7c, the penetration tool P can be
`added above the lock open tool T. The lock open tool
`terminates near shoulder 51 at thread 95. The assembly of
`the tool T and the tool P are initially suspended in grooves
`38 and 40 as collet 94 springs outwardly. Collet 94 com-
`prises an internal shoulder 96 and a lower end 98, which
`covers window 100. Mandrel 102 is connected to the jarring
`tool (not shown). Shear pin 104 secures sleeve 106 to
`mandrel 102 so that the entire assembly is initially supported
`by collet 94. Outer housing 108 has an exterior shoulder 110
`near its upper end 112. Window 100 is in outer housing 108.
`At its lower end 114, outer housing is attached by shear pin
`80 to segment 78, as previously described. Guide pin 114 is
`biased by spring 116 but lower end 98 of collet 94 holds in
`pin 114 until shear pin 104 is broken. When mandrel 102 is
`advanced after shear pin 104 is broken, pin 114 is pushed out
`by spring 116 to contact spiral ramp 118 that is part of the
`SSSV. Such contact coupled with advancement of the man-
`drel 102 creates rotation as pin 114 advances along spiral
`ramp 118 and toward longitudinal groove 120. Eventually,
`
`MEGCO EX. 1012
`
`MEGCO Ex. 1012
`
`

`

`US 6,902,006 B2
`
`5
`all rotational movement is complete as pin 114 in groove 120
`and shoulder 110 hits shoulder 96. This is the position in
`FIG. 8. Now shear pin 122 can break as mandrel 102 and
`wedge surface 124 push penetrator assembly 126 through
`window 100 and into control system 128 above piston 32
`(see FIG. 9).
`While the rotation to get alignment for penetration is
`going on, the tool T is opening the flapper 12 and latching
`into groove 90 as shown in FIGS. 26—46. When the pen-
`etration occurs the shear out of thread 30 occurs and the
`
`flapper 12 is displaced into groove 92. Thus both steps can
`occur in a single trip or either step can be done individually
`without the other.
`
`FIGS. 10 and 11 show a variation of holding the flapper
`12in the open position. It can be held open with a combi-
`nation of groove 92, as previously described as well as an
`enlarged diameter hinge 130 that is forced down into a
`reduced diameter segment 132 for an interference fit. FIG.
`11 shows that groove 92 can be eliminated and the interfer-
`ence fit between hinge 130 and reduced diameter segment
`132 can be the sole mechanism to insure the flapper 12 stays
`open after the thread 30 is sheared out.
`The foregoing disclosure and description of the invention
`are illustrative and explanatory thereof, and various changes
`in the size, shape and materials, as well as in the details of
`the illustrated construction, may be made without departing
`from the spirit of the invention.
`We claim:
`
`1. A method of taking a well safety valve out of service,
`comprising:
`providing a housing comprising a hinged flapper actuated
`by a flow tube where the flow tube is biased by a flow
`tube spring against a pressure control system;
`mounting said flapper on a base;
`positioning said flapper in the open position;
`moving said flapper base after said positioning.
`2. The method of claim 1, comprising:
`penetrating into said pressurized control system in said
`housing in the same trip into the wellbore as said
`moving of said flapper base.
`3. A method of taking a well safety valve out of service,
`comprising:
`providing a housing comprising a hinged flapper actuated
`by a flow tube where the flow tube is biased by a flow
`tube spring against a pressure control system;
`mounting said flapper on a base;
`positioning said flapper in the open position;
`moving said flapper base;
`providing retaining groove in said housing;
`shifting said flapper into said groove.
`4. The method of claim 2, comprising:
`biasing said flapper as a result of said shifting said flapper.
`5. A method of taking a well safety valve out of service,
`comprising:
`providing a housing comprising a hinged flapper actuated
`by a flow tube where the flow tube is biased by a flow
`tube spring against a pressure control system;
`mounting said flapper on a base;
`positioning said flapper in the open position;
`moving said flapper base;
`biasing said flapper as a result of said moving of said
`flapper base;
`biasing said flapper after said moving of said flapper base.
`
`10
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`15
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`20
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`25
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`30
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`35
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`40
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`45
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`60
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`65
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`6
`6. A method of taking a well safety valve out of service,
`comprising:
`providing a housing comprising a hinged flapper actuated
`by a flow tube where the flow tube is biased by a flow
`tube spring against a pressure control system;
`mounting said flapper on a base;
`positioning said flapper in the open position;
`moving said flapper base;
`providing a reduced diameter section in the valve hous-
`mg;
`
`forcing a portion of said flapper into an interference fit in
`said reduced diameter section to hold it open.
`7. A method of taking a well safety valve out of service,
`comprising:
`
`providing a housing comprising a hinged flapper actuated
`by a flow tube where the flow tube is biased by a flow
`tube spring against a pressure control system;
`mounting said flapper on a base;
`positioning said flapper in the open position;
`moving said flapper base;
`providing a reduced diameter section in the valve hous-
`mg;
`
`forcing a portion of said flapper into an interference fit in
`said reduced diameter section to hold it open;
`using the hinge portion of said flapper to create said
`interference fit.
`
`8. A method of taking a well safety valve out of service,
`comprising:
`providing a housing comprising a hinged flapper actuated
`by a flow tube where the flow tube is biased by a flow
`tube spring against a pressure control system;
`mounting said flapper on a base;
`positioning said flapper in the open position;
`moving said flapper base;
`selectively securing said base to the housing of the valve;
`and
`
`releasing said base from said housing to allow moving of
`said flapper base.
`9. The method of claim 8, comprising:
`using a thread for said selective securing; and
`shearing said thread.
`10. The method of claim 8, comprising:
`using at least one shear pin for said selective securing; and
`shearing said pin.
`11. The method of claim 8, comprising:
`supporting one end of said flow tube spring on said base:
`and
`
`biasing said base with said flow tube spring after said
`releasing of said base.
`12. The method of claim 8, comprising:
`inserting a flapper tool into the valve;
`pushing said flapper toward its open position with said
`tool.
`
`13. The method of claim 12, comprising:
`intially retaining at least one outwardly biased collet on a
`mandrel of said tool;
`releasing said collet;
`fully moving said flapper to the open position with said
`collet.
`
`14. The method of claim 13, comprising:
`engaging said base with said collet;
`
`MEGCO EX. 1012
`
`MEGCO Ex. 1012
`
`

`

`US 6,902,006 B2
`
`7
`shifting said mandrel With said collet engaging said base
`to accomplish said releasing of said base from said
`housing.
`15. The method of claim 14, comprising:
`using a thread for said selective securing; and
`shearing said thread.
`16. The method of claim 14, comprising:
`supporting one end of said flow tube spring on said base:
`and
`biasing said base With said spring after said releasing of
`said base.
`
`17. The method of claim 16, comprising:
`providing a retaining groove in said housing of the valve;
`shifting said flapper into said groove.
`18. The method of claim 17, comprising:
`
`5
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`10
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`15
`
`8
`providing a reduced diameter section in said housing;
`forcing a portion of said flapper into an interference fit in
`said reduced diameter section to hold it open.
`19. The method of claim 16, comprising;
`providing a reduced diameter section in said housing;
`forcing a portion of said flapper into an interference fit in
`said reduced diameter section to hold it open.
`20. The method of claim 16, comprising:
`attaching a penetration tool to said flapper tool;
`orienting said penetration tool to the pressurized control
`system;
`penetrating into said control system.
`*
`*
`*
`*
`*
`
`MEGCO EX. 1012
`
`MEGCO Ex. 1012
`
`