Apparatus and method for connecting casing to lateral casing using thermoset plastic molding

[0002] 1. Field of the Invention

[0003] This invention relates to connecting a main casing section to a lateral casing section in a well, and more particularly, to an apparatus and method using a thermoset plastic molding in the form of a sock seal at the intersection of the casing sections.

[0004] 2. Description of the Prior Art

[0005] Many oil and gas wells today include a laterally extending portion which extends away from a substantially vertical main portion of the well. These lateral sections, also sometimes referred to as horizontal sections or deviated sections, are used to intersect formations or zones of interest that cannot easily be accessed by merely a vertical well.

[0006] After a vertical portion of the well and a lateral portion have been drilled, casing is placed in both. At the intersection or joint of the main or vertical section of casing with the lateral section of casing, it is necessary to provide sealing so that proper well operations may be carried out and well fluids flowed out of the well without leakage in or out of the well casing.

[0007] Sealing at the joint or intersection presents problems, solutions to which have been proposed through the years. For example, sealing can be successfully achieved by using cements or other similar materials. However, a problem exists in keeping such a seal intact. Any slight earth movements, or pipe movements due to contraction or expansion in the casing may sever such seals. In these instances, the cement will crack, breaking the seal, and allowing leakage into or out of the casing joint, neither of which is desirable.

[0008] The present invention solves this problem by providing a flexible sock made of a hardenable material which can be placed at the joint so that the legs of the sock extend into the main casing section and the lateral casing section. The sock is inflated to an operating position and the material hardened. In this way, a single piece, uninterrupted seal is formed. Even with some casing or earth movement, the integrity of the one-piece seal is not broken.

[0009] The present invention includes an apparatus for sealing a connection between a main casing section and a lateral casing section in a well. The apparatus comprises a housing adapted for attachment to a tubing string and a sock having an upper end attached to the housing. The sock also has a first leg and a second leg and is made of a hardenable material. The apparatus may further comprise a bent sub connected to the housing and extending through the second leg of the sock. The housing, sock and bent sub may be positioned in the well adjacent to an intersection of the main and lateral casing sections, the sock may be inflated and placed in an operating position in which the first leg of the sock extends into the main casing section beyond the intersection and the second leg extends into the lateral casing section beyond the intersection, and the sock may be hardened in the operating position.

[0010] In one embodiment, the first leg of the sock has a closed end. The housing and the upper end of the sock are sealingly engaged, and the bent sub and the second leg of the sock are also sealingly engaged.

[0011] The sock is preferably made of a thermoset plastic material, and the apparatus may thus further comprise heating means for applying heat to the sock and thereby hardening the sock in the operating position. The heating means may comprise a heater connected to the housing and/or may comprise chemicals disposed in a cavity defined in the housing for providing an exothermic reaction when released from the cavity. The apparatus may thus comprise a rupture disc in communication with the cavity such that the rupture disc may be ruptured by applying pressure thereto, thereby releasing the chemicals from the cavity.

[0012] The invention may also be described as including a method of connecting and sealing between a main casing section and a lateral casing section in a well. The method comprises the steps of (a) positioning a flexible sock made of a hardenable material adjacent to an intersection of the main and lateral casing portions, the sock comprising a first leg and a second leg, (b) placing the sock in an operating position wherein the first leg of the sock is in contact with an inner surface of the main casing section, and the second leg of the sock is in contact with an inner surface of the lateral casing section, and (c) curing the hardenable material such that the sock is hardened in the operating position. Step (b) may comprise inflating the sock. Steps (b) and (c) may be substantially simultaneous.

[0013] Step (c) may comprise applying heat to the hardenable material. This step of heating may comprise releasing a volume of chemicals adjacent to the sock such that an exothermic reaction is generated and/or activating a heater positioned adjacent to the sock. The step of releasing the chemicals may comprise rupturing a rupture disc retaining the chemicals in a cavity defined in a housing positioned inside the sock.

[0014] Numerous objects and advantages of the invention will become apparent as the following detailed description of the preferred embodiment is read in conjunction with the drawings which illustrate such embodiment.

[0015] FIG. 1 shows the apparatus for connecting casing to lateral casing of the present invention as it is run into a well adjacent to an intersection between main and lateral casing sections.

[0016] FIG. 2 shows the apparatus in an operating position, forming a seal at the casing intersection.

[0017] Referring now to the drawings, the apparatus for connecting a main casing section to a lateral casing section of the present invention is shown and generally designated by the numeral 10. Apparatus 10 is designed for use in a well 12. Well 12 has a main portion 13 with a casing section 14 therein and a lateral portion 15 extending therefrom with a casing section 16 therein, such that a joint or intersection 18 is formed between the two casing sections 14 and 16.

[0018] Apparatus 10 is run into well 12 on a tubing string 20 of a kind known in the art. Tubing string 20 may be a pipe string or a coiled tubing string, or any other means of conveying a tool into a well. As shown in FIG. 1, apparatus 10 is positioned adjacent to intersection 18, ready to be placed in an operating position.

[0019] At the upper end of apparatus 10 is a housing 22 adapted for connection to tubing string 20 and defining a cavity 24 therein. Cavity 24 is initially closed by a rupture disc 26 so that a volume of chemicals 28 are retained in the cavity. Chemicals 28 may be contained in a plastic bag (not shown) which is ruptured when pressure is applied thereto. Chemicals 28 are selected to produce heat when released as further described herein. For example, but not by way of limitation, the reaction of acids and metals produce heat. Decomposing mixes such as: Al+Fl₂O₃→Al₂O₃+Fl produces extremely high heat. Another example is the mixing of CaCl+baking soda.

[0020] In the illustrated embodiment, a heater 30 is attached to the lower end of housing 22. Heater 30 is of a kind known in the art and is preferably an electrical heater. Wiring 32 extends from heater 30 up through tubing string 20 to a power source (not shown).

[0021] A bent sub or tool 34 of a kind known in the art is attached to the lower end of heater 30, and thus housing 22, heater 30 and bent sub 34 are all connected to each other. Bent sub 34 is adapted for guiding a portion of apparatus 10 into lateral casing section 16.

[0022] A flexible sock 36 is disposed around housing 22, heater 30 and bent sub 34. Sock 36 has an upper end 38 which is disposed around the upper portion of housing 22. Upper end 38 of sock 36 is attached and sealed to housing 22 using retaining and releasing mechanisms known in the art such as a string 40 which lightly retains sock 36 on housing 22 when positioning apparatus 10, but which is easily broken so that the housing may be removed from the sock when desired, as further described herein. Other known mechanisms such as a releasable clamp could be used.

[0023] Sock 36 also has a first leg 42 and a second leg 44. Second leg 44 of sock 36 is disposed around the lower portion of bent sub 34 and sealed and attached thereto by engagement of another retaining and releasing mechanism known in the art, such as string 46. String 46, like string 40 previously described, lightly retains second leg 44 of sock 36 on bent sub 34, but is easily broken so that the bent sub may be removed from the sock when desired, again as further described herein. Again, other known mechanisms such as a releasable clamp may be used instead.

[0024] As seen in FIG. 1, sock 36 is in a collapsed configuration draped limply around the other components in apparatus 10. Sock 36 is preferably made of an initially flexible material which may subsequently be hardened. One preferred material is a thermoset plastic material, such as a composite matrix. One specifically preferred composite matrix is a polyamide material reinforced with glass fibers or the like, having a curing temperature of about 550° F., but the invention is not intended to be limited to this one particular thermoset material.

[0025] Pressure is applied to tubing string 20 so that an annular volume 48 defined between sock 36 and housing 22, heater 30 and bent sub 34 is pressurized. Pressure is applied to annular volume 48 through means such as a port 50 in housing 22. This application of pressure into annular volume 48 inflates sock 36. Simultaneous with pressurization or subsequently thereto, sock 36 is moved to the operating position shown in FIG. 2. It will be seen that sock 36 conforms to the inner surfaces of main casing section 14 and lateral casing section 16. Sock 36 is preformed to a shape which closely conforms to the casing in well 12 when the sock is inflated as shown in FIG. 2.

[0026] While positioning, bent sub 34 is manipulated so that it extends at least partially into lateral casing section 16, as seen in FIG. 2. Thus, it will be seen that second leg 44 of sock 36 is guided into lateral casing section 16 and beyond intersection 18. First leg 42 of sock 36 is free to drape down into main casing section 14.

[0027] The pressurizing of annular volume 48 also ruptures rupture disc 26 so that chemicals 28 are released from housing 22. The release of chemicals 28 causes an exothermic reaction which applies heat to sock 36. Preferably, sufficient heat is generated that at least partial curing of the hardenable material of sock 36 is initiated.

[0028] Additional pressure on sock 36 will break strings 40 and 46. Alternatively, as previously mentioned, other known releasing devices could be used. For example, this connection can be disconnected using a J-slot mechanism. Another means of disconnecting sock 36 could be the application of excessive heat at the top and bottom portions of the sock thus creating a weak and brittle connection between the sock and the component to which it is attached. The invention is not intended to be limited to any particular retaining or releasing means.

[0029] If necessary, additional heating may be applied by activating heater 30 to thoroughly cure the material of sock 36.

[0030] To facilitate inflation, first leg 42 of sock 36 extends beyond intersection 18 and has a closed end 52. Closed end 52 may be easily cut or drilled out later if desired.

[0031] Once sock 36 is set and hardened into the operating position shown in FIG. 2, tubing string 20 may be raised in well 12 which will be seen to remove housing 22, heater 30 and bent sub 34 from the sock. Sock 36 is left in well 12 at intersection 18 to provide a reliable seal at the intersection. The seal is not easily damaged, even with some earth or piping movement. Also, the material for sock 36 may be selected such that it is stable at elevated temperatures and pressures. Also, sock 36 provides a smooth inner surface at intersection 18 so that subsequently run tools into lateral casing section 16 will not hang up.

[0032] While the apparatus has been described as using a thermoset plastic material which may be hardened into the operating position, the invention is not intended to be limited to this particular type of material. Other materials which may be molded into a flexible sock and subsequently hardened would also be suitable.

[0033] It will be seen, therefore, that the apparatus and method for connecting a main casing section to a lateral casing section using thermoset plastic molding of the present invention is well adapted to carry out the ends and advantages mentioned as well as those inherent therein. While the presently preferred embodiment of an apparatus and method have been described for the purposes of this disclosure, numerous changes in the arrangement and construction of parts in the apparatus and in steps in the method may be made by those skilled in the art. All such changes are encompassed within the scope and spirit of the appended claims.