Completion Component

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:

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.