Back Pressure Valve Recovery Tool and Methods of Use

The present disclosure relates generally to back pressure valve (BPV) retrieval tools and, more particularly, to a BPV recovery tool operable to retrieve a broken section of a BPV retrieval tool stuck in a back pressure valve.

Throughout the lifetime of an oil and gas well, proper sealing and pressure isolation equipment is required to prevent undesirable fluid flow out of the system, including oil, gas, injection fluids, formation water, or a combination thereof. One common mechanical barrier utilized in sealing a wellhead of an oil and gas well is a back pressure valve (BPV). The BPV is typically secured within a specially machined profile in the bore of a tubing hanger, and the tubing hanger is arranged within a tubing head adapter forming part of the wellhead or wellhead installation. A production tree (alternately referred to as a “Christmas tree”) is commonly attached to the top of the tubing head adapter to control flow into and out of the wellbore extending from the wellhead.

The BPV operates as a one-way check valve designed to isolate the well pressure from below while enabling at least a small amount of fluid to flow from above; i.e., from the Christmas tree. In some applications, for example, and depending on design, the BPV can allow pumping through the tubing to kill any undesired flow or pressure. Moreover, the BPV allows for the safe exchange or repair of valves included in the wellhead and Christmas tree without lengthy and costly kill operations to eliminate well pressure. Furthermore, the BPV can also provide well control at certain stages of completion and de-completion operations, as well as an extra level of safety when potential surface damage to the Christmas tree or wellhead exists.

BPVs are normally retrieved with a specially designed retrieval tool connected to a running tool or “tool string,” which is run and controlled hydraulically to set within a BPV profile. BPV retrieval tools can pose significant challenges, especially when the retrieval tool becomes stuck within the wellhead. In some scenarios, for example, a retrieval tool can be severed from the tool string after being subjected to large amounts of torque, and thereby leave a broken part or section of the retrieval tool latched in the BPV profile. In such scenarios, a well operator will typically attempt to mill out the broken tool inside the BPV. Such milling operations, however, are time-consuming and can often take days or even weeks to complete. Moreover, such milling operations require specialized equipment and expertise, making them expensive and difficult to organize.

Stuck BPV retrieval tools can create a range of problems for oil and gas operations, such as wellbore inaccessibility, losing a crucial means of well control and securement, production delays, and increased expenses. The problem of stuck BPV retrieval tools is exacerbated by the fact that many of these tools are expensive and difficult to replace. Even a single instance of a tool being stuck may lead to significant costs and delays for oil and gas operations.

Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

According to an embodiment consistent with the present disclosure, a back pressure valve recovery tool is disclosed and includes an elongate, cylindrical body having opposing upper and lower ends, and a matable feature provided at the lower end and matable with an inner profile provided on an upper end of a broken section of a back pressure valve (BPV) retrieval tool, wherein the broken section of the BPV retrieval tool is received within a back pressure valve installed within a wellhead.

According to an embodiment consistent with the present disclosure, a method for retrieving a broken section of a back pressure valve (BPV) retrieval tool is disclosed and includes the steps of lowering a back pressure valve (BPV) recovery tool into a wellhead having a back pressure valve installed therein and a broken section of the BPV retrieval tool received within the back pressure valve, the BPV recovery tool including an elongate, cylindrical body having opposing upper and lower ends, and a matable feature provided at the lower end and matable with an inner profile provided on an upper end of the broken section of the BPV retrieval tool. The method further including the steps of upon reaching the broken section of the BPV retrieval tool, rotating the BPV recovery tool until the matable feature is received within the internal profile, rotating the BPV recovery tool to transfer torque from the BPV recovery tool to the broken section of the BPV retrieval tool, and thereby separating the BPV retrieval tool from the back pressure valve, and removing the BPV recovery tool and the BPV retrieval tool from the wellhead.

Any combinations of the various embodiments and implementations disclosed herein can be used in a further embodiment, consistent with the disclosure. These and other aspects and features can be appreciated from the following description of certain embodiments presented herein in accordance with the disclosure and the accompanying drawings and claims.

Embodiments of the present disclosure will now be described in detail with reference to the accompanying Figures. Like elements in the various figures may be denoted by like reference numerals for consistency. Further, in the following detailed description of embodiments of the present disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the claimed subject matter. However, it will be apparent to one of ordinary skill in the art that the embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Additionally, it will be apparent to one of ordinary skill in the art that the scale of the elements presented in the accompanying Figures may vary without departing from the scope of the present disclosure.

Embodiments in accordance with the present disclosure generally relate to a back pressure valve (BPV) retrieval tools, and BPV recovery tools operable to retrieve stuck BPV retrieval tools. The BPV recovery tools described herein can be run into a wellhead using the same running tool and tool string used to convey a BPV retrieval tool, and may provide a matable feature configured to locate and mate with an internal profile of a severed section of the BPV retrieval tool that remains stuck in a back pressure valve. In some embodiments, the matable feature may exhibit a hexagonal cross-section configured to locate and mate with a corresponding hexagonal cross-section of the internal profile of the BPV retrieval tool. As further described herein, in some embodiments, the BPV recovery tool may exhibit magnetic properties capable of magnetically attracting ferromagnetic materials, such as the broke section of the BPV retrieval tool. Consequently, the BPV recovery tool may be able to release the BPV retrieval tool from the BPV, and simultaneously pull the BPV retrieval tool from the wellhead via magnetic interaction all in the same run into the wellhead.

depicts a schematic view of an example wellheadthat may be used in accordance with the principles of the present disclosure. The wellheadmay be arranged at a well surface location(e.g., land based, floating platform, subsea, etc.) and a wellboreextends from the wellheadand penetrates one or more subterranean formations. The wellheadhelps facilitate hydrocarbon production from the well, but also provides a means of introducing downhole tools and fluids into the wellbore.

As illustrated, the wellheadincludes a casing head housingwith a casing hangersecured therein. The wellheadmay further includes a casing headsecured to the top of the casing head housing, and a casing hangermay be secured within the casing head housing. The wellheadfurther includes a tubing head adapterwhich is secured to the top of the casing head housing, and a tubing hangerwhich is secured within the tubing adapter. In the illustrated figure, a back pressure valve or “BPV”(generically shown as a box) is received within the tubing hangerand, more particularly, within a specially machined profile within the bore of the tubing hanger. The BPVmay comprise, for example, a type-H back pressure valve that is threaded into a corresponding threaded interface (profile) of the tubing hanger. In other embodiments, however, the BPVmay be installed in a plug bushing or the like forming part of the wellhead.

Once installed, the BPVhelps prevent the escape of well fluids or gases from the wellboreto the surrounding environment. The BPVis an essential component for maintaining well control during production and well completion/stimulation operations, thereby preventing uncontrolled releases of well fluids or gases that could endanger personnel and the environment.

As needed, the BPVmay be installed and removed from the wellheadusing a BPV retrieval tool (not shown) operatively coupled to a corresponding running tool and associated tool string. The BPV retrieval tool is run into the wellheadconnected to the running tool and controlled hydraulically to set the BPVin a profile provided in the wellhead; e.g., a threaded interface (profile) of the tubing hanger. As desired, the BPVmay be removed from the wellheadby again running the BPV running tool into the wellhead, mating the BPV retrieval tool with the BPV, disengaging the BPVfrom the wellhead, and extracting the BPVas coupled to the BPV running tool. In some removal operations, however, the BPV retrieval tool can break or otherwise be severed upon assuming large axial and/or torsional loads. In such a scenario, a broken or severed portion of the BPV retrieval tool may be left within the BPVas the running tool and the remaining portions of the PBV retrieval tool are retracted from the wellhead.

According to embodiments of the present disclosure, a back pressure valve (BPV) fishing or “recovery” tool is disclosed and operable to locate and extract a broken or severed BPV retrieval tool from the wellheadand, more particularly, from engagement with the BPV. The BPV recovery tool may be run into the wellheadwith the same tool string and running tool as the BPV retrieval tool and may exhibit an external profile (i.e., matable feature) configured to mate with an internal profile of the broken/severed BPV retrieval tool. In some embodiments, the distal end of the BPV recovery tool may also exhibit magnetic properties that allows the BPV recovery tool to magnetically attract the BPV retrieval tool to ensure retrieval of the BPV retrieval tool once disengaged from the BPV and as the BPV recovery tool is retracted from the wellhead.

is a schematic side view of an example back pressure valve (BPV) recovery tool, according to one or more embodiments of the present disclosure. As illustrated, the BPV recovery toolincludes an elongate, cylindrical bodyhaving a first or “upper” endand a second or “lower” endopposite the upper end. The upper endmay be configured to be operatively coupled to a tool string or running tool (not shown) operable to convey the BPV recovery toolinto and out of the wellhead(). In at least one embodiment, the upper endmay be threaded and configured to threadably engage corresponding threaded portions of the running tool. In other embodiments, however, the upper endmay be operatively coupled to the running tool in other conventional ways.

The lower endof the bodymay be configured to locate and engage a broken section or portion of a BPV retrieval tooloperatively coupled to the BPV. As described above, the BPVmay be installed (set) within the wellhead() using the BPV retrieval tool, which may also be used to subsequently retrieve the BPV. As illustrated, the BPV retrieval toolmay have a first or “upper” endand a second or “lower” endopposite the upper end. The lower endmay be operatively coupled to the BPV, such as via a threaded engagement or the like.

In the illustrated embodiment, the upper endof the BPV retrieval toolmay be broken or otherwise severed from upper portions (not shown) of the BPV retrieval tool, which have been removed by reversing (retracting) the running tool from the wellhead(). As indicated above, in some applications, the BPV retrieval toolmay be broken or severed upon assuming large torsional and/or axial loads associated with attempting to remove the BPVfrom the wellhead. As a result, a lower portion of the BPV retrieval toolremains attached (stuck) to the BPVat the lower end, and the broken (severed) upper endmay be exposed and otherwise open-ended.

As illustrated, the upper endmay provide or otherwise define an internal profileconfigured to receive and mate with the lower endof the BPV recovery tool. More specifically, in some embodiments, the lower endof the BPV recovery toolmay provide a matable featuresized and otherwise configured to locate and be received within the internal profileof the BPV recovery tool. In some embodiments, as illustrated, the matable featuremay exhibit a polygonal cross-section and the internal profilemay exhibit a corresponding polygonal cross-section sized to receive the matable feature. In such embodiments, for example, the matable featuremay exhibit a hexagonal cross-section and the internal profilemay provide a corresponding hexagonal cross-section that receives the matable feature. In other embodiments, however, matable featuremay be configured to releasably mate with the internal profilevia a bayonet connection, or the like.

is a schematic side view of the BPV recovery tooloperatively coupled to the BPV retrieval tool, according to one or more embodiments. More specifically, in, the matable featurearranged at the lower endof the BPV recovery toolis shown received within the BPV retrieval tooland, more specifically, within the internal profile.

In some embodiments, the matable featuremay form an integral part and extension of the body. In such embodiments, the matable featuremay be machined and otherwise defined at the lower endto exhibit the geometry and characteristics necessary to properly locate and mate with the internal profile. In other embodiments, however, the matable featuremay comprise a separate component part operatively coupled to the lower endof the body. In such embodiments, the matable featuremay be machined and designed separate from the BPV recovery toolwith the necessary geometry and characteristics for mating with the internal profile. Moreover, in such embodiments, the matable featuremay be operatively coupled to the lower endvia a variety of attachment means including, but not limited to, welding, mechanical fasteners, mechanical attachments, and adhesive, an interference fit, a shrink fit, or any combination thereof.

Referring to both, example operation of the BPV recovery toolwill now be provided. The BPV recovery toolmay be lowered into the wellhead() as coupled to the running tool and associated tool string. As the BPV recovery toolis lowered, or just before reaching the broken section of the BPV retrieval tool, the BPV recovery toolmay be slowly rotated (e.g., either manually or hydraulically) via the running tool until the matable featurelocates and is received within the internal profileprovided within the upper endof the BPV retrieval tool. Once the matable featureis received within the internal profile, the BPV recovery toolmay be further rotated to separate the BPV retrieval toolfrom the BPV. More specifically, rotating the BPV recovery tooltransfers torque from the BPV recovery toolto the broken section of the BPV retrieval toolvia the mated interface between the internal profileand the matable feature. The transferred torque helps loosen the attachment between the BPV retrieval tooland the BPV, and further rotation of the BPV retrieval toolmay cause the lower endof the BPV retrieval toolto detach (e.g., unthread) and separate from the BPV.

In some embodiments, the lower endof the BPV recovery toolmay exhibit magnetic properties operable to magnetically attract ferromagnetic materials. In at least one embodiment, for example, the matable featuremay comprise a magnet and may otherwise exhibit magnetic properties configured to magnetically attract the broken section of the BPV retrieval tool. In other embodiments, however, or in addition thereto, the BPV recovery toolmay further include a magnet() coupled to or otherwise forming part of the lower endof the body. Accordingly, after the BPV retrieval toolis separated (unthreaded) from the BPV, magnetic attraction of the ferromagnetic material of the BPV retrieval toolwill allow the BPV recovery toolto extract the broken section of the BPV retrieval toolfrom the wellhead(). As will be appreciated, and in contrast to conventional back pressure valve fishing operations, this enables the broken section of the BPV retrieval tooland the BPVto be retrieved in one run into the wellhead.

In embodiments that include the magnet, the magnetmay be operatively coupled to or form an integral part of the matable featureat the lower endof the body. The magnetmay be operatively coupled to the lower end(e.g., the matable feature) via a variety of coupling means including, but not limited to, one or more mechanical fasteners, welding, soldering, an interference fit, a mechanical engagement, an adhesive, or any combination thereof. In some embodiments, the magnetmay exhibit a similar geometry as the matable feature. In such embodiments, the magnetmay exhibit a polygonal cross-section, such as a hexagonal cross-section, configured to mate with the corresponding cross-section of the internal profile. Moreover, in such embodiments, the magnetmay help transfer torque to the BPV retrieval toolonce received within the internal profile. In other embodiments, however, the magnetmay exhibit other geometries (e.g., circular), but nonetheless sized to be able to be received within the internal profile.

The magnetmay comprise any type of known magnet including, but not limited to, a permanent magnet, an electromagnet, a paramagnetic material, or any combination thereof. In embodiments where the magnetcomprises an electromagnet, the BPV recovery toolmay further include an internal power sourceconfigured to provide the necessary electrical power to operate the electromagnet. The power sourcecan include, for example, one or more batteries or fuel cells. In other embodiments, however, the internal power sourcemay be omitted and the electromagnet may instead be powered via a direct power line extending through the running to from a source of grid power or a generator. Moreover, in embodiments where the magnetcomprises an electromagnet, the electromagnet may be operated via remote or direct control, and may be automated or selectively operated by a user. Embodiments where the magnetcomprises an electromagnet may be advantageous since the magnetmay be operated only as needed, thus not attracting ferromagnetic materials until arranged adjacent the BPV retrieval tool.

In some embodiments, the BPV recovery toolmay further include a centralizeroperatively coupled to or forming an integral part of the bodybetween the upper and lower ends. As illustrated, the centralizermay exhibit a diameter that is greater than a diameter of the body, which allows the centralizerto help guide the BPV recovery toolwithin the wellhead(). More specifically, the centralizermay be configured to help guide the lower endof the BPV recovery toolinto mated engagement with the upper endof the BPV retrieval tool, thereby operatively coupling the BPV recovery toolto the BPV retrieval tool. In some embodiments, for example, the centralizermay be configured to engage inner walls of the wellheadas the BPV recovery toolis lowered into the wellhead. In at least one embodiment, the axial location of the centralizercan be adjustable along the axial length of the body.

is a schematic flowchart of an example methodfor retrieving a broken section of a back pressure valve (BPV) retrieval tool, such as the BPV retrieval tooldescribed herein. As illustrated, the methodincludes lowering a back pressure valve (BPV) recovery tool into a wellhead, as at. The wellhead may have a back pressure valve installed therein and a broken section of the BPV retrieval tool may be received within the back pressure valve. Moreover, the BPV recovery tool may include an elongate, cylindrical body having opposing upper and lower ends, and a matable feature provided at the lower end and matable with an inner profile provided on an upper end of the broken section of the BPV retrieval tool. Upon reaching the broken section of the BPV retrieval tool, the methodmay further include rotating the BPV recovery tool until the matable feature is received within the internal profile, as at. The methodmay further include rotating the BPV recovery tool to transfer torque from the BPV recovery tool to the broken section of the BPV retrieval tool, and thereby separating the BPV retrieval tool from the back pressure valve, as at. The methodmay also include removing the BPV recovery tool and the BPV retrieval tool from the wellhead, as at.

Therefore, the proposed BPV recovery toolis designed as a specialized tool used in the oil and gas industry for retrieving a broken section of the BPV retrieval tool that has become lodged inside the BPV. The BPV recovery toolincludes the elongated body, which is designed for lowering and operating the BPV recovery tool. Moreover, the BPV recovery toolincludes the matable feature, which may exhibit a hexagonal cross-section configured to mate with a corresponding hexagonal cross-section of an internal profile provided by the broken section of the BPV retrieval tool. In some embodiments, the lower end of the BPV recovery toolmay exhibit magnetic properties, which ensures secure engagement and retrieval of the broken tool. The magnetic properties of the BPV recovery toolattract the broken section of the BPV retrieval tool, to pull out the broken BPV retrieval tool. The BPV recovery toolcan eliminate and reduce the need for large and expensive milling jobs for retrieving the broken section of the BPV retrieval tool.

The BPV recovery toolprovides faster retrieval process of lost tools compared to milling, thereby saving time and money, and improving efficiency. The BPV recovery toolrestores full accessibility for well control and securement, and provides clear path for BPV operation. The BPV recovery toolprovides simple installation on any of the shelf BPV string. The BPV recovery tooldoes not require special pressure control equipment. Further, the same BPV operation set is required. Thus, the proposed BPV recovery toolsaves resources and minimizes disruption to operations and could be considered as a leading retrieving method to enhance one of the oil/gas field applications.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, for example, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “contains”, “containing”, “includes”, “including,” “comprises”, and/or “comprising,” and variations thereof, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Terms of orientation are used herein merely for purposes of convention and referencing and are not to be construed as limiting. However, it is recognized these terms could be used with reference to an operator or user. Accordingly, no limitations are implied or to be inferred. In addition, the use of ordinal numbers (e.g., first, second, third, etc.) is for distinction and not counting. For example, the use of “third” does not imply there must be a corresponding “first” or “second.” Also, if used herein, the terms “coupled” or “coupled to” or “connected” or “connected to” or “attached” or “attached to” may indicate establishing either a direct or indirect connection, and is not limited to either unless expressly referenced as such.

The use of directional terms such as above, below, upper, lower, upward, downward, left, right, up-hole, downhole and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure, the up-hole direction being toward the surface of the well and the downhole direction being toward the toe of the well.

While the disclosure has described several exemplary embodiments, it will be understood by those skilled in the art that various changes can be made, and equivalents can be substituted for elements thereof, without departing from the spirit and scope of the invention. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, situation, or material to embodiments of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, or to the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, or component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative.