Casing Hanger Compression Ring System

This Non-Provisional Patent Application is related to and claims the benefit of priority from U.S. Provisional Application No. 63/663,407, titled “CASING HANGER COMPRESSION RING SYSTEM AND METHOD,” filed on Jun. 24, 2024, and incorporated by reference herein in its entirety for all intents and purposes.

Embodiments of the present disclosure relate to oil and gas tools, and in particular, to systems and methods for compression rings implemented in casing hangers.

In the drilling phase of oil and gas extraction operations, casing hangers allow casing to be set in the wellbore. Casing hangers also connect the casing string to the wellhead and seal the annulus. Within a casing hanger, various seals, including compression seals (also known as compression rings), may be used to seal and maintain the pressure in the annulus. Compression seals are compressed axially to generate a radial sealing force against the casing to prevent a loss of fluid (e.g., oil, gas, solid, or a combination thereof) from the annulus. However, during a blowout, such as occurring from excess downhole pressure, typical compression seals used in a casing hanger may fail by breaking, tearing, leaking, deforming, etc. Moreover, typical compression seals often fail at the cut (the interface at which two or more parts of the seal come together) and at the cap screw holes. What is needed in the industry is a system and method for a compression seal with greater resistance to failure in order to better maintain annulus pressure.

Applicants recognized the problems noted above herein and conceived and developed embodiments of compression seals, according to the present disclosure, for providing an increased resistance to sealing failure via alternative sealing geometries at the cut between segments of the compression seal.

In an embodiment, a seal for a piece of oil and gas equipment includes a first segment of the seal, a second segment of the seal, a cut defined by the separation in the seal between the first segment and the second segment of the seal, and an interface formable at the cut when a first face of the first segment and a second face of the second segment make contact. The interface formed at the cut increases a surface area of contact between the first segment and the second segment.

In another embodiment, a casing hanger assembly includes a casing hanger housing having a bore extending along a casing hanger axis, one or more top plates axially aligned with the casing hanger housing along the casing hanger axis, one or more bottom plates axially aligned with the casing hanger housing along the casing hanger axis, a seal axially aligned with the casing hanger housing along the casing hanger axis and positioned between the one or more top plates and the one or more bottom plates, and one or more fasteners configured to secure the seal between the one or more top plates and the one or more bottom plates. The seal of the casing hanger assembly includes first segment and a second segment of the seal, a cut defined by the separation in the seal between the first segment and the second segment of the seal, and an interface formable at the cut when a first face of the first segment and a second face of the second segment make contact, the interface increasing a surface area of contact between the first segment and the second segment.

The foregoing aspects, features and advantages of the present technology will be further appreciated when considered with reference to the following description of preferred embodiments and accompanying drawings, wherein like reference numerals represent like elements. In describing the preferred embodiments of the technology illustrated in the appended drawings, specific terminology will be used for the sake of clarity. The present technology, however, is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment”, “an embodiment”, “certain embodiments,” or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as “above,” “below,” “upper”, “lower”, “side”, “front,” “back,” or other terms regarding orientation are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations. Moreover, references to “substantially” or “approximately” or “about” may refer to differences within ranges of +/−10 percent.

Embodiments of the present disclosure are directed toward a compression seal to be used in oil and gas equipment, particularly casing hangers. The compression seal may comprise one or more segments, separated by a cut. At the cut of the compression seal, one or more faces of the one or more segments may be designed to form an interface. Embodiments of the present disclosure are directed towards different geometries on the faces of the segments of the compression seal. Different angles, shapes, and patterns on the faces at the cut may better prevent failure (via e.g., breaking, tearing, leaking, deforming, etc.) of the compression seal at the cut. These various embodiments may overcome one or more problems with existing systems, such as systems in which the faces at the interface are merely a straight and flat. Systems and methods discussed herein may address failure of compression seals in casing hangers by having geometries on the faces at the interface that create a tighter seal at the cut between the segments of the compression seal. The embodiments may also increase the sealing surface at the interface, which may eliminate a seal leak path. During situations of excess pressure, the various embodiments discussed herein may be able to better resist the radial blowout at the cut of the compression seal.

is a perspective view of an embodiment of a compression sealthat has had a blowout failure. The compression sealmay include a first segmentand a second segment(together, “segments,” “portions,” “pieces,” etc.). As illustrated, the segments,include one or more seal aperturesthat may allow the compression sealto be secured to other components via fasteners (not depicted in), such as cap screws. The compression sealalso includes a cut, defined as a physical separation between two segments,of the compression seal. In, the compression seal also has a blowoutat the cut, which, as can be seen, comprises a tearing and deformation at the cut. The tearing and deformation of the blowoutmay be defined as a failure of the compression seal. The failure of the compression sealdue to the blowoutmay result in a loss of pressure in the equipment in which the compression sealis installed. Pressure from the inside of the compression sealmay escape radially through the cutto an external surfaceof the compression sealand cause the blowoutat the external side.

is a perspective view of an embodiment of a compression sealthat has had a blowout failure, with segments,separated to allow for a view of the cut. Additionally, the compression seal, similar to compression sealof, includes one or more seal apertures, a blowout, and an external surface. In the present view of, a faceof segmentmay be seen. In the embodiment illustrated, the faceis a straight and flat surface.

is an exploded isometric view of an embodiment of a casing hanger assembly, which shares several similar features with the compression sealofand compression sealof, such as the first segmentand second segment, and others, which will be identified with like reference numerals for convenience purposes only and not to limit the scope of the present disclosure. It should be appreciated that although a casing hanger assemblyis depicted, compression seal embodiments of the present disclosure may be used in conjunction with other surface or subsea oil and gas equipment besides casing hangers, such as tubing hangers, Christmas trees (XTs), wellheads, and other equipment. The casing hanger assembly ofincludes a casing hanger housingthat comprises a casing hanger housing boreextending along a casing hanger axis. It should be appreciated that the casing hanger may also be referred to as a slip hanger. The casing hanger housingmay comprise housing aperturesthat may be designed to allow fastenersto secure other components to the casing hanger housing.

also includes a first top plateand a second top plate. It should be appreciated that although two top plates,are depicted in, there may be any reasonable number of top plates. The first top plateand the second top platemay be configured to fit together such that bringing the top plates,together on the same plane and aligning the edges of the top plates,creates substantially a single circular top plate. Also illustrated inis a first bottom plateand a second bottom plate. It should similarly be appreciated that although two bottom plates,are depicted in, there may be any reasonable number of bottom plates. The first bottom plateand the second bottom platemay be configured to fit together such that bringing the bottom plates,together on the same plane and aligning the edges of the bottom plates,creates substantially a single circular bottom plate.

Additionally, the first segmentand second segmentof the compression seal may be configured to fit together such that bringing the segments,together on the same plane and aligning/fitting together the first facesof the first segmentwith the second facesof the second segmentcreates substantially a single circular compression seal. The faces,may have different geometries, as will be explained further in connection with. It should be appreciated that although as depicted in, there are just two segments,coming together to form a single compression seal, there may be any reasonable amount of segments per compression seal, as well as any reasonable amount of circular compression seals included in the casing hanger assembly.

Furthermore, in the casing hanger assemblythat is fully assembled, the top plates,, the compression seal segments,, and the bottom plates,may be in axial alignment with the casing hanger housingalong the casing hanger axis. Also in the fully assembled assembly, the top plates,, compression seal segments,, and bottom plates,each create substantially a single circular plate or seal, as applicable. The compression seal segments,may be positioned and secured between the top plates,and the bottom plates,.

Moreover, the top plates,may include one or more top plate aperturesand the bottom plates,may include one or more bottom plate apertures. The top plate apertures, the seal apertures, and the bottom plate aperturesmay be aligned with the housing aperturescircumferentially along the casing hanger axis. When the all of the apertures,,,are aligned, the fastenersmay be able to extend through the apertures,,,in order to secure the top plates,, compression seal segments,, and bottom plates,to the casing hanger housing. Fastening the top plates,, compression seal segments,, and bottom plates,to the casing hanger housingusing the fastenerscompresses the compression seal segments,, sealing a leak path. Used in conjunction with the fastenersto secure the plates, compression seal, and housing together, may be engaging ringsand/or nuts, which also may be aligned with the apertures,,,circumferentially along the casing hanger axisand the fastenersmay extend through the rings.

is an isometric view of an embodiment of a compression seal, which shares several similar features with the compression sealof, the compression sealof, and the casing hanger assemblyof, such as the first segment, second segment, one or more seal apertures, cut, and external surface, which will be identified with like reference numerals for convenience purposes only and not to limit the scope of the present disclosure. The compression sealmay include a first faceof the first segmentand a second faceof the second segment. As illustrated, the first facecan include at least one recess, and the second facecan include at least one protrusioncorresponding to the recesssuch that the recessis configured to receive the protrusionwhen the first and second faces,engage. In the specific embodiment shown in, there are depicted two recessesand two protrusions, but any appropriate number of recessesand protrusionscan be used.

When the first segmentis brought together with the second segmentso that the first facemakes contact with the second face, it may form an interface at the cutof the compression seal. It may be the case that the more recesses and protrusions,there are in the faces,, the larger the surface area of the interface is, which may increase the ability for the compression sealto prevent leaks from seeping through the interface of the cutto the external surfaceof the compression seal. It should be appreciated that although in, the recesses and protrusions,in the faces,are radially aligned with the external surfaceof the compression seal, the recesses and protrusions,may be directed at any angle relative to the external surface. The geometry of the faces,at the interface, here being the recesses and protrusions,, may be able to better prevent failure of the compression seal.

is an isometric view of an embodiment of a compression seal, which shares several similar features with the compression seals,,of, respectively, and the casing hanger assemblyof, such as the first segment, second segment, one or more seal apertures, cut, and external surface, which will be identified with like reference numerals for convenience purposes only and not to limit the scope of the present disclosure. The compression sealmay include a first faceof the first segmentand a second faceof the second segment. As illustrated, the first faceincludes two wide recesses, and the second faceincludes two wide protrusions. It should be appreciated that although only two wide recesses and protrusions,are depicted in, there may be any reasonable number of recesses and protrusions,.

When the first segmentis brought together with the second segmentso that the first faceengages the second face, such engagement can form an interface at the cutof the compression seal. It may be the case that the more wide recesses and protrusions,there are in the faces,, the larger the surface area of the interface is, which may increase the ability for the compression sealto prevent leaks from seeping through the interface of the cutto the external surfaceof the compression seal. It should be appreciated that although in, the wide recesses and protrusions,in the faces,are radially aligned with the external surfaceof the compression seal, the wide recesses and protrusions,may be directed at any angle relative to the external surface. The geometry of the faces,at the interface, here being the wide recesses and protrusions,, may be able to better prevent failure of the compression seal.

is an isometric view of an embodiment of a compression seal, which shares several similar features with the compression seals,,,of, respectively, and the casing hanger assemblyof, such as the first segment, second segment, one or more seal apertures, cut, and external surface, which will be identified with like reference numerals for convenience purposes only and not to limit the scope of the present disclosure. The compression sealmay include a first faceof the first segmentand a second faceof the second segment. As illustrated, the first faceincludes first grooves, and the second faceincludes second grooves.

When the first segmentis brought together with the second segmentso that the first facemakes contact with the second face, it may form an interface at the cutof the compression seal. The first groovesand second groovesmay be designed to fit together flush, forming a gap-free interface at the cut. It may be the case that the more first and second grooves,there are in the faces,, the larger the surface area of the interface is, which may increase the ability for the compression sealto prevent leaks from seeping through the interface of the cutto the external surfaceof the compression seal. Additionally, it may be the case that the deeper the first and second grooves,are, the larger the surface area of the interface is, which may increase the ability for the compression sealto prevent leaks from seeping through the interface of the cutto the external surfaceof the compression seal. It should be appreciated that although in, the grooves,in the faces,are radially aligned with the external surfaceof the compression seal, and the grooves,may be directed at any angle relative to the external surface. The geometry of the faces,at the interface, here being the first and second grooves,, may be able to better prevent failure of the compression seal.

is an isometric view of an embodiment of a compression seal, which shares several similar features with the compression seals,,,,of, respectively, and the casing hanger assemblyof, such as the first segment, second segment, one or more seal apertures, cut, and external surface, which will be identified with like reference numerals for convenience purposes only and not to limit the scope of the present disclosure. The compression sealmay include a first faceof the first segmentand a second faceof the second segment. As illustrated, the first faceincludes two first recesses, and the second faceincludes two second recesses. It should be appreciated that although only two recesses,are depicted in each of the faces,in, there may be any reasonable number of recesses,. The compression sealalso may include one or more seal members, which may each be configured to fit within the first recessof the first faceand the second recessof the second face.

When the first segmentis brought together with the second segmentso that the first facemakes contact with the second face, it may form an interface at the cutof the compression seal. It may be the case that the more recesses,and seal membersthere are in the faces,, the larger the surface area of the interface is, which may increase the ability for the compression sealto prevent leaks from seeping through the interface of the cutto the external surfaceof the compression seal. It should be appreciated that although in, the recesses,and seal membersare radially aligned with the external surfaceof the compression seal, the recesses,and seal membersmay be directed at any angle relative to the external surface. The geometry of the interface, here being the recesses,and seal members, may be able to better prevent failure of the compression seal.

is an isometric view of an embodiment of a compression seal, which shares several similar features with the compression seals,,,,,of, respectively, and the casing hanger assemblyof, such as the first segment, second segment, one or more seal apertures, cut, and external surface, which will be identified with like reference numerals for convenience purposes only and not to limit the scope of the present disclosure. The compression sealmay include a first faceof the first segmentand a second faceof the second segment. As illustrated, the first faceis concave with the point of curvature originating at the external side surfacesof the seal, and the second faceis convex. As such, the linear portions of the cutexist on the external side surfacesof the sealand may extend perpendicular to the internal diameter of the seal. It should be appreciated that the compression sealofmay be referred to as a “vertical configuration,” as compared to a “horizontal configuration” of the compression sealof(discussed below). The concave first faceis configured to engage the convex second facealong substantially the entire surface area of the first faceand the second face. It should be appreciated that although the faces,have a curved parabolic shape, the faces,may have any type of curved or wave shape.

When the first segmentis brought together with the second segmentso that the first facemakes contact with the second face, it may form an interface at the cutof the compression seal. It may be the case that the more dramatic the curve of the faces,are, the larger the surface area of the interface is, which may increase the ability for the compression sealto prevent leaks from seeping through the interface of the cutto the external surfaceof the compression seal. The geometry of the interface, here being the vertical parabolic curved faces,, may be able to better prevent failure of the compression seal.

is an isometric view of an embodiment of a compression seal, which shares several similar features with the compression seals,,,,,,of, respectively, and the casing hanger assemblyof, such as the first segment, second segment, one or more seal apertures, cut, and external surface, which will be identified with like reference numerals for convenience purposes only and not to limit the scope of the present disclosure. The compression sealmay include a first faceof the first segmentand a second faceof the second segment. As illustrated, the first faceincludes two first angled portionsand one first flat portion, and the second faceincludes two second angled portionsand one second flat portion. It should be appreciated that although two angled portions,and one flat portion,are included in each of the faces,as depicted in, there may be any reasonable number of angled portions,and flat portions,. For example, in each face there may be one angled portion and two flat portions, or four angled portions and three flat portions, or three angled portions and three flat portions, or any other reasonable combination. Additionally, the angled portions,may be at any reasonable angle oblique to the flat portions,.

When the first segmentis brought together with the second segmentso that the first facemakes contact with the second face, it may form an interface at the cutof the compression seal. It may be the case that the more angled portions,and flat portions,there are in the faces,, the larger the surface area of the interface is, which may increase the ability for the compression sealto prevent leaks from seeping through the interface of the cutto the external surfaceof the compression seal. The geometry of the interface, here being the angled portions,and flat portions,, may be able to better prevent failure of the compression seal. In, the angled portions,are positioned adjacent to the external surfacesof the compression seal. As such, the linear portions of the cutexist on the external side surfacesof the sealand may extend perpendicular to the internal diameter of the seal. It should be appreciated that the compression sealofmay be referred to as a “vertical configuration” of the compression seal.

One would appreciate that the sealmay also be in a “horizontal configuration” where the angled portions,are positioned adjacent to the top and bottom surfaces of the compression seal. As such, the linear portions of the cutwould exist on the top and bottom surfaces of the sealand may extend horizontally and along the internal diameter of the seal. It should be appreciated that this compression seal may be referred to as the “horizontal configuration,” as compared to the “vertical configuration” of the compression sealof. In other words, one would appreciate that this “horizontal configuration,” as compared to the “vertical configuration” of the compression sealofis similar to how the compression sealofis the “vertical configuration” as compared to the “horizontal version” of the compression sealof. The difference here being the shaped surfaces of the faces of the two pairs of compression seals (i.e., angled and flat portions, versus concave and convex portions).

is an isometric view of an embodiment of a compression seal, which shares several similar features with the compression seals,,,,,,,of, respectively, and the casing hanger assemblyof, such as the first segment, second segment, one or more seal apertures, cut, and external surface, which will be identified with like reference numerals for convenience purposes only and not to limit the scope of the present disclosure. The compression sealmay include a first faceof the first segmentand a second faceof the second segment. As illustrated, the first faceis concave with the points of curvature originating at the top and bottom surfaces of the seal, and the second faceis convex. As such, the linear portions of the cutexist on the top and bottom surfaces of the sealand may extend horizontally and along the internal diameter of the seal. It should be appreciated that the compression sealofmay be referred to as the “horizontal configuration,” as compared to the “vertical configuration” of the compression sealof. The concave first faceis configured to engage the convex second facealong substantially the entire surface area of the first faceand the second face. It should be appreciated that although the faces,have a curved parabolic shape, the faces,may have any type of curved or wave shape.

When the first segmentis brought together with the second segmentso that the first facemakes contact with the second face, it may form an interface at the cutof the compression seal. It may be the case that the more dramatic the curve of the faces,are, the larger the surface area of the interface is, which may increase the ability for the compression sealto prevent leaks from seeping through the interface of the cutto the external surfaceof the compression seal. The geometry of the interface, here being the horizontal parabolic curved faces,, may be able to better prevent failure of the compression seal.

Although the technology herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present technology. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present technology as defined by the appended claims.