Containment Systems for Sealing a Pass-Through in a Well, and Methods Therefore.

Abstract

A system formed to provide sealed passage through the wellhead for cables, lines, tubes or the like for down-hole applications. A unitary or split/wrap around hanger, packer or other apparatus having a main seal is formed to receive and provide sealed passage through of power and control cables, lines, conduits, or other threaded components having various configurations and applications. A bowl cap, tubing adapter or other surface component with adapters to allow sealed pass-through utilizing a compression seal. A tubing encapsulated wire for pass-through for power cables or the like as well as a compression fitting with right angle connector is configured to provide a seal at the tubing adapter or the like, as well as a two-piece interlocking F.A.N. cover plate utilizing insertable inner plates to provide various cable penetration and other passage layouts, pressure ratings, and other specifications.

I claim: 
     
         1 ) An apparatus for sealing off an annulus between a string of tubing and casing for a well, comprising:
 a slot formed to receive a component,   a gripper to grip said component in said slot,   a sealing element having a component passage formed therethrough in alignment with said slot,   said apparatus formed to engage said tubing with said component threaded through said component passage and said slot, and gripped by said gripper, said sealing element formed to expand to facilitate a seal about said component and said annulus with the application of tension thereto.   
     
     
         2 ) The apparatus of  claim 1 , wherein said apparatus comprises a tubing hanger formed to be situated about a completion coupling associated with said string of tubing, said tubing hanger formed to be supported by and at least partially situated in a tubing head bowl, such that said sealing element is formed to expand to seal about said component with the application of a weight of said string of tubing, said sealing element formed to further expand via said weight of said tubing string so as to engage said tubing head bowl, so as to seal said annulus. 
     
     
         3 ) The apparatus of  claim 2 , wherein said gripper comprises a side door having a raised area positioned to grip said component upon closing said side door over said slot. 
     
     
         4 ) The apparatus of  claim 3 , wherein said component comprises an power line for a submersible pump. 
     
     
         5 ) The apparatus of  claim 4 , wherein said power line comprises three separate insulated conductors. 
     
     
         6 ) The apparatus of  claim 5 , wherein each said three insulated conductors envelope a separate tube so that said conductors pass through said component passage in said sealing element while enveloped by said tubes. 
     
     
         7 ) The apparatus of  claim 6 , wherein each of said tube passes through said slot and is positioned to be gripped by said gripper. 
     
     
         8 ) The apparatus of  claim 6 , wherein said three insulated conductors comprise tubing encapsulated conductors. 
     
     
         9 ) The apparatus of  claim 5 , wherein tubing encapsulated conductors pass through said sealing element and are spliced to respective conductors in a jacketed ESP power line situated under said hanger. 
     
     
         10 ) The apparatus of  claim 9 , wherein said tubing head bowl is situated in a tubing head, and wherein said tubing encapsulated conductors engage a right angle connector out of said tubing head, said right angle connector comprising a conductor block having first and second ends having first and second conductor wire receiving sockets, respectively, and first and second threaded fastener passages laterally engaging said first and second conductor wire receiving sockets respectively, whereby, upon inserting a power line at said first wire receiving socket and a conductor from said tubing encapsulated conductor in said second wire receiving socket and engaging first and second threaded fasteners to said first and second threaded passages, respectively, power flow from said power line to said tubing encapsulated conductor. 
     
     
         11 ) The apparatus of  claim 10 , wherein there are provided three tubing encapsulated conductors engaging three conductor blocks, respectively. 
     
     
         12 ) The apparatus of  claim 11 , wherein said first and second ends of said right angle connector are situated at a right angle relative to one another. 
     
     
         13 ) The apparatus of  claim 12 , wherein said conductor block is encased by an insulating of non-conductive material. 
     
     
         14 ) The apparatus of  claim 13 , wherein said non-conductive material encasing said conductor block comprises thermoset plastic. 
     
     
         15 ) The apparatus of  claim 13 , wherein said tubing hanger is positioned in said tubing head with a tubing adapter mounted thereto, and wherein said tubing encapsulated conductor passes from below said tubing hanger out of said tubing adapter via a compression fitting. 
     
     
         16 ) The apparatus of  claim 13 , wherein there is a tubing adapter attached to said tubing head, and wherein said tubing encapsulated conductors pass from said tubing head, through said tubing adapter, and out of said tubing adapter via a compression fitting. 
     
     
         17 ) The apparatus of  claim 15 , wherein there is a cover plate attached to said tubing head, and wherein said tubing encapsulated conductors pass from said tubing head, through said cover plate, and out of said tubing adapter via said compression fitting. 
     
     
         18 ) The apparatus of  claim 17 , wherein said cover plate comprises an outer mounting ring and an inner plate. 
     
     
         19 ) The apparatus of  claim 18 , wherein said outer mounting ring is affixed to a mounting flange of said tubing head via threaded fasteners. 
     
     
         20 ) The apparatus of  claim 18 , wherein said outer mounting ring has a receiver formed therein with a lip formed to receive and retain said inner plate when said mounting ring is affixed to said tubing head. 
     
     
         21 ) The apparatus of  claim 20 , wherein said inner plate is interchangeable with other inner plates having varying characteristics depending on the application. 
     
     
         22 ) The apparatus of  claim 21 , wherein said varying characteristics comprise penetration aperture configuration. 
     
     
         23 ) The apparatus of  claim 21 , wherein said varying characteristics comprise pressure specifications. 
     
     
         24 ) The apparatus of  claim 21 , wherein said outer mounting ring is interchangeable with other outer mounting rings having alternative bolt hole patterns. 
     
     
         25 ) The apparatus of  claim 1 , wherein said component comprises a packer and said sealing element comprises a packer element, and whereby, upon applying tension to said packer element, said packer expands to seal said component passage against said component as well as a space between said tubing and said casing, sealing said annulus. 
     
     
         26 ) The apparatus of  claim 25 , wherein said gripper comprises a side door having a raised area positioned to grip said component upon closing said side door over said slot. 
     
     
         27 ) The apparatus of  claim 26 , wherein said component comprises a power line for a submersible pump. 
     
     
         28 ) The apparatus of  claim 27 , wherein said power line comprises three separate insulated conductors. 
     
     
         29 ) The apparatus of  claim 28 , wherein each said three insulated conductors are situated in a separate tube so that said conductors pass through said component passage in said sealing element while enveloped by said tubes. 
     
     
         30 ) The apparatus of  claim 29 , wherein each of said tubes pass through said slot and is positioned to be gripped by said gripper. 
     
     
         31 ) The apparatus of  claim 29 , wherein each of said three insulator conductors with tubes comprise tubing encapsulated conductors. 
     
     
         32 ) The apparatus of  claim 31 , wherein each of said tubing encapsulated conductors having first and second ends, with said first and second ends spliced to respective conductors in jacketed ESP power lines above and below said packer, respectfully. 
     
     
         33 ) A method of sealing an annulus in a wellhead having a component emanating therefrom, comprising the steps of:
 a) providing a hanger having a main seal;   b) threading said component through a passage formed in said main seal;   c) engaging said hanger to said tubing string;   d) positioning said hanger in a bowl;   e) compressing said main seal, providing a compressed main seal;   f) utilizing said compressed main seal to reposition a portion thereof so as to seal said component and said bowl, sealing said annulus.   
     
     
         34 ) The method of  claim 33 , wherein there is provided after step wherein there is provided after step “f” the added step “g” of securing a surface component over said wellhead. 
     
     
         35 ) The method of  claim 34 , wherein step “g” comprises the added sub-step “g 1 ” threading a length of said component through a compression fitting associated with said surface component, and engaging said compression fitting, providing sealed pass-through of said component through said surface component. 
     
     
         36 ) The method of  claim 35 , wherein in step “g 1 ” said surface component has formed therein pass-through passage having a compression receiver, and wherein there further comprises the added sub-step “g 2 ” of mounting a pass-through adapter to said surface component, providing a split insert about said component in said compression receiver, then tightening fasteners mounted to said pass-through adapter so as to urge said split insert into said compression receiver, so as to provide a pass-through seal at said surface component. 
     
     
         37 ) The method of  claim 36 , wherein said surface component comprises a bowl cap. 
     
     
         38 ) The method of  claim 36 , wherein said surface component comprises a tubing head adapter. 
     
     
         39 ) A surface component, comprising:
 a mounting surface for receiving a pass-through adapter;   a passage formed through said surface component, said passage comprising
 a socket formed in said mounting surface, said socket having an inner diameter (ID) formed to engage a sleeve associated with said pass-through adapter; and 
 a compression receiver formed in said surface component, said compression receiver formed to receive a frustoconical split insert; 
   whereby, upon passing a conduit or wire through said passage between said frustoconical split insert in said compression receiver and tightening threaded fasteners to mount said pass-through adapter to said mounting surface, said split insert forms a seal about conduit or wire and said compression receiver, providing sealed pass-through of said line or conduit through said surface component.   
     
     
         40 ) The apparatus of  claim 39 , wherein said wherein said frustoconical split insert has a profile formed to engage said line or conduit situated therebetween. 
     
     
         41 ) The apparatus of  claim 40 , wherein there is further provided a conduit connector mounted to said pass-through adapter, said conduit connector engaging said line or conduit. 
     
     
         42 ) The apparatus of  claim 40 , wherein said surface component comprises a conductors' bowl cap. 
     
     
         43 ) The apparatus of  claim 40 , wherein said surface component comprise a tubing head adapter. 
     
     
         44 ) A packer for sealing an annulus between a string of tubing and casing in a well, comprising:
 a slot formed to receive a component,   a gripper to grip said component in said slot,   a packing element having a component passage formed therethrough in alignment with said slot,   whereby, upon a) mounting said packer to said tubing and threading said component through said component passage and slot, b) engaging said gripper to said component, and positioning said packer downhole, and c) expanding said packing element, said expanded packing element seals said component passage about said component and the space between said tubing and said casing, sealing said annulus.   
     
     
         45 ) The apparatus of  claim 44 , wherein said gripper comprises a side door having a raised area positioned to grip said component upon closing said side door over said slot. 
     
     
         46 ) The apparatus of  claim 45 , wherein said raised area of said side door has a profile shaped to engage said component. 
     
     
         47 ) The apparatus of  claim 46 , wherein said component profile is formed on the side of said door facing said slot. 
     
     
         48 ) The apparatus of  claim 47 , wherein said component profile comprises a first insert situated in said slot. 
     
     
         49 ) The apparatus of  claim 48 , wherein there is further provided a second insert facing said slot to engage said component. 
     
     
         50 ) The apparatus of  claim 49 , wherein said second insert comprises a raised area positioned to grip said first component upon closing said side door over said first slot. 
     
     
         51 ) The apparatus of  claim 50 , wherein said second insert has a profile shaped to engage said component. 
     
     
         52 ) The apparatus of  claim 51 , wherein said first and second inserts are interchangeable with inserts having different profiles formed to engage different components. 
     
     
         53 ) A method of sealing an annulus between a string of tubing and casing in a well, comprising:
 a) providing a packer having:
 a first slot formed to receive a component; 
 a gripper to grip said component in said slot; and 
 a packing element having a component passage formed therethrough in alignment with said slot; 
   b) mounting said packer to said tubing and threading said component through said component passage and first slot;   c) engaging said gripper to said component   d) positioning said packer downhole, and   e) expanding said packing element such that expanded packing element seals said component passage about said component and the space between said tubing and said casing.   
     
     
         54 ) The method of  claim 53 , wherein in step “a” said gripper comprises a side door having a raised area; and in step “c” said gripper is positioned to grip said component upon closing said side door over said first slot. 
     
     
         55 ) The method of  claim 54 , wherein step “a” further comprises the sub-step “ai” of providing in said raised area of said side door a profile formed to engage said component. 
     
     
         56 ) The method of  claim 53 , wherein in step “ai” said raised area comprises a first raised area selected from a group of profiles, and there is further included the step “aia” of mounting said component to said side door so as to face said slot. 
     
     
         57 ) The method of  claim 53 , wherein in step “a” said gripper comprises a first insert having a profile selected from a group of profiles, said first insert formed to formed to engage said component via said slot. 
     
     
         58 ) The method of  claim 57 , wherein in step “a” said gripper further comprises a second insert having a raised area having profile formed to engage said component in said slot opposite said first component. 
     
     
         59 ) The method of  claim 58 , wherein step “c” further comprises the added sub-step “ci” of positioning said raised areas of said first and second inserts to engage and grip said component in said slot. 
     
     
         60 ) The method of  claim 59 , wherein in step “a” said first and second inserts are formed so as to facilitate interchangeability with inserts having different profiles formed to engage different components. 
     
     
         61 ) The method of  claim 1 , wherein said component comprises a bridge plug and whereby, upon expanding said sealing element, said expands to seal said component passage against said component as well as the space between said tubing and said casing, sealing off said annulus. 
     
     
         62 ) The method of  claim 61 , wherein said gripper comprises a side door having a raised area positioned to grip said component upon closing said side door over said slot. 
     
     
         63 ) A method of sealing off an annulus between tubing and casing in a well, comprising the steps of:
 a) providing an apparatus comprising at least one gripper formed to engage and grip component(s) passing therethrough;   b) providing for said apparatus a main seal having passage(s) having a profile formed to receive said component(s) therethrough, said passage(s) situated in alignment with said gripper of step a, said passage(s) formed receive a length of said component(s) therethrough;   c) mounting said apparatus about said tubing;   d) positioning said component(s) to pass through said gripper and through said main seal;   e) engaging said gripper to grip said component(s);   f) positioning said apparatus at a desired position in the well;   g) applying pressure to said main seal to seal said component(s) passing therethrough, expanding to form a seal between said tubing and said casing, sealing off the annulus therebetween.   
     
     
         64 ) The method of  claim 63 , wherein said apparatus comprises a packer. 
     
     
         65 ) An apparatus for sealing off an annulus between a string of tubing and casing for a well, comprising:
 a slot formed to receive a component, a gripper formed to grip said component in said slot,   a sealing element having a component passage formed therethrough in alignment with said slot,   said apparatus formed to engage said tubing with said component threaded through said component passage and slot, and gripped by said gripper, said sealing element formed to expand to facilitate a seal about said component;   said apparatus further comprising a packer wherein said sealing element is formed such that, upon expansion of said packer element, said packer expands to seal said component passage against said component as well as a space between said tubing and said casing, so as to seal said annulus.   
     
     
         66 ) The apparatus of  claim 65 , wherein said gripper comprises a side door having a raised area positioned to grip said component upon closing said side door over said slot. 
     
     
         67 ) The apparatus of  claim 66 , wherein said raised area of said side door has a profile shaped to engage said component. 
     
     
         68 ) The apparatus of  claim 67 , wherein said component profile is formed on the side of said door facing said slot. 
     
     
         69 ) The apparatus of  claim 68 , wherein said component profile comprises a first insert situated in said slot. 
     
     
         70 ) The apparatus of  claim 69 , wherein there is further provided a second insert facing said slot to engage said component. 
     
     
         71 ) The apparatus of  claim 70 , wherein said second insert comprises a raised area positioned to grip said first component upon closing said side door over said first slot. 
     
     
         72 ) The apparatus of  claim 71 , wherein said second insert has a profile shaped to engage said component. 
     
     
         73 ) The apparatus of  claim 72 , wherein said first and second inserts are interchangeable with inserts having different profiles formed to engage different components.