ALIGNABLE GUIDANCE DEVICE FOR CASING ENTRY MILLING OPERATIONS

Abstract

An alignable guidance device includes a tube section and a casing milling shoe within the tube section, a pre-contoured tube within the casing milling shoe that terminates in an exit point in the tube section, the pre-contoured tube exiting the tube section at an exit angle of between 0° and 45°, and guidance sensors within the tube section.

Description

TECHNICAL FIELD/FIELD OF THE DISCLOSURE

The present disclosure relates to a downhole casing milling guidance device in reference to an in-situ casing.

BACKGROUND OF THE DISCLOSURE

During the life cycle of an oil well, an operator may need to gain hydraulic access to an existing cased wellbore when the wellbore is not accessible by typical re-entry procedures. For example, during the creation of the wellbore, if the wellbore penetrates a zone with pressure higher than the hydrostatic mud weight in the wellbore and pressure control systems fail, a blowout may occur that may result in the release of oil and/or natural gas. One method to control such a blowout is to drill a relief well to intercept the blowout wellbore.

As another example, at the end of a well's life cycle, a well is plugged and abandoned. Occasionally, the plugged and abandoned (P&A) well is improperly abandoned and may leak. Such a situation may require the drilling of an intercept well to fix and properly abandon the well.

In another example, during the drilling or completion phase of the well, a tubular “fish” or damaged tubular section may have been left in the well. An intercept well may be drilled to re-enter the wellbore to secure continued use of the wellbore and/or set abandonment plugs.

To gain hydraulic access to the existing cased wellbore, an operator may need to drill the intercept wellbore. Once the operator has drilled the intercept wellbore sufficiently close to the existing wellbore, a casing entry tool may be used to penetrate the existing tubular and gain hydraulic access thereto.

SUMMARY

An alignable guidance device is disclosed. The alignable guidance device includes a tube section and a casing milling shoe within the tube section, a pre-contoured tube within the casing milling shoe that terminates in an exit point in the tube section, the pre-contoured tube exiting the tube section at an exit angle of between 0° and 45°, and guidance sensors within the tube section.

In another embodiment, a method of intercepting an existing well is disclosed. The method includes supplying an alignable guidance device, the alignable guidance device including a tube section, a casing milling shoe within the tube section, a pre-contoured tube within the casing milling shoe that terminates in an exit point in the tube section, and guidance sensors within the tube section. The method also includes running the alignable guidance device into a wellbore and aligning the alignable guidance device relative to a casing using information from the sensors based on the alignment of alignable guidance device. The method further includes, after aligning the alignable guidance device, holding in place or anchoring the alignable guidance device and inserting a casing milling tool into the pre-contoured tube. The method also includes cutting a hole in the in-situ casing with the casing milling tool and removing the casing milling tool.

In yet another embodiment, a system for forming a hole in in-situ casing is disclosed. The system includes an alignable guidance device including a tube section, a casing milling guidance device within the tube section, the casing milling guidance device pre-contoured, the casing milling guidance device exiting the tube section at an exit angle of between 0° and 45°, and guidance sensors within the tube section. The system also includes a hydraulic release tool, the hydraulic release tool connected at a first end to the alignable guidance device and at a second end to a run-in string. The system further includes a retrievable EM tool, the retrievable EM tool positioned within the run-in string and electrically connected to the guidance sensors.

In yet another embodiment, a method is disclosed. The method includes supplying a system for forming a hole in in-situ casing. The system includes an alignable guidance device including a tube section, a casing milling guidance device within the tube section, the casing milling guidance device pre-contoured, the casing milling guidance device exiting the tube section at an exit angle of between 0° and 45°, and guidance sensors within the tube section. The system also includes a hydraulic release tool, the hydraulic release tool connected at a first end to the alignable guidance device and at a second end to a run-in string, wherein the hydraulic release tool includes a latch. In addition, the method includes positioning a retrievable EM tool within the run-in string, the retrievable EM tool connected to the guidance sensors. The method also includes inserting the system for forming a hole in in-situ casing into a wellbore, using the run-in string until the system for forming a hole in casing contacts casing. In addition, the method includes measuring the orientation of the casing milling guidance device relative to the casing using the guidance sensors and rotating the casing milling guidance device until the casing milling guidance device is facing a centerline of the casing. The method further includes anchoring the alignable guidance device and detaching the retrievable EM tool from the alignable guidance device. In addition, the method includes removing the retrievable EM tool from the wellbore and unlatching the latch. Also, the method includes inserting a casing milling tool through the alignable guidance device and cutting a hole in the in-situ casing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIG. 1 is a vertical cross-sectional view of an alignable guidance device consistent with certain embodiments of the present disclosure in proximity to casing.

FIG. 1A is a horizontal cross-sectional view of an alignable guidance device consistent with certain embodiments of the present disclosure in proximity to casing.

FIG. 1B is a portion of the tube section of an alignable guidance device consistent with certain embodiments of the present disclosure.

FIG. 1C is a depiction of an alignable guidance device proximate casing.

FIG. 2 is a vertical cross-sectional view of an alignable guidance device in conjunction with a retrievable EM tool and a hydraulic release tool consistent with certain embodiments of the present disclosure.

FIG. 3 is a vertical cross-sectional view of an alignable guidance device in conjunction with a hydraulic release tool consistent with certain embodiments of the present disclosure.

FIG. 4 is a vertical cross-sectional view of an alignable guidance device in conjunction with a hydraulic release tool with a ball seated consistent with certain embodiments of the present disclosure.

FIG. 4A is a vertical cross-sectional view of an alignable guidance device in conjunction with a hydraulic release tool including a shearing device with a ball seated consistent with certain embodiments of the present disclosure.

FIG. 5 is a vertical cross section of an alignable guidance device in conjunction with the hydraulic release tool in its release position consistent with certain embodiments of the present disclosure.

FIG. 6 depicts the collet and alignable guidance device anchored in place in the hole.

FIG. 7 depicts the insertion of a casing milling tool inserted into the alignable guidance device.

FIG. 7A depicts the insertion of a cement stinger inserted into the alignable guidance device.

FIGS. 8a -8c show the operation of a latch consistent with certain embodiments of the present disclosure.

DETAILED DESCRIPTION

It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

The present disclosure includes embodiments of alignable guidance device 100 for guiding a casing milling tool to in-situ casing 20. As shown in FIG. 1, alignable guidance device 100 includes casing milling shoe 120 within tube section 140. Tube section 140 surrounds casing milling shoe 120. Within casing milling shoe 120 is pre-contoured tube 135. Pre-contoured tube 135 terminates in exit point 150 in tube section 140 as shown in FIG. 1B.

In one non-limiting example, pre-contoured tube 135 is in the shape of a slim curved bore inside tube section 140. Pre-contoured tube 135 exits tube section 140 radially at an exit angle of between 0° and 45°, or between 10° and 30°. In the non-limiting example shown in FIGS. 1 and 1C, the exit angle is 20°. In certain embodiments, pre-contoured tube 135 has coned starting hole 125. Coned starting hole 125 may act to ease the entry of a milling tool, such as a micro turbine milling or micro motor milling tool that may be run through casing milling shoe 120 before the milling operation begins. In certain embodiments, as shown in FIG. 1B, tube section 140 may include notch 137 near or at exit point 150. Notch 137 may assist in maintaining the orientation between alignable guidance device 100 and in-situ casing 20.

Casing milling shoe 120 may be manufactured in a casting mold process and be made of epoxy, cement, or steel, for example. In other embodiments, casing milling shoe 120 may be manufactured by mechanical milling, 3D printing, casting technique, or a welding process, such as a pre-contoured steel tube welded within tube section 140.

As further shown in FIG. 1, in certain embodiments, alignable guidance device 100 may also include guidance sensor(s) 190. Guidance sensor(s) 190 may act to orient casing milling shoe 120 so that casing milling shoe 120 is properly set at centerline 25 of in-situ casing 20. An example of guidance sensor(s) 190 may be found in U.S. provisional application No. 63/433,672, filed Dec. 19, 2022, which is incorporated herein by reference.

In some embodiments, alignable guidance device 100 may be run-in using casing, coiled tubing or drill string. FIG. 1C depicts alignable guidance device 100 connected to casing 152. Alignable guidance device 100 may then be aligned based on guidance sensors 190, for example, such that alignable guidance device 100 is centered on the centerline of in-situ casing 20. After alignment, alignable guidance device 100 may be held in place from the surface using a top drive, rotary table, or kelly drive, which holds the casing, tubing, or drill string in place. In other embodiments, alignable guidance device 100 may be anchored using clamps or cement. In some embodiments, no release mechanism exists to release alignable guidance device 100 once anchored.

In yet other embodiments, as shown in FIG. 2, alignable guidance device 100 may be attached to collet 160, which is attached to tube section 140 adaptable for holding a running tool, described hereinafter. Situated within collet 160 is open hole hydraulic set packer 180. In certain embodiments, as shown in FIG. 2, alignable guidance device 100 may work in conjunction with retrievable EM tool 200 and hydraulic release tool 300. Prior to milling, hydraulic release tool 300 may be positioned in wellbore 10, for example, along with alignable guidance device 100 and retrievable EM tool 200. FIG. 2 depicts hydraulic release tool 300 in its run-in position. In other embodiments, EM signals may be passed up-hole using mud pulse or wireline transmission. In certain embodiments, when EM signals are transmitted via wireline, the wireline may be deployed via coiled tubing.

Hydraulic release tool 300 is connected to run-in string 15 with connector latch portion 310 of hydraulic release tool 300. The combination of connector latch portion 310, movable latch portion 320, and collet 160 act to form latch 340. In certain embodiments, centralizer 210 holds retrievable EM tool 200 in place during the deployment phase and the alignment phase of the casing entry drilling method, described herein below.

When in the run-in position, such as during the deployment phase, male snap arm 312 of connector latch portion 310 is held in collet recess 332 of collet 160 by shoulder 322 of movable latch portion 320. Movable latch portion 320 further includes movable latch portion orifice 324, which is aligned with collet orifice 334 and both are adapted to pass fluid to open hole hydraulic set packer 180 positioned within packer inflation element cut out 336 of collet 160.

During the deployment phase and the alignment phase, retrievable EM tool 200 is positioned within run-in string 15. Retrievable EM tool 200 may be held in place with centralizer 210 positioned between retrievable EM tool and connector latch portion 310. Retrievable EM tool 200 may contain electronics 220. Retrievable EM tool 200 may be connected via wireline 240 to power and communication cable 250. Wireline 240 and power and communication cable 250 may be connected together with decoupling device 260. Decoupling device 260 may be any device capable of carrying communications and power, but able to decouple wireline 240 and power and communications cable 250 when retrievable EM tool 200 is removed from wellbore 10.

Power and communications cable 250 is connected to guidance sensor(s) 190 to provide power to the sensors and to transmit sensor information to retrievable EM tool 200. The guidance sensor(s) 190 in some embodiments may be disposed in an end plate 202 included as part of the tube section 140 of alignable guidance device 100. In certain embodiments, retrievable EM tool 200 may gather sensor information and determine the orientation of casing milling shoe 120. Retrievable EM tool 200 may then transmit the orientation of casing milling shoe 120 to the surface through a telemetry system. In other embodiments, retrievable EM tool 200 may transmit sensor information to the surface through a telemetry system for determination of the orientation of casing milling shoe 120 at the surface.

After the deployment phase, the alignment phase begins. During the alignment phase, power is delivered to guidance sensor(s) 190 and data from guidance sensor(s) 190 is sent to retrievable EM tool 200, wherein the orientation of casing milling shoe 120 is determined in retrievable EM tool 200 or at the surface. Power may be supplied from a battery, an MWD, or from the surface. If the orientation of casing milling shoe 120 is not facing centerline 25 of in-situ casing 20, casing milling shoe 120 may be rotated by rotating run-in string 15.

Once casing milling shoe 120 is facing centerline 25 of in-situ casing 20, retrievable EM tool 200 may be removed as shown in FIG. 3 during the EM tool removal phase. As described above, wireline 240 may be detached from power and communications cable 250 with decoupling device 260 as retrievable EM tool 200 is removed from wellbore 10.

Following the EM removal phase, tool set phase begins. Ball 400 is dropped into wellbore 10 and seats on seat 350 of connector latch portion 310, as shown in FIG. 4. Next, as shown in FIGS. 4 and 5, fluid is pumped into wellbore 10 and through movable latch portion orifice 324 and collet orifice 334, which expands open hole hydraulic set packer 180 to anchor in place collet 160 and therefore alignable guidance device 100. In addition, the weight of the fluid causes hydraulic release tool 300 to move downhole into its release position. In its release position, movable latch portion 320 is pushed downhole such that male snap arm 312 is no longer held in collet recess 332 by shoulder 322. Movable latch portion 320 is pushed down until lip 327 of movable latch portion 320 contacts inner diameter profile 313 of connector latch portion 310, locking movable latch portion 320 to connector latch portion 310 as shown in FIG. 5.

In an alternate tool set phase, depicted in FIG. 4A, shearing device 314, such as shear pins or shear bolts, may connect hydraulic release tool 300 to connector latch portion 310. Ball 400 is dropped into wellbore 10 and seats on seat 350 of connector latch portion 310, as shown in FIG. 4. Next, as shown in FIGS. 4A and 5, fluid is pumped into wellbore 10 and through movable latch portion orifice 324 and collet orifice 334 at a first pressure. The first pressure is insufficient to shear shearing device 314. Once the open hole hydraulic set packer 180 has been inflated, the fluid pressure is increased from the first pressure to the second pressure. The second pressure is sufficient to shear shearing device 314. Once shearing device 314 is sheared, the pressure of the fluid causes hydraulic release tool 300 to move downhole into its release position. In its release position, movable latch portion 320 is pushed downhole such that male snap arm 312 is no longer held in collet recess 332 by shoulder 322. Movable latch portion 320 is pushed down until lip 327 of movable latch portion 320 contacts inner diameter profile 313 of connector latch portion 310, locking movable latch portion 320 to connector latch portion 310 as shown in FIG. 5.

The actions to release alignable guidance device 100 from run-in string 15 are shown in detail in FIGS. 8a -8c. As shown in FIG. 8a, male snap arm 312 is positioned within collet recess 332 by shoulder 322. Male snap arm 312 and collet recess 332 may together form a cantilever or annular snap-fit joint, which is held and locked in engagement by shoulder 322, as shoulder 322 prevents male snap arm 312 from moving radially inward and thus disengaging from collet recess 332. FIG. 8b shows how movable latch portion 320 is pushed downhole such that shoulder 322 no longer holds male snap arm 312. FIG. 8c depicts how male snap arm 312 retracts from collet recess 332, thus allowing for the separation of connector latch portion 310 and tube section 140.

Run-in string 15 is removed, along with connector latch portion 310 and movable latch portion 320. As shown in FIG. 6, collet 160 and alignable guidance device 100 remain anchored in the hole. As shown in FIG. 7, casing milling tool 600 may be run in wellbore 10 through alignable guidance device 100. Casing milling tool 600 may then drill through tube section 140 and into in-situ casing 20 to form a fluid channel from inside the in-situ casing 20 into tube section 140 to wellbore 10 (or casing 152 for the embodiment shown in FIG. 1C) through pre-contoured tube 135. One example of a suitable casing milling tool 600 is a micro turbine cutter described in German patent application DE 10 2020 205 764 A1, which is incorporated herein by reference. Casing milling tool 600 upon cutting a hole in in-situ casing 20 is then removed, and, in certain embodiments as shown in FIG. 7A, cement stinger 700 is inserted in alignable guidance device 100, where cement is pumped through the hole in in-situ casing 20 and into in-situ casing 20. In certain embodiments, cement stinger 700 may extend into in-situ casing 20.

The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.

Claims

1. An alignable guidance device, comprising: a tube section;a casing milling shoe within the tube section, a pre-contoured tube within the casing milling shoe that terminates in an exit point in the tube section, the pre-contoured tube exiting the tube section at an exit angle of between 0° and 45°; andguidance sensors within the tube section.

2. The alignable guidance device of claim 1, wherein the pre-contoured tube is in the shape of a slim curved bore section within the tube section.

3. The alignable guidance device of claim 1, wherein the pre-contoured tube has a coned starting hole opposite the exit of the pre-contoured tube.

4. The alignable guidance device of claim 1, wherein the casing milling shoe is made of epoxy, cement, or steel.

5. The alignable guidance device of claim 1, wherein the casing milling shoe is manufactured by mechanical milling, 3D printing, casting technique, or a welding process.

6. The alignable guidance device of claim 1, wherein the tube section has a notch proximate the exit point.

7. A method of intercepting an existing well, comprising: supplying an alignable guidance device, the alignable guidance device including: a tube section;a casing milling shoe within the tube section, a pre-contoured tube within the casing milling shoe that terminates in an exit point in the tube section; andguidance sensors within the tube section;running the alignable guidance device into a wellbore;aligning the alignable guidance device relative to a casing using information from the sensors based on alignment of alignable guidance device;after aligning the alignable guidance device, holding in place or anchoring the alignable guidance device;inserting a casing milling tool into the pre-contoured tube;cutting a hole in the in-situ casing with the casing milling tool; andremoving the casing milling tool.

8. The method of claim 7 further comprising after removing the casing milling tool: inserting a cement stinger through the pre-contoured tube and into the casing; andintroducing cement into the casing through the cement stinger.

9. The method of claim 7, wherein the casing milling tool is a micro-turbine cutter.

10. The method of claim 7, wherein the alignable guidance device is held using a top drive, rotary table, or kelly drive.

11. The method of claim 7, wherein the alignable guidance device is anchored using clamps or cement.

12. A system for forming a hole in casing, comprising: an alignable guidance device including: a tube section;a casing milling guidance device within the tube section, the casing milling guidance device pre-contoured for exiting the tube section at an exit angle of between 0° and 45°; andguidance sensors within the tube section;a hydraulic release tool, the hydraulic release tool connected at a first end to the alignable guidance device and at a second end to a run-in string; anda retrievable EM tool, the retrievable EM tool positioned within the run-in string and electrically connected to the guidance sensors.

13. The system of claim 12, wherein the hydraulic release tool includes a connector latch portion, a movable latch portion, and a collet to form a latch.

14. The system of claim 13, wherein the connector latch portion includes a male snap arm, the collet includes a collet recess, and the movable latch portion includes a shoulder.

15. The system of claim 14, wherein the male snap arm is held in the collet recess by the shoulder.

16. The system of claim 12, wherein the electric connection between the retrievable EM tool is made by a wireline connected to the EM tool, the wireline connected to a decoupling device, and a power and communications cable connected to the sensors and the decoupling device.

17. A method, comprising: supplying a system for forming a hole in casing comprising: an alignable guidance device including: a tube section;a casing milling guidance device within the tube section, the casing milling guidance device pre-contoured for exiting the tube section at an exit angle of between 10° and 30°; andguidance sensors within the tube section; anda hydraulic release tool, the hydraulic release tool connected at a first end to the alignable guidance device and at a second end to a run-in string, wherein the hydraulic release tool includes a latch;positioning a retrievable EM tool within the run-in string, the retrievable EM tool connected to the guidance sensors;inserting the system for forming a hole in casing into a wellbore using the run-in string until the system for forming a hole in casing contacts a casing;measuring orientation of the casing milling guidance device relative to the casing using the guidance sensors;rotating the casing milling guidance device until the casing milling guidance device is facing a centerline of the casing;anchoring the alignable guidance device;detaching the retrievable EM tool from the alignable guidance device;removing the retrievable EM tool from the wellbore;unlatching the latch;inserting a casing milling tool through the alignable guidance device; andcutting a hole in the casing.

18. The method of claim 17, further comprising after cutting a hole in the casing: removing the casing milling tool from the alignable guidance device;inserting a cement stinger though the hole in the casing; andpumping cement into the casing.

19. The method of claim 17, wherein power is supplied to the retrievable EM tool via battery, MWD, or from the surface.