Patent Grant
6863126
The present invention relates generally to operations performed and equipment utilized in conjunction with a subterranean well and, in an embodiment described herein, more particularly provides a multilateral well injection/production system utilizing at least one alternate path.
In general, flow control between a main or parent wellbore and multiple branch wellbores intersected by the parent wellbore is accomplished either by installing a production or completion string in casing lining the parent wellbore, or by installing flow control devices in the individual branch wellbores. Each of these types of systems has its own disadvantages. For example, the completion string in the parent wellbore obstructs the interior of the casing, and the flow control devices in the branch wellbores require difficult and time-consuming procedures to access the devices for maintenance, provide power to and control of the devices, etc.
Furthermore, these prior systems and methods do not provide for conducting other beneficial operations in a multilateral well, for example, drilling one branch wellbore while producing from or performing other operations in another branch wellbore, separating hydrocarbons and water from fluid flowed out of one branch wellbore and injecting the water into another branch wellbore, retrieving flow control devices for maintenance while leaving the rest of the completion system undisturbed, etc.
Therefore, it is well known to those skilled in the art that improved systems and methods for drilling and completing multilateral wells are needed.
In carrying out the principles of the present invention, in accordance with an embodiment thereof, a completion system is provided which solves at least some of the above described problems in the art. Methods of drilling and completing multilateral wells are also provided. These systems and methods utilize an apparatus which includes a mandrel having various passages formed therein. The passages are uniquely configured and interconnected to enable a variety of operations to be performed in a multilateral well.
In one aspect of the invention, a system for completing a well is provided. The system includes two apparatuses interconnected in a casing string in a wellbore. An internal flow passage of the casing string extends through a first passage of each of the apparatuses. Each of the apparatuses further has a second passage intersecting the first passage. In addition, a third passage of each of the apparatuses provides fluid communication between the apparatuses separate from the casing string flow passage.
In another aspect of the invention, another system for completing a well having intersecting wellbores is provided. The system includes a casing string positioned in one of the wellbores and at least one apparatus interconnected in the casing string. The apparatus includes a mandrel having intersecting passages formed therein.
The first passage extends longitudinally through the mandrel and is in fluid communication with an interior of the casing string. The second passage extends laterally relative to the first passage and is configured for drilling the other wellbore therethrough. The mandrel further includes at least one third passage extending longitudinally in the mandrel.
In yet another aspect of the invention, a method of drilling and completing a well having intersecting wellbores is provided. The method includes the steps of: interconnecting at least one apparatus in a casing string having an internal longitudinal flow passage formed therethrough, the apparatus including first and second passages formed therein, the first passage extending longitudinally through the apparatus and forming a portion of the casing string flow passage; positioning the apparatus in one of the wellbores at a location where it is desired to drill the other wellbore; drilling the other wellbore by passing a drill string through the first and second passages; and flowing fluid between the second wellbore and a remote location through a third passage of the apparatus, the third passage being isolated from the first passage in the apparatus.
In a further aspect of the invention, a system for completing a well having intersecting wellbores is provided. The system includes at least one apparatus positioned in one of the wellbores and having first and second passages formed therethrough. The first passage forms a portion of an internal flow passage of a casing string in which the apparatus is interconnected, and the second passage provides access between the first passage and the other wellbore. The apparatus also has a third passage isolated from the first passage while fluid is flowed between the third passage and the other wellbore.
In a still further aspect of the invention, a method of completing a well having a first wellbore intersecting each of second and third wellbores is provided. First and second apparatuses are interconnected in a casing string. Each of the apparatuses has a first passage formed therethrough which forms a portion of an internal flow passage of the casing string, and a second passage intersecting the first passage and extending laterally relative to the first passage.
The casing string is positioned in the first wellbore. Fluid is received from one of the second and third wellbores into one of the first and second apparatuses. Hydrocarbons and water are separated from the fluid received into the one of the first and second apparatuses. One of the separated hydrocarbons and water is flowed to the other of the first and second apparatuses through a third passage interconnected between the first and second apparatuses.
These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of representative embodiments of the invention below and the accompanying drawings.
Representatively illustrated in
In the system 10, an apparatus 12 is interconnected in a casing string 14 and positioned in a main or parent wellbore 16. As used herein, the terms “casing”, “casing string”, “cased” and the like are used to indicate any tubular string used to form a protective lining in a wellbore. A casing string may be made of any material, such as steel, plastic, composite materials, aluminum, etc. A casing string may be made up of separate segments, or it may be a continuous tubular structure. A casing string may be made up of elements known to those skilled in the art as “casing” or “liner”.
The apparatus 12 includes a mandrel 18 in which several passages 20, 22 are formed. The mandrel 18 may be made as a single structure, or it may be made up of any number of separate elements.
The passage 20 extends longitudinally through the mandrel 18 and forms a part of an internal flow passage 28 through the casing string 14. The passage 22 intersects the passage 20 and extends laterally relative to the passage 20. A deflector (not shown) may be installed in the mandrel 18 to deflect cutting tools, etc., from the passage 20 and through the passage 22 to drill a branch wellbore, and after the branch wellbore is drilled, to deflect completion equipment, tools, etc., from the parent wellbore 16 into the branch wellbore.
A flow control device 24 is interconnected between the passages 20, 22 via passages 38, 40 to control flow therebetween when a plug 26 is installed to block flow directly between the passages. The flow control device 24 may be controlled and communicated with using lines 30 extending to a remote location, such as the earth's surface or another location in the well. Sensors (not shown) may be included in the apparatus 12 to monitor downhole conditions, interface with the flow control devices 24, etc. The sensors may also be connected to the lines 30. Alternatively, the flow control device 24 and/or sensors may be controlled by or communicate with the remote location via any form of telemetry.
A similar apparatus is more fully described in the application incorporated herein and entitled SURFACE CONTROLLED SUBSURFACE LATERAL BRANCH SAFETY VALVE AND FLOW CONTROL SYSTEM. The various alternative embodiments and optional features and configurations described in the incorporated application may also be used in the system 10, without departing from the principles of the invention.
The apparatus 12 and the remainder of the casing string 14 are being cemented in the parent wellbore 16 as depicted in FIG. 1. For this purpose, cement 32 is flowed through an annulus 34 formed between the casing string 14 and the wall of the wellbore 16. As used herein, the terms “cementing”, “cement” and the like are used to indicate any process using a material which is flowed between a tubular string and a wellbore, and which secures the tubular string in the wellbore and prevents fluid flow therebetween. Cement may include cementitious material, epoxies, other polymer materials, any hardenable and/or adhesive sealing material, etc.
Since the mandrel 18 extends outward from the remainder of the casing string 14 as depicted in
Referring additionally now to
Referring additionally now to
In the system 50, two of the apparatuses 12 are interconnected in the casing string 14 and positioned and cemented in the parent wellbore 16. A branch wellbore 52 has been drilled extending outward from the parent wellbore 16 by deflecting one or more cutting tools from the passage 20 through the passage 22 of the upper mandrel 18. After drilling the branch wellbore 52, the plug 26 is installed to prevent direct flow between the passages 20, 22 of the upper mandrel.
Another branch wellbore 54 is then drilled through the lower mandrel 18 by deflecting a drill string 58 including one or more cutting tools 56 from the passage 20 through the passage 22 using a deflector, such as a drilling whipstock 60 positioned in the passage 20. It will be appreciated by those skilled in the art that would be beneficial to be able to perform operations in the upper branch wellbore 52 while the lower branch wellbore 54 is being drilled. For example, fluid could be produced from the upper branch wellbore 52 to generate revenue while the lower branch wellbore 54, or another branch wellbore, is being drilled.
To enable these other operations to be performed simultaneously with drilling in the lower branch wellbore 54, the upper mandrel 18 is provided with one or more alternate paths, similar in some respects to the passages 36 shown in FIG. 2 and described above. Representatively illustrated in
In
As depicted in
The passage 62 is in fluid communication with a tubular string 64 extending to a remote location (see FIG. 3). By opening the flow control device 24 to permit flow between the passages 22, 62, fluid may be produced from the branch wellbore 52 to the remote location through the tubular string 64 while the other branch wellbore 54 is being drilled through the passage 20.
As another alternative, the branch wellbore 52 may be stimulated, such as by acidizing, fracturing, etc., by flowing stimulation fluid from the remote location through the tubular string 64, through the passage 62, through the flow control device 24, through the passage 22 and into the branch wellbore. These types of stimulation operations may be performed in the upper branch wellbore 52 while the lower branch wellbore 54 is being drilled.
As yet another alternative, a formation test may be performed in the upper branch wellbore 52 while the lower branch wellbore 54 is being drilled. For example, the flow control device 24 may be closed to perform a pressure buildup or shut in test procedure, the flow control device may be opened to flow between the passages 22, 62 to perform a pressure drawdown or flow test procedure, etc., with the associated pressures and temperatures being monitored using the sensors in the apparatus 12 described in the incorporated application.
Additional versatility may be achieved by providing fluid communication between passages 62 formed in both of the upper and lower mandrels 18 using a tubular string 66 interconnected between the mandrels. That is, each of the upper and lower mandrels 18 is configured as depicted in
One example of this increased versatility is that the upper branch wellbore 52 could be drilled while fluid is produced from the lower branch wellbore 54. In this situation, the flow control device 24 of the lower apparatus 12 would be open to flow between the passages 22, 62, while the flow control device of the upper apparatus 12 would be closed to such flow.
Another example of this increased versatility is that fluid could be produced from both of the branch wellbores 52, 54 while yet another branch wellbore is being drilled, either above or below the illustrated branch wellbores 52, 54. In this situation, the flow control devices 24 in each of the mandrels 18 would be open to flow between the respective passages 22, 62.
It should also be understood that the combinations of operations which may be performed in separate wellbores using the system 50 is not limited to production and drilling. For example, one wellbore could be stimulated while a formation test is performed in another wellbore. Any combination and number of operations may be performed in any combination and number of wellbores in keeping with the principles of the invention.
Another tubular string 68 may provide fluid communication between the passages 62 in the illustrated mandrels 18 and any number of additional apparatuses 12 interconnected in the casing string 14. These additional apparatuses 12 may be positioned above or below the illustrated apparatuses.
In
This configuration may be useful, for example, in circumstances in which it is desired to flow fluids between one or more of the mandrels 18 and the remote location. One fluid, such as steam, water or a stimulation fluid, could be injected into selected one or more branch wellbores through the passage 62, while another fluid, such as oil or gas, is produced from other selected one or more branch wellbores through the other passage 70. In that situation, the flow control device(s) 24 of the mandrel(s) 18 selected for injection would be open to flow between the corresponding passage(s) 62 and the respective passage(s) 22, and the flow control devices of the mandrel(s) selected for production would be open to flow between the corresponding passage(s) 70 and the respective passage(s) 22.
In order for the flow control device 24 to selective control flow between the passages 20, 22, 62, 70, the flow control device may be a “four way” valve. Alternatively, separate flow control devices may be used to control corresponding separate fluid communication selections. For example, one flow control device may be used to control flow between the passages 22, 62, while another flow control device is used to control flow between the passages 22, 70, and yet another flow control device is used to control flow between the passages 20, 22. Thus, any combination and number of flow control devices may be used, without departing from the principles of the invention.
In
This configuration may be useful in situations in which a larger flow area is desired for the passage 62 than may be provided by a single larger diameter passage, for example, due to space limitations in the mandrel 18. As another example, the passage 62 may be susceptible to plugging by material, such as sand, carried in the fluid flowed therethrough, and so a redundant passage 62 is available in the event one of the passages becomes plugged.
The above described alternate configurations of the mandrel 18 and alternate paths formed therein as depicted in
Referring additionally now to
In the system 80, an alternate path, such as the passage 62 described above, is formed in a mandrel 82 and extends to a remote location through the tubular string 64 connected to the mandrel. The mandrel 82 is connected in the casing string 14 at an upper end thereof. However, a lower end of the mandrel 82 is connected in the casing string 14, and is also connected to another tubular string 84.
An annulus 86 between the casing string 14 and the tubular string 84 provides fluid communication between the passages 62 in the mandrel 82 and another mandrel 88 also connected to the casing string and tubular string. The passages 62 extend through the annulus 86 in a similar manner to that in which the passages 62 extend through the tubular string 66 between the mandrels 18 as depicted in FIG. 3. Additional mandrels may be interconnected to the mandrel 88 using more of the casing string 14 and the tubular string 84 therebelow.
Referring additionally now to
The system 90 includes a mandrel 92 which has the passages 20, 22 formed therein. However, instead of one of the flow control devices 24, the system 90 includes two of the flow control devices for selectively controlling flow between the passages 20, 22. One of the flow control devices 24 is positioned above the passage 22, and another of the flow control devices is positioned below the passage 22. Any number of the mandrels 92 may be interconnected, for example, as described above and depicted in
In
As mentioned above in the description of the alternate configuration of the system 50 depicted in
As an example of use of the system 90, the upper flow control device 24 may be opened to flow between the passages 62, 22 when it is desired to flow fluid from the passage 62 into the passage 22, such as to stimulate a branch wellbore extending outward from the passage 22, dispose of water produced from another wellbore, etc., and the lower flow control device may be opened to flow between the passages 70, 22 when it is desired to flow fluid from the passage 22 into the passage 70, such as to produce fluid from a branch wellbore, perform a formation test, etc. Of course, other types of operations, and other combinations and numbers of operations, may be performed using the system 90 in keeping with the principles of the invention.
Referring additionally now to
The system 100 includes a mandrel 102 which has the passages 20, 22 formed therein. As with the system 90 described above, the system 100 includes two of the flow control devices 24. However, only one of the flow control devices 24 (the upper flow control device as depicted in
In
When it is desired to permit flow between the passages 22, 70, the lower flow control device 24 is opened to such flow. In this situation, the lower flow control device 24 may or may not also permit flow between the passages 70, 104, depending upon the construction of the flow control device. However, flow between the passages 20, 70 is preferably not permitted at the same time flow between the passages 22 is permitted by the lower flow control device 24.
When it is desired to permit flow between the passages 20, 70, the upper flow control device 24 is opened to permit flow between the passages 38, 104, and the lower flow control device is opened to flow between the passages 70, 104. This situation may be desirable, for example, to inject a chemical, such a corrosion inhibitor or paraffin solvent, from the passage 70 into the passage 20 during production of the well.
Yet another flow control device 24 could be provided in the mandrel 102 to control flow between the passages 40, 62, in a manner similar to that in which the lower flow control device controls flow between the passages 40, 70. The system 100 further demonstrates the extraordinary versatility in multilateral well operations provided by the invention.
Referring additionally now to
As described above for the system 50 depicted in
As depicted in
However, the tool 124 could instead be retrieving a battery, actuator or other portion 122 of the flow control device 118 for repair, maintenance, inspection, recharging or replacement, etc. As another alternative, the tool 124 could be a shifting tool used to manually shift the sleeve 122 to a desired position in the event that an actuator of the flow control device 118 fails to operate properly.
All of the operations described above in relation to the system 110 may be performed without obstructing the passage 116 or interfering with flow through the passage 116. Thus, the system 110 further demonstrates the additional convenience and functionality provided by the alternate paths incorporated into systems embodying the principles of the invention.
Referring additionally now to
The system 130 is similar in some respects to the system 80 described above and illustrated in FIG. 5. That is, the upper mandrel 82 is connected to another mandrel 136 using a casing string 14 and a tubular string 84 extending between the mandrels. The annulus 86 between the casing string 14 and the tubular string 84 provides fluid communication between the passage 62 in the upper mandrel 82 and another passage 138 in the lower mandrel 136.
However, in the system 130, the passage 138 in the lower mandrel 136 is an annular chamber in which is disposed a centrifugal-type separator 140. Centrifugal-type separators for separating hydrocarbons and water from fluid received therein are known to those skilled in the art, and an example is described in U.S. Pat. No. 5,484,383. The entire disclosure of that patent is incorporated herein by this reference.
In the system 130, the separator 140 is not positioned within a casing string, but is instead positioned in the annular passage 138 which extends about the passage 20 (and, thus, the internal passage 28 of the casing string 14). Fluid (indicated by arrows 142) containing a mixture of water and hydrocarbons is produced from the upper branch wellbore 132 into the passage 22 of the upper mandrel 82. The flow control device 24 permits the fluid 142 to flow from the passage 22 into the passage 62 in the upper mandrel 82.
The fluid 142 then flows downward through the annulus 86 between the casing string 14 and the tubular string 84. Note that it is not necessary for the fluid to flow through the annulus 86, since the system 130 could be configured similar to the system 50 shown in
The fluid 142 flows into the annular passage 138 wherein it enters the separator 140. The separator includes a rotating assembly 144 which, through centripetal force transmitted to the fluid 142, separates relatively dense fluid (such as water) from relatively light fluid (such as oil or gas). Accordingly, the separator 140 directs the separated hydrocarbons (indicated by arrows 146) to flow inward into the passage 20, and directs the separated water (indicated by arrow 148) to flow into the passage 22 of the lower mandrel 136.
The hydrocarbons 146 are produced through the casing string passage 28 to a remote location, such as the earth's surface or another location in the well. The water 148 is flowed into the lower branch wellbore 134, where it is injected into a disposal formation 150. The formation 150 could be the same as the formation from which the mixed fluid 142 was originally produced, or it could be another formation or zone.
Note that the system 130 performs the original production of the fluid 142, the separation of the hydrocarbons 146 and water 148, production of the hydrocarbons, and injection of the water into the disposal formation 150, without obstructing the casing string passage 28 at all. Thus, the system 130 further demonstrates the benefits which may be achieved in systems incorporating principles of the invention.
Although the separator 140 is depicted in the system 130 as being positioned in the annular passage 138, it should be clearly understood that the separator could be otherwise positioned in keeping with the principles of the invention. For example, the separator 140 could be retrievable from the mandrel 136 for maintenance, etc. The separator 140 could be configured as described in the incorporated U.S. Pat. No. 5,484,383 and conveyed into the passage 20 on wireline or on a rigid or coiled tubular string, such as a production tubing string, through which the hydrocarbons 146 are produced. In that case, the fluid 142 would be received into the separator 140 in the production tubing string, the hydrocarbons 146 would be separated from the water 148, the water would be flowed back out of the production tubing string into the lower mandrel 136, and the hydrocarbons would be produced through the production tubing string.
Although the hydrocarbons 146 and water 148 are separately indicated in
Referring additionally now to
Referring additionally now to
Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the invention, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to these specific embodiments, and such changes are contemplated by the principles of the present invention. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims and their equivalents.
The present application is related to two copending applications: U.S. appl. Ser. No. 10/253,671, entitled SURFACE CONTROLLED SUBSURFACE LATERAL BRANCH SAFETY VALVE AND FLOW CONTROL SYSTEM, and U.S. application Ser. No. 10/253,136, entitled MULTILATERAL INJECTION/PRODUCTION/STORAGE COMPLETION SYSTEM, each filed concurrently herewith, and the disclosures of each being incorporated herein by this reference.
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