Patent Grant
10677025
This invention relates to the use of perforating guns, that can be positioned without the use of a surface rig for multiple same location perforations of tight reservoir formations, e.g., deep penetrations in preparation for the hydraulic fracturing of the formation.
Tight gas formations, such as Khuff carbonate, pre-Khuff sandstone and shale gas formations with high compressive strength require hydraulic fracturing procedures in order to open the reservoir formation and enhance the flow of gas to the well bore for production. In such tight gas-containing reservoir formations, a perforating gun is used to initiate formation breakdown by detonating high-performance deep-penetrating shaped charges that maximize perforation length and entry hole size to start the hydraulic fracturing or “hydrofracking”, in order to enhance hydrocarbon production and optimize well flow.
The tubing-conveyed perforating (TCP) gun employs a drilling rig at the surface in operation to handle the tubing that conveys the gun to the desired depth in the well bore.
Perforating guns are available in various configurations. In each case, the key objective of the selection of the gun and the size, nature and set up of the shaped charges is to create a predetermined pattern of perforations over a predetermined wellbore interval.
The creation of deep perforations with large diameters has been addressed with varying degrees of success. To create deep perforations that bypass damaged zones, the perforation diameter should be small and the force of the shaped charge narrowly focused.
A method and apparatus are disclosed in U.S. Ser. No. 14/959,942 (US 2016/0108708) for multiple same location firings of a perforating gun to extend the depth of the initial lateral penetrations further into the surrounding formation. A latching tool and tubing-conveyed perforating (TCP) gun are lowered into the wellbore by a surface rig and engage a latch coupling that was previously secured to a section of a well casing proximate the predetermined interval in the wellbore that is to be penetrated to provide a fixed reference point. Withdrawal after the first firing and recharging of the gun, followed by its return and engagement of the latching tool with the latch coupling permits the perforation of the formation repeatedly and at the same position. The prepositioned latch coupling and releasably secured engagement of the latching tool provide a consistent, reproducible reference point at the predetermined depth and orientation for repeated use of the TCP gun in vertical and lateral wells.
An advance in the art is disclosed in published application US 2016/0160620 where the latch coupling is secured to the end of the production tubing which permits the assembly to be deployed downhole without the use of a surface rig, thereby reducing the overall costs associated with the penetration operation. The end of the tubing with the latch coupling, which serves as the gun anchoring point, are landed so that the latch coupling is proximate the perforation interval. However, if the perforation plan for the well is changed so that a perforation is to be performed at a lower depth, or further into a lateral/horizontal open hole wellbore, the accuracy at the new depth of a perforation at the same point will be jeopardized.
Current perforation practices can fail to provide a deep and large diameter penetration when the target zone is behind more than one casing. A problem also exists in formations with high compressive strength and can also fail to bypass formation damage caused by the explosive forces.
A problem to be solved then is to provide apparatus, systems and methods in preparation for hydraulic fracturing operations that operate without a rig for securely positioning a perforating gun at the desired location for the first of a planned series of firings and returning the gun after reloading at the surface to the same position and radial orientation for one or more firings to complete a plurality of reservoir perforations or penetrations to the same position in order to produce a deep penetration having a larger diameter than is currently possible.
The problem can also be stated as how to position and to subsequently return the perforating gun to the same location for successive or repeated reservoir penetration shots in wells, preferably operating without the use of a rig, i.e., perforating guns that are deployed by wireline and/or a coiled tubing unit, and also withdrawing all of the components after the penetration has been completed.
An additional problem to be addressed is maintaining the accuracy of the perforation when the perforation plan includes at least an additional perforation interval at a position in the wellbore that is displaced, e.g., beyond, the first perforation interval.
As used herein, the term “downhole” refers to both vertical and lateral wellbores. The figures illustrate vertical well orientations for convenience, and it will be understood that references to “above” and “below” are relative to the apparatus regardless of the orientation of the wellbore.
For convenience, the following describes the installation and use in a well lined with a casing, but as will be understood by one of ordinary skill in the art, the method is equally applicable to perforating an interval in an open hole wellbore.
The above problems are resolved and other benefits and advantages are achieved by the use of the landing base assembly and perforating gun assembly of the present disclosure. The landing base assembly includes a through-tubing retrievable bridge plug and receiving member that is secured in axial alignment to the top or upper end of the bridge plug.
The perforating gun assembly includes a guide member that is dimensioned and configured to mate with the receiving member of the landing base assembly. The guide member is secured to the perforating gun in axial alignment with its longitudinal axis. A rotating head member is secured in axial alignment to the top or upper end of the perforating gun. The perforating gun remains attached by the rotating head to the coiled tubing when the gun assembly is downhole and is only released from the end of the coiled tubing at the surface in order to remove a gun that has been fired and load another gun with the same charge configuration. After securing a loaded gun to the coiled tubing, the gun assembly is lowered into engagement with the receiving member. The rotating head member permits relative rotational movement of the perforating gun and attached guide member, as will be described in more detail below, in order to facilitate the mating of the landing base assembly and the perforating gun assembly in preparation for firing.
The top or end of the rotating head member opposite the gun is secured to a stationary locking device that is provided with a releasable attachment fitting adapted to matingly engage with a cooperating fitting on the downhole end of the length of coiled tubing or other intermediate component. Such releasable fittings are known in the art.
As will be described in greater detail below, in one aspect. This disclosure broadly comprehends a method and apparatus in which a stationary receiving member is dimensioned and configured to receive a guide member that is attached directly or indirectly, to the downhole end of a perforating gun, whereby the two members enter into a secure mating engagement by their relative rotating movement until the advancement of the downhole end of the guide member is arrested by contact with the interior surface of the bottom of the stationary receiving member. The rotational movement is defined by a spiral path. The descent of the guide member into the receiving member is the result of gravitational force applied to the perforating gun assembly, which assembly optionally includes additional mass to overcome frictional forces created by well contaminants contacting the sliding surfaces of the respective members. This additional mass is provided, for example, by a supplemental weight member that is secured to comprise an element of the perforating gun assembly and in axial alignment with the perforating gun in order to maximize the downward gravitational force vector.
In an embodiment suitable for the practice of the invention, the apparatus is assembled and put into position for use in accordance with the following stepwise procedure:
1. A suitable bridge plug of a size and configuration adapted to securely engage the interior walls of a section of well liner or casing below the interval that is to be penetrated by the perforating gun is securely fastened in axial alignment to the base of the receiving member. As will be apparent to those of ordinary skill in the art, the size of the bridge plug selected will be based on the interior diameter of the well liner, e.g., a 7-inch or 4.5-inch liner, or of the wellbore itself in the case where the perforation interval is located in an open hole. A wireline or the end of a length of coiled tubing is attached by appropriate means well known in the art. The receiving member has an inside diameter that is sufficient to permit a conventional bridge plug setting and actuating tool to be connected directly to the bridge plug. The landing base assembly is lowered downhole through the production tubing. When the retrievable bridge plug has reached the predetermined depth proximate to, and below the reservoir interval that is to be penetrated, the bridge plug is actuated and the arms are extended to engage the interior wall, e.g., of the adjacent well liner or casing, thereby securing the bridge plug in a fixed and stable position in the wellbore. At the same time, the central seal portion of the bridge plug is expanded until it engages the wall of the liner or casing, thereby forming a fluid-tight seal. The wireline tool or coiled tubing is disengaged from the attachment point and withdrawn from the wellbore via the production tubing. The female profile of the gun guide receiving member on top of the retrievable bridge plug has an inside diameter that is sufficient to permit the bridge plug setting/releasing tool to be connected directly to the bridge plug.
2. The perforating gun is fitted with the desired number and size of shaped charges in accordance with instructions provided by the well engineer. The guide member is secured to the downhole end of the perforating gun and the rotating head member is secured to the top or upper end of the perforating gun opposite the guide member. A stationary locking device is secured to the rotating head member which has one or more conventional releasable attachment fittings on its upper surface for engagement with a mating fitting on the downhole end of the wire line or coiled tubing, or other intermediate component, such as a supplemental weight member as described below. As will be understood by one of ordinary skill in the art, both the landing base assembly and the perforating gun assembly are most conveniently assembled in a shop or other remote location and multiple assemblies can be stocked for eventual delivery to the well site where they are fitted with the prescribed number and size of shaped charges for use in the penetration of the reservoir.
3. The perforation gun assembly is secured to the end of a length of coiled tubing or wire line that is sufficient to lower the gun assembly into mating engagement with the landing base assembly. It will be understood by those familiar with the art that the interval to be penetrated is known to span a predetermined vertical depth range and that the positioning of the landing base assembly can be done with sufficient precision to permit the perforating gun assembly to be put into the desired predetermined position in the wellbore to perforate the surrounding casing and provide repeated firings through the casing openings to penetrate the surrounding hydrocarbon-containing zone that is to be subjected to hydrofracturing.
4. The perforating gun assembly can be lowered rapidly through the production tubing until it has reached a predetermined depth approaching the known depth of the landing base assembly, after which it is lowered more slowly. When the guide member makes initial contact with the upper end of the receiving member, it is directed into mating relation with the receiving member. In an embodiment, a radially projecting pin enters a corresponding spiral channel or groove in the adjacent member and by virtue of the force provided by a supplemental weight, the guide member advances into the receiving member and rotates clockwise as the projecting pin moves along the spiral groove of the receiving member, moving along the longitudinal axis of the members until it reaches the end of the spiral groove. At the same time, the rotating head makes a predetermined number of rotations based on the distance of the downward by advancing movement until it reaches the end of the spiral groove, at which point the rotating head locks the system beneath it into position. In an alternative embodiment, the downhole end of the gun assembly is provided with an external grooved guide member having a spiral profile or configuration that engages a corresponding internal spiral groove, thereby producing a rotational movement of the gun assembly, until the gun assembly locks into its final desired position.
5. After the secure mating engagement of the gun assembly with the landing base assembly, the perforating gun shaped charges are fired using conventional control means that are located at the wellhead.
6. Following the first firing, the perforating gun assembly is released from the receiving member by applying a predetermined over pull force to unlock the rotating head, after which the head rotates counter-clockwise as the guide retraces its path to disengage the guide from the receiving member. The perforating gun assembly is withdrawn via the production tube to the surface where it is reloaded or replaced with a fresh loaded gun and lowered again as described above.
7. This procedure can be repeated for as many firings as the well engineer has determined are necessary to achieve the desired depth and diameter of the reservoir penetration. That is, a third or subsequent charge(s) can be fired following this procedure which provides for accurate same-location penetrations, even though the gun is withdrawn from its downhole position for reloading and then repositioned downhole.
8. Following the final firing of the perforating gun, the gun assembly is withdrawn through the production tubing by the coiled tubing. As will be understood by one of ordinary skill in the art, a wireline or coiled tubing secured to a bridge plug retrieving tool is lowered into the well via the production tubing. The retrieving tool will pass through the central opening of the receiving member that is positioned above the plug and engages the plug in the conventional manner to effect its release as is known to the prior art. The landing base assembly is then retrieved via the production tubing and removed from the well at the surface. As will be understood from the above, following the final firing, both the perforation gun assembly and the landing base assembly apparatus are withdrawn from downhole and nothing remains to interfere with subsequent operations.
From the preceding description it will also be understood that the landing base assembly provides the assurance of a secure fixed position for the repeated engagement of the receiving member with the guide member, and that the gun to which it is attached will assume the same axial orientation when it is repeatedly lowered into its final position for successive firings. The depth of the gun is consistently the same because it comes to rest, or lands, on the landing assembly, the position of which is fixed by the secure engagement of the expanded bridge with the casing wall below the interval that is to be penetrated by the perforating gun charges. After the first and subsequent firings of the gun, the gun assembly is retrieved to the surface for replacement or reloading or, after the final firing, for permanent removal from the well along with the entire landing base assembly, leaving no components behind.
It will also be understood that the new landing base assembly of the present disclosure functions to by-pass the near-wellbore damaged zone and can provide better penetration of more than one casing by same location repeated reservoir penetrations when the well is not equipped with the latch coupling system, such as is described in U.S. Pat. No. 9,506,330, “System and Method Employing Perforating Gun for Same Location Multiple Reservoir Penetrations”.
The invention will be described in more detail below and with reference to the attached figures in which the same or similar elements have the same number, and where:
Referring now to the schematic illustration of
With continuing reference to
With reference to
As will be described in more detail below, the receiving member 120 is dimensioned and configured to mate with the guide member 130 of the perforating gun assembly 200 in a rotational locking engagement. As the two members are brought into contact and vertical alignment, one passes into the other. In an embodiment, the receiving member 120 comprises a hollow or annular body having a descending spiral channel 122 formed in its interior side wall. The guide member 130 at the downhole end of gun assembly 200 is dimensioned to enter the annular portion of the receiving member and has a radially projecting guide pin 132 extending from its exterior surface that engages the guide channel 122. This permits the perforating gun assembly 200 to descend vertically with a rotational motion that is permitted by the rotating head member 150 until the guide member assumes a locked position in the interior of the receiving member. This specific configuration of the receiving member 120 and guide member 130 are described in more detail below and in various embodiments. The receiving member 120 is also provided with one or more fluid discharge ports 124 to allow trapped fluids and any settled solids to be ejected from the interior of its hollow body when the guide member 130 enters.
The two assemblies are shown in a fully engaged position in
After the firing of the gun 140, a sufficient pulling force, or over pull, is exerted on the coiled tubing 40 to overcome the gravitational and initial frictional forces on the sliding surfaces of the groove and pin and to rotate the guide member as the projecting guide pin 132 moves upwardly through the spiral groove 122 in order to disengage the guide member from the receiving member which is retained by the expanded bridge plug 110 in its original secured stationary position with the landing base assembly 100.
Referring to
Referring now to
From the above description and the attached illustrations, it will be understood that after the second firing, the gun can be reloaded or replaced with a fresh loaded gun and returned with the gun assembly for engagement with the landing base assembly for a third firing to effect even deeper penetrations at the same location in the interval 4. The selection of shaped charges for the second and any subsequent firings of the gun 140 in order to produce the depth and diameter of the penetrations 14 in specific types of reservoir rock is within the skill of the art.
Referring now to
An alternative embodiment for accomplishing the rotational mating engagement is illustrated in
As shown in both
As will be apparent to one of ordinary skill in the art, other shapes, e.g., conical, pyramidal, and combinations, can be employed to facilitate the initial alignment and any rotation needed to pass the pin into the groove.
Referring now to the embodiment of
The respective male and female threads are machined to a very smooth and preferably a polished finish to facilitate their respective rotational movement after engagement. Upon engagement of the free end of the guide member with the open end of the receiving member, the downward force causes the guide member and the elements above it to rotate, e.g., in a clockwise direction by virtue of at the rotating head member 150 attached to the stationary locking device 152 on top of the gun assembly to advance the guide member into the receiving member. Similarly, disengagement is initiated by an upward force which causes the guide member and the gun assembly above it to rotate in a counterclockwise direction to withdraw the guide member.
In accordance with an embodiment as illustrated in
If the initial contact between the guide and receiving members does not result in the desired rotational engagement, the assembly is withdrawn via the coiled tubing 40 and then lowered, repeatedly if necessary, until the members engage for relative rotational movement and entry of the guide member 130B into the receiving member 12A. As will be understood by one of ordinary skill in the art, because of the nature of coiled tubing, following each attempt there will be a change in the radial orientation of the guide member.
As will be understood by one of ordinary skill in the art, the contact surfaces of the grooves or channels in the respective members as well as the interior and exterior surfaces of the receiving and guide member can be contaminated with drill mud and debris so that fit tolerances between the various moving elements must take into account the environmental conditions and the nature of the contaminants. Thus, the actual weight of the supplemental weight member 44 will be determined by taking these environmental factors into account. This problem can also be reduced by flushing the section of the wellbore to remove contaminants to the extent practically possible. Also as shown in
Other configurations for the receiving member and guide member will be apparent to those of ordinary skill in the art and can be adapted for the secure mating of these two elements.
It will be understood from this description that the two elements undergo a relative axial rotational movement upon initial engagement which is the result of gravitational forces and the weight or mass of the gun assembly and, optionally, the supplemental weight member 44. This relative rotational movement can be facilitated by providing the engagement surfaces with a highly-polished finish, with a coating or layer of low friction materials, ball or roller bearings, and the like. Releasable locking devices such as a spring-biased ball and corresponding detent can be provided.
The size of the wellbore drilled in tight gas reservoir rock depends upon the overall well design descending from the surface to the reservoir target zone. In some wells, the target zone is drilled with an 8⅜″ hole: in other wells, the target zone is drilled with a 5⅞″ hole. The 8⅜″ hole is cased with 7″ pipe liner. The 5⅞″ hole is cased with a 4½ liner. In an open hole, or OH completion. The hole drilled in the target zone is left open without a cemented pipe liner. In a closed hole, or CH completion, the target zone is provided with a cemented pipe liner. The liner extends from the bottom of the OH to +/−300 feet inside the casing above the open hole. The casing extends to the earth's surface. The design of the well will take into consideration the size and positioning of the various tools and fittings required in the practice of the invention as described.
From the above description, it will be understood that the method and apparatus of the present invention overcomes tight formation productivity problems because the same interval can be perforated two or more times to create the larger and deeper holes needed to reach the virgin portion of the reservoir for higher well productivity and/or well injectivity. Additionally, the method facilitates stimulation treatments in especially tight formations of high compressive strength where achieving deep perforation penetration is particularly difficult.
The use of the retrievable bridge plug also permits all of the elements of the system to be withdrawn from the site of the perforations, thereby simplifying the subsequent hydrofracturing operations and the eventual well completion, including the need to drill out the bridge plug. Importantly, the use of the retrievable bridge plug permits the penetration plan to include accurate penetrations at one or more additional intervals at locations downhole of the first interval because the positioning of the elements of the apparatus is entirely within the control of the well engineer and is not hampered by previously installed apparatus that is still in position. The use of the retrievable bridge plug permits the method to be practiced in any of a variety of diameters of lines and casings, as well as in open hole completions.
It will also be understood from the preceding description that the relative positions of the receiving member and guide member can be reversed. Thus, the hollow receiving member can be mounted on the downhole end of the perforating gun and the guide member secured to the upper surface of the bridge plug. The same relative rotational movement is achieved in this configuration as the downwardly facing open end of the receiving member descends into engagement with the guide member under the force of gravity.
The method and apparatus of this disclosure thus provides improvements for the more efficient repeated perforation of tight rock formations in preparation for the subsequent hydraulic fracturing treatments.
Although the apparatus and method have been described in detail above and illustrated in the drawings, modifications and variations from this description will be apparent to those of ordinary skill in the art, and the scope of protection for the invention is to be determined by the claims that follow.
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