Patent Application
20150186574
Operations, such as geophysical surveying, drilling, milling, logging, well completion, hydraulic fracturing, steam injection, and production, are typically performed to locate and collect valuable subterranean assets. Examples of subterranean assets include fluids (e.g., hydrocarbons such as oil or gas, water, etc.), as well as minerals, and other materials. In some cases, a casing may be installed within a wellbore of a well to improve the structural integrity of the wellbore or to isolate the wellbore from the surrounding formation. The casing may include one or more tubes made of steel. Cement and other materials may be positioned around the circumferential wall of the casing, in an annulus between the casing and the formation, to secure the casing in place within the wellbore.
When it is determined that a well should no longer be used (e.g., after a cost/benefit analysis indicates production has dropped below a cost for running the well), it may be desirable to seal the wellbore to prevent damage to the environment, among other reasons. In some instances, it may be desirable to seal off a selected portion of a wellbore (e.g., deviated boreholes, or sections between or below particular deviated boreholes). A process of sealing a well or selected portions of a wellbore is often referred to as well abandonment.
In some embodiments, systems, interfaces, methods, and computer-readable media are operable to simulate wellbore abandonment procedures to predict the effectiveness and outcome of physical wellbore abandonment processes and assemblies and to reflect how different configurations of wellbore abandonment assemblies and process parameters can change performance for different anticipated wellbore abandonment assemblies and procedures.
In some embodiments, simulated wellbore abandonment procedures are performed by one or more computing systems that are configured with one or more processors and specialized interfaces. These computing systems may also include one or more of an interface engine, visualizing engine, or simulation engine. Computer-executable instructions, when executed by the one or more processors and engines, are operable to implement the functionality described herein for analyzing and simulating wellbore abandonment procedures involving different combinations of tools and environments.
In some embodiments, the computing system accesses parameters of a virtual downhole environment and one or more virtual milling tool(s). The computing system also simulates an abandonment procedure that includes a simulated interaction of the virtual milling tool(s) with the virtual downhole environment (e.g., with casing in the virtual downhole environment). Corresponding output associated with the simulated abandonment procedure may then be rendered in one or more different formats or interfaces.
The virtual milling tool may include section mills, casing mills, or other tools that are capable of milling a section of casing within a wellbore, or any other mills or tools that are capable of removing debris and other material from a wellbore (e.g., cement, earth formation, tools, sensors, whipstocks, casing, plugs, etc.). A virtual downhole environment may include any material located in or adjacent to the sections of casing being removed during an abandonment procedure (e.g., additional casing(s), cement layer(s), earth formation(s), tool(s), sensor(s), whipstock(s), fluid(s), etc.).
The computing system may present the virtual milling tool and downhole environment and corresponding parameters (e.g., milling tool parameters, wellbore casing parameters, etc.) at one or more graphical user interfaces. The computing system may also access, select, or modify parameters of the virtual milling tool and parameters of the virtual downhole environment, as well as simulation parameters (i.e., parameters that at least partially control or define an interaction of the virtual milling tool and the virtual downhole environment) in response to user input directed at interactive elements that are presented at the user interfaces.
In some embodiments, the computing system accesses or selects parameters of the virtual milling tool and virtual downhole casing environment. In the same or other embodiments, the computing system may access, receive, or otherwise select simulation parameters input into an interface, or obtained from mesh simulation data defining at least a virtual state of one or more wellbores following a previous simulation of a downhole procedure involving the one or more wellbores.
In some embodiments, the computing system accesses or selects parameters of the virtual milling tool and virtual downhole environment, and/or the simulation parameters from one or more files having defined parameters corresponding to actual field data extracted from one or more sensors or measuring devices.
The computing system may utilize an interface engine to generate an abandonment interface that displays interactive elements that, in response to user input directed at the interactive elements, selects, defines, or modifies one or more of the milling tool parameters or wellbore casing parameters stored in one or more files accessible to the interface engine. Then, in response to receiving user input directed at the interactive elements, the computing system responsively selects, defines, or modifies at least one of the abandonment milling tool parameters or the wellbore casing parameters.
The computing system may utilize a visualizing engine to generate a visual representation of one or more virtual milling tools or one or more virtual wellbore casings associated with the user input, one or more simulations, or the like.
The computing system may utilize an interface engine to select at least one of one or more virtual milling tools, one or more virtual wellbore casings, or one or more abandonment simulation parameters that control or define an action of the one or more virtual milling tools or an interaction between the one or more virtual milling tools and the one or more virtual wellbore casings.
The computing system may utilizes a simulation engine to perform a simulation of an abandonment procedure based on at least a selected one or more of the abandonment simulation parameters, which involves an interaction of the selected one or more virtual milling tools with the selected one or more virtual wellbore casings. The computing system may perform the simulation after identifying the one or more abandonment simulation procedures, the one or more virtual milling tools, and the one or more virtual wellbore casings. The simulation may involve a finite element analysis on one or more of the selected virtual milling tools and virtual wellbore casings.
In some embodiments, a computing system may use one or more engines of a graphical user interface to perform a simulation of an abandonment procedure including a plugging operation. The simulation of the plugging operation may include an interaction between a virtual downhole environment and one or more virtual plugging tools (e.g., a bridge plug, a cement string, etc.). A wellbore abandonment simulation may include simulating a virtual milling procedure and/or a virtual plugging procedure.
The computing system may also utilize one or more simulation interfaces to render one or more outputs associated with the simulation of one or more of the abandonment procedure, the one or more virtual milling tools, the virtual wellbores, the virtual wellbore casings, or the virtual plugging tools. The output(s) may include performance data and other results associated with the simulated abandonment procedure. The output(s) may be rendered at one or more display devices or other output devices. The output(s) may visually reflect at least one of a casing diameter, wellbore diameter, wellbore quality, von Mises stress, vibration, bending moment, milling tool wear rate, casing material removal, cement material removal, earth formation removal, contact force, lateral acceleration, surface torque, mill axial acceleration, rate of penetration, downhole weight-on-bit, downhole rotational speed, plug material quantity, plug cure time, or mill trajectory.
This summary is provided to introduce a selection of concepts that are further described in the figures and the detailed description. This summary is not intended to identify key or essential features, nor is it intended to be used as an aid in limiting the scope of the disclosure, including the claimed subject matter. Additional features of embodiments of the disclosure will be set forth in the description and figures, and in part will be obvious from the disclosure herein, or may be learned by the practice of such embodiments. Features and aspects of such embodiments may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims, and otherwise described herein. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such embodiments.
A more particular description will be rendered by reference to specific, example embodiments which are illustrated in the appended drawings. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Such scale drawings should be understood to be so scale for some embodiments, but not to scale for other embodiments contemplated herein. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
One or more specific embodiments of the present disclosure are described herein. Some embodiments of the present disclosure relate to methods, systems, interfaces, and computer-readable media for simulating wellbore abandonment procedures including, but not limited to, section milling, casing milling, reaming, plugging, fishing, and other wellbore abandonment procedures. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of some actual embodiments may be described or illustrated. It should be appreciated that in the development of any such actual embodiments, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one embodiment to another. It should further be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
Simulated abandonment procedures according to embodiments of the present disclosure can, in some instances, help in the design, selection, or modification of a BHA for performance of a particular abandonment procedure in less time and/or in a more efficient way than was previously possible. Interfaces and systems of the disclosure may also, in some instances, improve the usability of stored files (e.g., simulation mesh files, data files, etc.) containing parameters associated with wellbore abandonment tools (e.g., section mills, casing mills, hole enlargement tools such as reamers and hole openers, plugs, cement strings, etc.), wellbore environments (e.g., casing(s), cement layer(s), formation, etc.) and corresponding abandonment procedures.
Embodiments of the present disclosure may also, in some embodiments, improve the efficacy of computing systems that are used to identify and design BHAs and BHA components that can be physically manufactured and used in actual abandonment procedures, through at least performing the simulations of the abandonment procedures described herein. For example, by making simulated predictions of defined abandonment procedures, which are performed by defined BHA assemblies, it can be possible to compare and identify assemblies and procedures that can be utilized to reduce costs and increase efficiency when performing actual, field abandonment procedures, such as section milling, casing milling, hole enlargement, fishing, plugging, and other abandonment procedures.
Most of the terms used herein will be recognizable to those of skill in the art. In certain instances, however, terms may be explicitly defined. Any terms not explicitly defined should be interpreted as adopting a meaning presently accepted by those skilled in the art.
The drill string 16 may include several joints of drill pipe 16-1 connected end-to-end through tool joints 16-2. The drill string 16 may be used to transmit drilling fluid (e.g., through its hollow core) and/or to transmit rotational power from the drill rig 10 to the BHA 18. In some cases, the drill string 16 may further include additional components such as subs, pup joints, etc. In some embodiments, the drill string 16 may include a single or extended string component (e.g., coiled tubing). Optionally, the rotational power for rotating the BHA 18 may be provided by one or more downhole components (e.g., turbine motor, mud motor, etc.).
The drill string 16 may also have, in some embodiments, a mill (e.g., a section mill or casing mill) that is specifically designed to mill through one or more casings linking the inner wall of the wellbore 14. The lining may include a single casing, or a plurality of casings. In
The BHA 18 may be used to mill into (and potentially radially through) a portion of the casings 20 and 22 within the wellbore 14. In some embodiments, the BHA 18 may be used to mill a single casing (e.g., inner casing 20). In other embodiments, the BHA 18 may be used to mill multiple casings (e.g., casings 20 and 22). In operation, the mill may include blades that extend radially outward from a tool body to initiate a cutout into the casing. As the BHA 18 is rotated, the cutout may be formed circumferentially around the casing. The BHA 18 may be moved axially while milling to also mill an axial section of the casing. When the BHA 18 mills radially through a full thickness of the casing 20 and/or 22, the BHA 18 may also mill cement outside the casings 20 and 22. In some embodiments, the BHA 18 may mill or otherwise cut into the formation surrounding the wellbore 14, such as, for example, to remove earth formations identified at sections 26. A single tool or multiple tools on the BHA 18 may mill the casing(s) 20 and 22 and/or remove the sections 26. In some embodiments, for instance, one section mill may mill both casings 20 and 22. In other embodiments, different section mills may mill each of casing 20 and casing 22. One or both section mills (or other milling tools) may remove the sections 26; however, in still another embodiment, a reamer or other hole enlargement device may remove at least a portion of the sections 26.
Sometimes, one or more deviated boreholes 28 may have also been drilled off of the wellbore 14. Occasionally, it is desired to seal the wellbore 14 or one or more boreholes 28. To create a seal, it may be helpful to ensure that the seal extends from rock-to-rock, or is in direct contact with the formation (e.g., for a cement plug). Where the wellbore 14 has one or more casings the BHA 18 may mill the casings 20 and/or 22, cement, or formation as desired to ensure enough material has been removed to allow a plug (e.g., a cement plug) to be set at least partially in direct contact with the formation. The process of milling away the material in and around the desired location for a plug is one example of an abandonment procedure. The material that may be removed includes casing material (including liner material), cement material, tool material, sensors, and other debris. In some embodiments, an abandonment procedure may include other or additional operations. By way of illustration, other abandonment procedures may include hole enlargement (e.g., reaming), wellbore isolation (e.g., installation of a bridge plug), cementing, other procedures, or combinations of the foregoing. In
It should be appreciated in view of the disclosure herein that the plug 21 in
In some embodiments, a cutting tool 30 of the BHA 18 can be a bit or other type of mill specifically configured for metal cutting (e.g., a section mill tool with expandable blades, a lead mill, a taper mill, a casing mill with fixed blades, a dress mill, a follow mill, or any other milling tool that is configured for milling through the casing(s) 20 and/or 22). The cutting tool 30 can include one or more cutting elements (e.g., polycrystalline diamond compacts, cubic boron nitride cutters, metal carbide cutters (e.g., tungsten carbide cutters), chunky carbide hardfacing, impregnated diamond, roller cone teeth, or other specially manufactured cutters, teeth, or other cutting elements).
In some embodiments, the cutting tool 30 may be a bit configured to mill or drill through concrete or subterranean formation. The cutting tool 30 can also be replaced or supplemented with a hole enlargement tool configured to expand a diameter of a wellbore segment. In some embodiments, the hole enlargement tool may be selectively expandable (e.g., a reamer) while in other embodiments the hole enlargement tool may have a fixed diameter (e.g., a hole opener).
To mill/drill through the structures of a wellbore or subterranean formation, sufficient rotational moment, radial, and axial force is applied to the BHA 18 to cause the cutting tools, bits, or other corresponding cutting elements to cut into the casing, cement, rock, debris, or other materials during rotation of the cutting tool(s).
The axial force applied on the cutting tool 30 (for a mill, a reamer, or any other tool component) may be referred to as “weight-on-bit” (WOB). The rotational moment applied to the downhole tool assembly 12 at the drill rig 10 (e.g., by a rotary table or a top drive mechanism) or using a downhole motor to turn the downhole tool assembly 12 may be referred to as the “rotary torque.” Additionally, the speed at which the rotary table or other device rotates the downhole tool assembly 12, measured in revolutions per minute (RPM), may be referred to as the “rotary speed.” The weight on bit (WOB), rotary speed and other factors (e.g., torque, casing thickness, casing material, type of cutting tool, etc.) may affect the rate at which the P&A section (including one or more casing layer(s), cement layer(s) and earth formation) is milled, drilled, cut, or resized, the quality of the P&A section, the rate of wear on the cutting tool, and the like.
During a wellbore abandonment procedure—including milling, fishing, hole enlargement, plugging (e.g., installation of bridge plug, cement plug formation, etc.—the BHA assembly can be subjected to various vibrations resulting from the different forces at play. These vibrations, which can include any combination of torsional, axial, or lateral vibrations, can have a very detrimental effect on the abandonment procedure and the overall integrity of the cutting tools and other BHA components. In some instances, the vibrations and forces involved can result in off-centered milling/drilling, slower rates of penetration, excessive wear of the cutting elements, premature failure of the milling/drilling components, over gage milling/drilling, and out-of-round milling/drilling.
When a cutting tool wears out or breaks during an abandonment or other downhole operation, the entire BHA is often lifted out of the wellbore, section-by-section, and disassembled to replace the broken components. Because the length of a BHA and drill string may extend for more than a mile, trips can take hours to complete and can pose a significant expense to the wellbore operator. Broken components may also be left downhole in some cases, complicating subsequent procedures.
The BHA 18 may also include additional or other components coupled to the drill string 16 (e.g., between the drill string 16 and the cutting tool 30). Example additional or other BHA components may include drill pipe, drill collars, transition drill pipe (e.g., heavy weight drill pipe), stabilizers (e.g., fixed and/or expandable stabilizers), measurement-while-drilling (MWD) tools, logging-while-drilling (LWD) tools, subs (e.g., shock subs, circulation subs, disconnect subs, cementing subs, etc.), hole enlargement devices (e.g., hole openers, reamers, etc.), jars, thrusters, downhole motors (e.g., turbines and mud motors), rotary steerable systems, vibration dampening tools, vibration inducing tools (e.g., axial, torsional, or lateral), cross-overs, mills (e.g., follow mills, dress mills, watermelon mills, taper mills, drill-mills, junk mills, section mills, rotary steerable mills, casing mills, etc.), rock drills, cement drills, other drills and other BHA tools.
As discussed herein, a wellbore may be lined with one or more casings, such as casings 20 and 22, which each may include a pipe or other tubular element that is lowered into the wellbore 14. The casings 20 and 22 may also be cemented into place. The cement may surround the entirety of each casing or only a portion of the casing(s). The casing(s) may be formed from a high strength material such as stainless steel, aluminum, titanium, fiberglass, other materials, or some combination of the foregoing. Optionally, the casing(s) may include a number of couplings and/or collars that connect a number of casing sections, or pipes, to one another. A series of connected casings is known as a casing string.
A plurality of different casings can also be at least partially nested within one another (e.g., a portion of the length of the casing 20 being nested within casing 22, see also
Some examples of abandonment procedures include milling operations or procedures for milling through one or more casing layers and/or cement surrounding the casing layer(s) to create an open section where a plug can be formed or otherwise positioned. This may include milling or grinding up pre-existing plugs, fish, or other downhole tools, or section milling or casing milling to remove entire sections of casing. Abandonment procedures may also include reaming, hole opening, or other hole enlargement operations to increase a diameter of a portion of a wellbore (optionally a portion of a wellbore where casing has been at least partially milled away). Isolation of a portion of a wellbore (e.g., using a bridge plug) may also be included in some abandonment procedures.
In some instances, wellbore abandonment procedures, may be performed with a cutting tool 30 (e.g., mill, reamer, hole opener, etc.) that includes a plurality of individual blades coupled to a body. The body may be coupled to an end of a drill string in a BHA. The blades may rotate about an axis extending longitudinally through the center of the body and potentially the drill string. The blades may include cutting elements having cutting surfaces. One or more nozzles in the blades or the body may facilitate the circulation of fluid in the wellbore 14 during an abandonment operation. The blades may be fixed or selectively expandable.
Some examples of mills that can be utilized in BHAs and abandonment milling procedures include section mills, pilot mills, tapered mills, junk mills, cement mills, dress mills, follow mills, watermelon mills, drill-mills, rotary steerable mills, casing mills, and so forth. In some embodiments, multiple mills may be used on the same or different BHA during a wellbore abandonment procedure. Other cutting tools (e.g., drill bits, hole enlargement tools, etc.) may also be used on the same or a different BHA during a wellbore abandonment procedure.
Some aspects of the present disclosure provide systems and methods for selecting, modifying, and analyzing the performance of different BHAs and BHA components (e.g., milling tools, plugging tools/materials, etc.) used in abandonment procedures to determine the performance of the different BHA assemblies and/or the possibility, probability, or degree of success or failure for the different BHA assemblies and components during anticipated abandonment procedures.
Some embodiments also include providing systems and methods for analyzing the performance of different BHAs against pre-selected criteria, against one another, against data acquired in the field, against other data, or against any combination of the foregoing. Such analysis may allow, for instance, different BHAs to be compared even before entering the wellbore to determine which milling/abandonment BHA will provide greater rate of penetration, reduced wear or risk or failure, and the like. Such analysis may also allow, for instance, performance data of simulated/virtual milling tools to be compared against field results of corresponding milling tools in a physical wellbore, thereby allowing the simulation system to be calibrated to improve accuracy of subsequent simulations.
Some embodiments disclosed herein may improve an ability of a system user (e.g., an engineer) to optimize the build of a BHA for an abandonment procedure and a plan for a particular abandonment procedure by enabling the user to efficiently interface with a simulation interface that is capable of any one or more of accessing, selecting, or modifying different parameters associated with an anticipated abandonment procedure, including simulation parameters, milling tool parameters, wellbore casing parameters, plug parameters, BHA parameters, and so forth. For sake of clarity, a number of definitions are provided below.
“Wellbore casing parameters” define one or more actual and/or virtual wellbore casings or casing environments and may include one or more dimensions or other parameters associated with a casing, including diameter, length, and thickness, as well as material properties of the corresponding casing (e.g., type, structure, weight, hardness, and material composition) for any or all sections of the corresponding casing. Wellbore casing parameters may also define a depth or axial location of the casing within a wellbore, type and geometry of casing couplings, a quantity of nested casings, or radial spacing between nested casings. In some instances, the properties and characteristics of a cement layer positioned between casings and/or between a casing and the surrounding earth formation can also be defined by wellbore casing parameters. Optionally characteristics and spacing between the wellbore wall and the outer circumference of the cement or casing may be defined by the wellbore casing parameters.
In some embodiments, wellbore casing parameters may be included in, or be associated with, a file including data obtained from a physical test. For instance, a cutting element in a test set-up may be physically scraped against samples of different casing materials (e.g., different types of steel or other metals for casings, liners, couplings, etc.). The cutting element may follow a circular or arcuate path while scraping the material sample, while in other embodiments the physical data may be obtained from a linear scrape test. Optionally, the linear scrape test may be performed at a higher speed than a rotational scrape test used for measuring properties of different rock or formation materials. In the rotational or linear scrape test, the test set-up may measure properties such as forces on the cutting element, volume of material removed, and the like. For instance, the cutting force and/or axial force may be measured during the test and stored in a file as a wellbore casing parameter. Similarly, the volume of material removed per distance over time may be measured. The wear rate of the cutting element may also be measured and/or correlated with the data on volume of material removed. Corresponding data may be obtained for various different axial forces applied on the cutting element. Example data that may be collected and/or stored is described in U.S. Pat. No. 8,185,366, which is incorporated herein by this reference in its entirety.
“Wellbore parameters” may include the geometry of a wellbore and/or the formation's material properties (i.e., rock profiles and other geologic characteristics). Wellbore parameters also include the characteristics and path or trajectory of a wellbore in which a downhole tool assembly may be confined, along with an initial wellbore bottom surface geometry. A wellbore trajectory may be straight, curved, or include a combination of straight and curved sections. As a result, wellbore path, in general, may be defined by defining parameters for each segment of the path. For example, a wellbore may be defined as having N segments characterized by the length, diameter, eccentricity/shape, inclination angle, and azimuth direction of each segment and an indication of the order of the segments (e.g., first, second, etc.). Wellbore parameters defined in this manner may then be used to mathematically produce a model of a path of an entire wellbore, or of the entire portion of the wellbore to be evaluated. Formation material properties at various depths along the wellbore may also be defined and used, including rock profiles and any other characteristics defining aspects of the subterranean formation surrounding the wellbore (e.g., material type, hardness, formation type, etc.). In this regard, wellbore parameters can include or be referred to, in some instances, as “formation parameters.” Wellbore casing parameters may be considered wellbore parameters in some embodiments of the present disclosure. Where a wellbore includes casing, the wellbore casing environment may include both the casing(s) and the surrounding formation.
In some embodiments, formation parameters may be included in, or be associated with, a file including data obtained from a physical test. For instance, a cutting element in a test set-up may be physically scraped against samples of different rock or other formation materials. The cutting element may follow a circular or arcuate path while scraping the material sample, while in other embodiments the physical data may be obtained from a linear scrape test. In the rotational or linear scrape test, the test set-up may measure properties such as forces on the cutting element, volume of material removed, and the like. For instance, the cutting force and/or axial force may be measured during the test and stored in a file as a formation parameter. Similarly, the volume of material removed per distance over time may be measured. The wear rate of the cutting element may also be measured and/or correlated with the data on volume of material removed. Corresponding data may be obtained for various different axial forces applied on the cutting element. Example data that may be collected and/or stored is described in U.S. Pat. No. 8,185,366, which was previously incorporated herein by this reference in its entirety.
Wellbore parameters may also include dip angle (i.e., the magnitude of the inclination of the formation from horizontal) and strike angle (i.e., the azimuth of the intersection of a plane with a horizontal surface) of the wellbore. One of ordinary skill in the art will appreciate in view of the disclosure herein that wellbore parameters may include additional properties, such as friction of the walls of the wellbore (e.g., formation or casing), casing and cement properties, and wellbore fluid properties, among others, without departing from the scope of the disclosure.
Wellbore parameters may also include other parameters, such as plug parameters and fish parameters. Plug parameters may include parameters associated with a plug installed (or to be installed) in a wellbore. Example plugs may include cement plugs, bridge plugs, frac plugs, and the like. In some embodiments, plug parameters may include the type, number, and location of different plugs. Fish parameters may include parameters associated with downhole tools, debris, or other fish within a wellbore.
“Milling tool parameters” define one or more actual and/or virtual milling tools (e.g., virtual mills or other cutting tools or virtual BHA components used in a simulated abandonment procedure) and may include one or more of: mill type; size of mill; shape of mill; blade geometry; blade position; number of blades; blade type; nozzle number; nozzle locations; nozzle orientation; type of cutting structures on the mill; cutting element geometry; number of cutting structures; or location of cutting structures. As with other components in a milling tool assembly, the material properties of the mill (including the mill body, the blades, and the cutting elements on the blades) may be defined for use in analyzing a mill and a milling tool assembly. Milling tool parameters can also include material properties used in designing or analyzing a milling tool, for example, the strength, elasticity, and density of the material used in forming the milling tool, as well as any other configuration or material property of the milling tool, without departing from the scope of the disclosure. Corresponding parameters for hole enlargement tools, fishing tools, and the like can also be included within the milling tool parameters.
Milling tool parameters may be included within a set of “BHA parameters,” which may also include any combination of one or more of the following: a type, location, or quantity of mills, bits or other components included in a BHA used for an abandonment procedure; the length, internal diameter of components, outer diameter of components, weight, or material properties of each component; the type, size, weight, configuration, or material properties of the tool assembly; or the type, size, number, location, orientation, or material properties of cutting elements on the milling/abandonment tools.
“Bit parameters,” which may also be included in the milling tool parameters, correspond to one or more bits or cutting tools used in a BHA and can define any characteristic(s) of the one or more bits or other cutting tools. Parameters related to drill bits, mill bits, milling tools (e.g., section mill, casing mill, etc.), hole enlargement tools (e.g., reamer, hole opener, etc.), fishing spears, and the like should all be considered as within the scope of the bit parameters.
“Simulation parameters,” which are also referred to as “operating parameters,” may include any parameters that are used to control a simulation of an abandonment procedure by at least controlling or defining an action or interaction of one or more virtual milling tools, virtual hole enlargement tools, isolation/plugging tools, or the like. The interaction may be with a virtual wellbore casing or a virtual wellbore. The simulation parameters may include one or more of: rotary torque and/or fluid flow rate, as well as the total number of revolutions to be simulated, the total distance to be milled/cut, the total operating time desired for the simulation, the trajectory of a downhole operation, surface rotational speed; the downhole motor rotational speed (if a downhole motor is included); the hook load; or the weight-on-bit, other related parameters, or any combination of the foregoing Simulation parameters may further include fluid parameters, such as the type of the drilling/milling fluid, and the viscosity and density of the fluid, for example.
The simulations of abandonment procedures may be referred to herein as being “dynamic” because the abandonment procedure is a “transient time simulation,” meaning that it is based on time or the incremental rotation of the virtual milling tool. For the purposes of calibrating a model and having a baseline for potential solutions, a simulation of an abandonment procedure using any of the foregoing parameters may be used. The abandonment simulation may be performed with finite element analysis and other simulation algorithms. In some embodiments, the finite element analysis may use parameters defined, selected, or otherwise modified at a user interface, parameters accessed through one or more files (e.g., formation, casing, fish, milling tool, or other parameters obtained from a scrape test, etc.).
Simulation parameters may also define metrics associated with wellbore abandonment simulations, including but not limited to a quantity and type of outputs to render at any particular time(s). In some embodiments, the simulation parameters may include additional types of parameters or components used to define performance of a simulated abandonment procedure.
Performance of a simulated abandonment procedure may be measured by one or more “performance parameters,” examples of which may include: rate of penetration (ROP); resulting casing width or thickness, material removed, material remaining, rotary torque; rotary speed; lateral, axial, or torsional vibrations and accelerations; weight-on-bit (WOB); forces acting on components of the tools; or forces acting on the components of the tools (e.g., on blades and/or cutting elements). Performance parameters may also include the inclination angle and azimuth direction, trajectory; drill string deformation; cutting tool deformation, walk rate or walking tendency; bending moment; von Mises stress; or tool geometry. One skilled in the art will appreciate, in view of the present disclosure, that other performance parameters related to abandonment, plugging, or other downhole operations (e.g., slot recovery) exist and may be considered without departing from the scope of the disclosure. For instance, quantity of plugging material used, cure time, seal quality, or other performance parameters may be generated for a plugging operation. Additionally, while embodiments of the present disclosure relate to abandonment of a cased wellbore using a section milling or casing milling procedure, use of a casing cutter and casing puller may simulated for a casing cutting and pulling operation.
In one or more embodiments, performance parameters may be rendered as visual outputs or other indicia. Further, the outputs may include tabular data and may be in the form of one or more of graphs, charts, or logs of a performance parameter, with respect to time, or with respect to location along the BHA, for example. When the outputs are given based on location along the BHA, the outputs may be presented as an average value for each location, or by using relative percentages.
Other outputs and plots, in some embodiments, include presentations or visualizations of the results at a minimum or maximum value, at a given location, over a period of time, or any combination of those results. Graphical visualizations of a cutting tool, drill string, hole enlargement tools, milling tools and assemblies, casings plugs, and other wellbore environmental components, may also be output. Graphical visualizations in 2-D, 3-D, or 4-D may include color schemes for any BHA (or BHA components) to indicate performance parameters at different locations on the corresponding component or at different instances in time for a given simulated procedure.
Outputs, in some embodiments, also include animations composed of a plurality of images sequenced together or that overlap. Animations can be run in real-time during simulation processing. Animations can also be rendered after the simulation processing and analysis is complete.
In some instances, simulation outputs also include aural output that may amplify or complement corresponding visual output. The aural output may also correspond with real-world sounds that are typically associated with different downhole processes (e.g., scraping, grinding, tearing, seizing, and so forth) and correspondingly different sounds of cutting different materials (e.g., casing wall, cement, rock, and so forth). In the same or other embodiments, the simulation outputs include haptic feedback that may further complement other simulated output.
In a broad context, the term “abandonment components” can refer to any combination of the aforementioned components and parameters associated with abandonment (including plugging/isolation) procedures that are utilized by the systems, storage devices, methods, and interfaces of the disclosure provided herein.
The parameters that are considered during a simulation analysis can be accessed and input in different ways. In some embodiments, the parameters are accessed from one or more stored files, such as tool files, wellbore casing files, simulation parameter files, rock/formation files, simulation mesh files, BHA files, and so forth. In other instances, a single file may contain a collection of one or more of the aforementioned different types of parameters.
In some embodiments, parameters are entered, defined, or otherwise modified manually through one or more simulation interfaces. In the same or other embodiments, parameters are obtained from actual field data or sensors associated with one or more BHA components, as described herein. The field data can, in some instances, be obtained before, during, or after a simulation. For instance, field data can be obtained prior to a simulation and considered in real-time during the simulation to compare against, calibrate, or tune simulations to attempt to match actual field data.
Attention will now be directed to
The illustrated computing system 300 of
In some embodiments, the computing processor(s) 306 may include integrated circuits for processing or executing computer-executable instructions that are stored in the storage device(s) 308 or memory 310 for implementing the methods and functionality disclosed herein. These processor(s) may include one or more core processor(s) and/or micro-core processor(s).
The storage device(s) 308 (and/or any information stored therein) may include a data store such as a database, a file system and/or one or more data structures (e.g., arrays, link lists, tables, hierarchical data structures, relational data structures, etc.) which are configured for computer storage. The data may be stored in any suitable format (e.g., as an extensible markup language (XML) file, a standard generalized markup language (SGML) file, hypertext markup language (HTML) file, or any other suitable storage format).
The storage device(s) 308 may include one or more devices internal to the computing device 302 and/or one or more external storage devices operatively connected to the computing device 302 (e.g., via a port, connector, network interface, etc.).
In some instances, the storage device(s) 308 store one or more files 316. The files 316 may include files as discussed herein, and in some embodiments may contain one or more of milling tool parameters, BHA parameters, wellbore casing parameters, wellbore parameters, simulation parameters, or image data corresponding to graphical representations of at least casings, wellbores, and milling tools, as well as other user interface images. In at least this regard, the wellbore casings, BHA assemblies, and milling tools described herein can also be referred to as virtual wellbore casings, virtual BHAs, and virtual milling tools.
The stored data can be stored separately in the storage device(s) 308 as separate files 316 or together as one or more composite files. The stored files 316 can also include files storing simulation parameters that control how a simulation is run (e.g., algorithms to be applied, simulation iterations, simulation comparisons, simulation inputs and outputs, and so forth). Actual simulation data can also be stored in the storage device(s) 308. Actual field result data can also be stored in the storage device(s) 308.
The GUI 312 may include various specialized computing engines for facilitating the methods and functionality disclosed herein. These specialized computing engines may include, for example, an interface engine 312-1, a visualizing engine 312-2, and a simulation engine 312-3. These engines may be instantiated and/or implemented by the computer processor(s) 306.
The interface engine 312-1 is usable to access (e.g., obtain data from and/or store data to) one or more of the files 316 containing any of the parameters discussed herein, as well as to generate an abandonment simulation interface 312-4 that displays interactive elements that are operable (e.g., in response to user input or automated processing) for selecting the aforementioned parameters in response to user input directed at the interactive elements. Selection of parameters may include accessing stored parameters, receiving new input, accessing previous simulation data, or the like. The GUI 312 may include any combination of display objects such as buttons (e.g., radio buttons, link buttons, etc.), data fields (e.g., input fields), banners, menus (e.g., user input menus), boxes (e.g., input or output text boxes), tables (e.g., data summary tables), sections (e.g., informational sections or sections capable of minimizing/maximizing), screens (e.g., welcome screen, home screen, data screen, login/logged out screen), user selection menus (e.g., drop down menus), or other components, or some combination of the foregoing.
In the same or other embodiments, the GUI 312 may include one or more separate interfaces and may be usable in a web browser as a service and/or as a standalone application. The GUI 312 may include program code or other modules (e.g., stored in storage device(s) 308 and/or memory 310) that may be executed by the computer processor(s) 306 to provide interfaces for input and/or output by a user.
The visualizing engine 312-2 is usable to generate a visual representation of actual or virtual milling tool(s), wellbore casing(s), other BHA component(s), or portions of downhole environments, operation data, or any combination of the foregoing. In some embodiments, the visual representations accurately reflect milling tools and wellbore components or other aspects of the downhole environment based on the aforementioned parameters that were accessed, modified, or otherwise selected. The components can be visualized separately and/or in an assembly by the abandonment simulation interface 312-4.
In accordance with some embodiments, the GUI 312 may be operated by a user (e.g., an engineer, a designer, an operator, an employee, or any other entity) using one or more input devices 322, and the GUI 312 may be visualized using one or more output devices 324 coupled to the computing device 302. The GUI 312 may also access and display data stored in the storage device(s) 308 or memory 310, as well as output that is generated as a result of the simulations.
The input device(s) 322 may include any number of components. For instance, the input device(s) 322 may include any combination of touchscreen, keyboard, mouse, microphone, touchpad, electronic pen, field sensor, camera, or other types of input device.
The output device(s) 324 may also include number of components. For instance, the output device(s) 324 may include any combination of one or more screens or other displays (e.g., a liquid crystal display (LCD), plasma display, light emitting diode (LED) display, touchscreen, cathode ray tube (CRT) monitor, projector, 2D display, 3D display, or other display device), a printer, speaker, haptic feedback device, external storage, or other output devices.
One or more of the output device(s) 324 may be the same or different from the input device(s) 322. The input and output device(s) 322, 324 may be locally or remotely connected to the computer device 302 through wired and/or wireless connections.
In some embodiments, the computing system 300 may also include one or more remote computing devices or systems. These remote devices and systems can include sensor and field systems 330 that are monitoring or that are otherwise connected to a BHA being used in the field, and/or one or more third party systems 340, such as clearinghouse systems or remote databases containing stored data accessed by the computing device 302 to perform one or more of the disclosed functions.
While the computing device 302 is shown as a single device, it will be appreciated that in other embodiments, the computing device 302 is actually a distributed computing system that includes the computing device 302 and one or more other computing devices 350 that each have their own hardware processor(s). In such a distributed computing environment (such as a cloud computing environment), the different computing components (e.g., memory 310, storage device(s) 308, GUI 312, and other components 314) can be shared and/or distributed in any way among the plurality of different computing devices 350.
The computing device 302 may be communicatively coupled to any combination of the foregoing computing systems and devices through a network 360 (e.g., a local area network (LAN), a wide area network (WAN) such as the Internet, mobile network, or any other type of network) through one or more network interfaces that include any combination of one or more wires, cables, fibers, optical connectors, wireless connections, network interface connections, or other network connections.
The aforementioned computing devices and systems may take various forms and configurations, including, physical servers, virtual servers, supercomputers, personal computers, desktop computers, laptop computers, message processors, hand-held devices, programmable logic machines, multi-processor systems, microprocessor-based or programmable consumer electronics, network PCs, tablet computing devices, minicomputers, mainframe computers, mobile telephones, PDAs, wearable computing devices, and the like.
In some embodiments, the computing device 302 and corresponding computing system 300 may be used to simulate an abandonment procedure performed by a virtual BHA and a virtual wellbore casing that is accessible and/or selected by a user from a pre-existing library of abandonment procedures (e.g., stored on storage device(s) 308 as file(s) 316). The specific milling tools and wellbore casings may also be selected from pre-existing files. For instance, a company may generate and maintain a log, journal, or other record of milling tools and wellbore casings that have been used or designed in the past and any of these, among others, may be stored in the pre-existing library of BHAs. Selecting a milling tool and/or wellbore casing from the pre-existing library may be done by the user using the GUI 312 and/or input device(s) 322, executed by the computing processor(s) 306, and may be visualized or otherwise rendered with the appropriate output device(s) 324.
In the same or other embodiments, the BHA assembles and wellbore casings and other abandonment components to be visualized and/or used in a simulation may be created or customized by the user (e.g., using the GUI 312). The user may create or customize any abandonment component(s), for example, by inputting, selecting, or modifying the abandonment components and/or their parameters with the GUI 312.
Additionally, any simulation of an abandonment procedure may be designed or customized by any combination of accessing, inputting, selecting, or modifying corresponding parameters with the GUI 312. For instance, the computing device 302 may present to the user a number of abandonment components (e.g., milling tool, BHA components, wellbore components, wellbore casings, wellbore abandonment procedures, etc.) for selection. The user may select one or more of the components to be included in a simulation. Based on the selection, a number of corresponding parameters may also be presented to the user via the GUI 312. In some embodiments, the user may instead, or additionally, modify a particular component based on desired or known operating parameters or any other conditions known to a person having ordinary skill in the art in view of the disclosure herein. A simulation may therefore be fully or partially based on any combination of pre-existing data, real-time data, customized data, or the like.
Various embodiments of some of the interfaces that can be provided by the GUI 312 are now described with reference to
As shown in
In some embodiments, for example, the BHA will include a bi-mill having two cutting tools (e.g., two section mills; a section mill and a follow-mill; a lead mill and a section mill; etc.). In another embodiment, the BHA will include a tri-mill having at least three cutting tools (e.g., two section mills and a reamer; a lead mill, section mill, and reamer; a lead mill and two section mills; etc.). In other embodiments, the BHA will include a spear or other fishing tool. In still other embodiments, the BHA may include any combination of one or more drill bits, stabilizers, plug/isolation tools, other components, or any combination of the foregoing. Each component includes parameters that are selectably modifiable by a user to control the corresponding simulation and visualization of each corresponding component. One or more stabilizers, drill collars, and the like may also be specified as part of the BHA.
The interface 400 also includes a data listing 420 that includes a detailed listing of one or more specific types of a cutting tool component that is identified in the BHA 412 and that is selectable from a component listing 430, which includes a plurality of listed and selectable components (e.g., casing mills, section mills, stabilizers, drill collars, hole enlargement tools, etc.). Parameters of the listed components can also be visualized within the data listing 420.
When a component is selected from the component listing 430, a visualization of the component can be presented in a separate window, like window 440, which is presently visualizing a drill collar 442. Dimensions or other parameters of the visualized component(s) in window 440 can also be called out in one or more references 444. The specific parameters, including dimensions and material properties of the selected component(s) are also displayable in another window frame, such as frame 450.
Frame 450 is presently used to list a plurality of parameters 452 and input fields 454 that are operable to receive user input for entering or modifying any of the parameters 452. When a parameter is modified or entered, the GUI 312 (
If a desired component is not presently listed in the component listing 430, it may be possible to access additional components by selecting an object like object 460 to access supplemental category listing 462 or supplemental subcategory component listing 464 (which is accessible by selecting a category from one or more listed categories in category listing 462).
Additional interface objects may also be presented, like objects 470, which are selectable to save or select a displayed/listed component for a subsequent simulation of an abandonment process or for inclusion into a milling tool and/or wellbore casing.
Objects 470 can also be provided for accessing one or more additional interfaces for viewing, modifying, or saving milling tools and other abandonment components. For instance, one of the displayed interactive objects 470 may be selected to cause the display of interface 480, which is presently illustrating aspects of a casing mill tool, along with a visualization window 482 showing visualizations associated with the milling tool. The visualizations in the visualization window 482 may be based on parameters for the corresponding component. In
The BHA 512 is also illustrated with various detailed callouts that identify and provide parameter information for some of the different BHA components. In this embodiment, the first call out 514 may be for a drill pipe, a second callout 516 may be for a taper mill, and a third callout 518 may be for a section mill or reamer. Other combinations of components may also be specified. Each callout can include corresponding identifiers and/or parameters.
An example visualization of a drill pipe 542 for use in a drill string is shown in window 540. Any portion(s) of the abandonment components identified by the interface 500 can be visualized. In some embodiments, the visualization window 540 visualizes a component selected from the visualization in the BHA view window 510. In another embodiment a user is able to select a component for visualization from another frame, such as from a listing in frames 530 or 550.
The user can also select and modify listed parameters 552 with input fields 554 provided in frame 550 or one or more other locations, such as listing 520.
Some objects and listings, and potentially each object and listing, can include a selectable object which, when selected, enables a user to provide additional input to modify a parameter and/or cause the corresponding abandonment component or assembly to be visualized and/or simulated.
Additional interactive elements 630 can also be used, when selected, to open, copy, modify, visualize, initiate, or quit a particular simulation or project.
Visualizations of abandonment components and simulations and simulation results can be rendered in different interface windows 640 and 650, of which one window may visualize an abandonment component and the other window may visualize performance data or parameters associated with the abandonment component.
Different parameter frames 720, 730, 740, and 750 each display different parameters corresponding to the different components that are visualized in the display frame 710. For instance, frame 720 displays parameters for the inner casing 716, frame 740 displays parameters for the outer casing 712, frame 750 displays parameters for the cement layer 713, and frame 760 displays parameters for the cement layer 714. Additional or fewer frames can be displayed in response to user input directed at interactive display objects 760, for different components. The display objects 760 can also be used, when selected, to control which parameters are displayed in any given frame. The parameters in each frame are operable, when selected to be modified in response to user input directed at the parameters.
Interactive objects 770 are also provided which, when selected, enable a user to control the visualization properties (e.g., to select components to be displayed and how they are displayed within the display frame 710).
As described herein, after a simulation is performed, the results of the simulation can be visualized or otherwise output in any number of forms. Example formats used to reflect an impact of a simulation are shown, for example, by the illustrations of
In some embodiments, a simulation can also include simulation parameters that are displayed and that are selectably modifiable to control the simulation accordingly. For instance, window 860 may include interactive elements 862, 864, and 866 which, when selected and have input received therein, are operable to control the RPM, WOB, load, or other simulation parameters of the BHA 840. When any of these parameters is changed, the GUI 312 (
Returning briefly to
The animated simulation includes a simulated interaction between the milling tool (e.g., including mill bits 876) and the wellbore or wellbore casing (e.g., casing 872 and cement 874). Where the simulation includes an interaction of other components (e.g., cementing string, bridge plug, etc.), the animated simulation may include a simulated interaction between such a component and the wellbore or wellbore casing(s).
The simulation may be performed by the simulation engine 312-3 of the GUI 312 using one or more of the methods set forth herein. In one or more embodiments, the BHA may be modeled with beam elements (using finite element analysis (FEA) techniques as known in the art). Briefly, FEA may involve dividing a body under study into a finite number of pieces (subdomains) called elements. Particular assumptions may then be made on the variation of the unknown dependent variable(s) across each element using so-called interpolation or approximation functions. This approximated variation may be quantified in terms of solution values at special element locations called nodes.
Through this discretization process, the FEA method can set up an algebraic system of equations for unknown nodal values which approximate the continuous solution. Element size, shape, and approximating scheme can be varied to suit the problem, and the method can therefore accurately simulate solutions to problems of complex geometry and loading.
Each beam element may have two nodes. For a MWD/LWD tool, for example, the tool may be divided into beam elements, based on the geometry of the tool and sensor locations. The nodes may be located at the division points of the elements. During the simulation, a milling tool may pass radially through one or more casing layers and cement layers. When the milling tool moves (e.g., rotates or moves axially) relative to the wellbore casing, the nodes will have history of accelerations, velocity, displacement, etc. The location of the nodes with reference to the well center or wellbore can be determined.
Representative results that are produced by a simulation may include: accelerations, velocities, trajectories, contact forces and other determined results at the bit, mill, stabilizers, reamers, drills, and other locations. Any or potentially each of these results may be produced in the form of a time history, box and whisker plot, 2D or 3D animation, picture, other representation, or some combination of the foregoing, including the examples illustrated in the figures.
Executing the simulation may generate a set of performance data (e.g., milling performance parameters). In some cases, the set of performance data generated may depend on the data selected or input by the user and/or data stored in one or more files (e.g., rock or material files based on physical tests or cutting elements scraping corresponding materials). User input may include instructions to generate specific performance data, such as, but not limited to, surface torque, WOB, bit RPM, cutter forces, build up rate, dogleg severity, bending moment, von Mises stress, walk rate, contact forces, tool wear rate, other data, or some combination of the foregoing. Additionally, the performance data may include bit/tool geometry, ROP, or hole size, among other things. The set of performance data may be stored in persistent storage (e.g., on storage device(s) 308) in some embodiments.
After and/or during a simulation, the set of performance data may be visualized through the GUI 312 (e.g., on the output device(s) 316). In some embodiments, visual outputs of the GUI 312 may include tabular data of one or more performance parameters. In the same or other embodiments, the outputs may be in the form of graphs and may be represented as ratios, percentages, absolute numbers, or the like. A graphical visualization of one or more of the bit, blades, cutters, BHA components, or other components may be output. In some embodiments, a graphical visualization (e.g., a 2-D, 3-D, or 4-D graph or plot) may include a color scheme. For instance, a color scheme may represent different components, different levels of forces (e.g., vibrations) or stresses, fatigue, wear rates, or the like.
Some specific, non-limiting examples of visualizing performance data are shown in, and described with respect to,
In
Window 1030 includes interactive elements which are operable, in response to user input entered therein, to select or modify parameters of abandonment components and corresponding simulation parameters. Example parameters that may be selected and/or modified in window 1030 include milling depth (1032), WOB (1034), RPM (1036), starting depth (1038), casing geometry and/or trajectory, fluid types and levels, and so forth. More detailed parameters for different abandonment phases can be broken out and defined with other interactive elements 1040, as well, by selecting and/or entering information into the corresponding parameter input fields for each phase. Visualizations of the simulation parameters can be presented to the user in one or more additional windows, such as window 1050.
For the surface WOB graph 1220, the surface WOB (e.g., in klbf) may be shown for different tool depths (e.g., measured in feet). In this embodiment, the surface WOB may vary from a minimum of 0 klbf at a tool depth of 31,520 ft. (9,607 m) to a maximum surface WOB of 40 klbf at a tool depth of 31,527 ft. (9,609 m) from the surface. The bit RPM graph 1230 may similarly show the RPM (e.g., in rotations per minute) of the tool at different tool depths. As shown in this plot, the bit RPM may rapidly fluctuate (e.g., at tool depths between 31,524 ft. (9,609 m) and 31,536 ft. (9,612 m). More particularly, in this plot, the tool is shown as having an RPM which may vary from 0 RPM at a tool depth of 31,512 ft. (9,605 m) to 220 RPM at a tool depth of 31,523 ft. (9,608 m).
The performance data in
In some embodiments, the user can selectably interact with the node object 1410, by selecting and moving the node object to another node to thereby cause the computing system to render different output corresponding to the other node. In the same or other embodiments, the user can select a plurality of different nodes on the virtual BHA to cause the computing system to dynamically generate/render a plurality of corresponding outputs for the selected nodes.
The user can also utilize the interface objects to select different types of simulation outputs to render, as well as different simulation scenarios to graph, in the simulation output. When the interface objects 1450 are selected, the interface 1400 displays different selectable options for modifying the simulation scenarios, graphing options (e.g., types of graphs, performance metrics to graph, etc.), node selection options, BHA component selection options, and so forth.
The interactive objects 1530 can also be used to select the display of additional images and graphs, such as the uncertainty plots 1540 and 1550, which visually indicate that cement behind a casing could, in this embodiment, reduce the corresponding bending moment by up to 20% or more.
In the embodiment of
The bending moments are also plotted as a function of downhole depth in another plot 1740. This plot 1740 specifically shows bending moments occurring over time for a selected simulation at a particular node defined by node selection object 1720. Any of the plot parameters used to control the rendering of the performance data for plots 1730 and 1740 can be modified through selectable options that are presented to a user in response to a user selection of the interactive objects 1750.
In another set of interfaces 1800 and 1900, shown in
Any combination of performance data graphs can be selected for display, as can the graphing options, in response to a user selection of an interactive menu object displayed by the interface 1800 and 1900. For instance, a user can select an interactive menu object displayed by the interface 1900 to cause the interface 1900 to display additional graphing options which enable the user to select additional or other graphs to be displayed (e.g., lateral acceleration, or any other graphing option) corresponding to a simulated abandonment procedure.
In some embodiments, once a simulation is run and after the user is presented with a set of performance data and/or the simulation visualizations, the user may modify at least one parameter associated with the simulation (e.g., any abandonment component or corresponding simulation parameter), such as, for example, a quantity, position, location, or size of nested casings, dimensions of removed casing section, cutting tool parameters, cutting tool RPM, axial acceleration, milling tool size or location, rotational speed, weight-on-bit, and so forth. Modification may involve selecting a parameter from pre-existing values or receiving input of the parameter with any of the interfaces of the GUI 312 (
After modification, a second simulation may optionally be executed (e.g., by the computing system 300 of
Similar to the first simulation, the second simulation may include instructions to generate specific performance data, such as, but not limited to, surface torque, weight on bit (WOB), surface weight on bit (SWOB), bit RPM, cutter forces, build-up rate, bending moment, von Mises stress, window quality, window size/geometry, resulting whip profile, walk rate, contact forces, vibrational data, axial acceleration, lateral acceleration, other data, or some combination of the foregoing. Additionally, the performance data may include resulting bit/tool geometry (e.g., after wear of cutting elements), wear rate, rate of penetration (ROP), surface weight on bit, hole size/geometry, or hole quality, among others. The set of performance data may be stored (e.g., persistently on storage device(s) 308).
The initial set of performance data and the second set of performance data may be presented using GUI 312 (
Further, similar to the first and second simulation requests, field data may be obtained from one or more sensors (e.g., an MWD or LWD, a downhole sensor, a surface sensor, etc.) to generate additional sets of performance data to compare to the first and/or second sets of performance data. Any of the foregoing performance data can then be used to selectably tune/calibrate the simulation system. With a calibrated simulation system, additional or other simulations may be run to otherwise improve a design of a BHA, a corresponding milling tool, or abandonment procedure. In some embodiments, sensors used to obtain field data may be located at one or more discrete locations on a BHA. In some embodiments, the obtained field data may be used to tune/calibrate a simulation system by comparing field data to simulated results for the corresponding, discrete locations on the BHA. The calibration may also increase reliability of simulated performance data at other locations within the BHA, and for which field data is not available.
The abandonment simulations described herein may be performed using one or more of the methods set forth below or as otherwise described herein. By way of example,
The flow diagram 2000, shown in
As indicated above, the virtual milling tool may include section mills or casing mills that are capable of milling an axially and removing a full or partial thickness of casing lining a wellbore wall, or any other mills or drills that are capable of removing debris and other material from a wellbore (e.g., cement, earth formation, tools, sensors, whipstocks, casing, etc.). The virtual downhole casing environment, on the other hand, may include any material located in or adjacent to the sections of the casing being removed during an abandonment procedure (e.g., one or more additional casing(s), cement layer(s), earth formation(s), tool(s), sensor(s), whipstock(s), fluid(s), plug(s), etc.).
In some embodiments, the computing system accesses parameters for the various abandonment components from mesh simulation data defining at least a virtual state of one or more wellbores and/or milling tools following a previous simulation of a downhole procedure involving the one or more wellbores and/or milling tools. In other embodiments, the parameters are obtained from one or more files corresponding to actual field data extracted from one or more sensors or measuring devices.
The computing system 300 (
The computing system may also utilize one or more simulation interfaces 312-4 to render one or more outputs associated with the simulation of the abandonment procedure, including simulation animations, visualizations, and presentations of corresponding performance data, as described herein.
In the flowchart 2100 of
The method of
In another method, illustrated by the flowchart 2200 of
The computing system utilizes a visualizing engine to generate a visual representation(s) of selected abandonment components (e.g., the virtual milling tool(s) and/or the virtual wellbore casing(s)) (act 2240). The computing system 300 also uses the interface engine to access simulation parameters and the corresponding virtual milling tool(s) and wellbore casing(s) to be used in a simulation of an abandonment procedure (act 2250). Then, a simulation engine is used to perform a simulation of an abandonment procedure that involves at least an interaction of the virtual milling tool(s) and wellbore casing(s) (act 2260). Output is then rendered by the computing system 300 to reflect attributes and characteristics of the abandonment procedure (act 2270).
Although many of the foregoing embodiments are specifically described in reference to abandonment procedures in which material is extracted from a wellbore, it will be appreciated that the systems, interfaces and methods of the present disclosure can also be used to perform abandonment procedures that include adding material to a wellbore. For instance, in one embodiment the abandonment procedure is the positioning/adding of a plug to a wellbore, such that a virtual plug is used instead of, or in addition to, a virtual milling tool in the processes described herein. In such an embodiment, the abandonment procedure that is simulated may include a simulated installation of a plug (e.g., a cement plug, a bridge plug, etc.) in a wellbore region where at least a portion of the one or more virtual wellbore casings were previously removed by a selected one or more virtual milling tools, or in which the casing environment was designed with a void region where the virtual plug is installed. In some embodiments, an abandonment procedure may be simulated that includes installing a plug or other isolation tool within casing. For instance, a bridge plug may be installed in casing to isolate a portion of the wellbore and form a base for a cement plug to be installed. The cement plug may then be formed in the cased and/or section milled portion of the wellbore.
In some instances, a virtual BHA (including the virtual milling tool(s) used in the simulation of an abandonment procedure) replicate an actual BHA that was previously used to perform a correspondingly similar and actual abandonment procedure. In the same or other embodiments, the virtual BHA is designed from scratch or by modifying a stored file of a virtual BHA that does not replicate an actual BHA that was previously used in an actual abandonment procedure.
The virtual BHA may then be modified into a virtual modified BHA, in response to user input, to change one or more components of the BHA or one or more corresponding parameters of the BHA components. The virtual modified BHA may then be used in another simulation of the abandonment procedure to determine which of the virtual BHAs is better suited for the abandonment procedure and whether the virtual modifications should also be made in real life for an actual corresponding abandonment procedure, thereby enabling a user to more efficiently predict performance of an abandonment component for an abandonment procedure and/or to compare and contrast performance characteristics of one or more abandonment components for various downhole casing environments.
In some embodiments, a BHA designer may also review simulated performance of a BHA as a function of location along the BHA (or distance from a cutting tool or other component). By providing outputs that show performance as a function of length or distance, the BHA designer can obtain information indicative of locations with high stress, high vibration, high accelerations, or other deleterious effects. The BHA designer can then add, remove, move, or modify components on the BHA to reduce, modify, or eliminate these deleterious effects. By allowing a designer to review locational information, the overall performance of the BHA may be improved.
Aspects of the present disclosure allow a BHA designer to investigate the performance of multiple BHAs having a dynamic input. A dynamic input includes an input that varies during the course of a simulation. For example, the RPM may be varied (e.g., with the bit either drilling or not drilling) to determine a speed to be avoided during drilling. Similarly, the WOB may be varied over the course of the simulation (e.g., from 0 to a selected value, or between two values higher than 0). Similarly, the WOB of the BHA may be entered as a dynamic input, and allowed to change over the course of the simulation. Further still, the size of a bit, stabilizer, mill, hole enlargement tool, or other component may change over time (e.g., as wear occurs). By having a dynamic input (which may be fed into the simulation system from a performance parameter in some embodiments), selected embodiments of the present disclosure may allow a BHA designer to suggest operating parameters to be avoided, or to be used by a driller when actually drilling a well with a correspondingly structured BHA.
Embodiments of the present disclosure may allow for an engineer, or BHA designer, to efficiently select or modify a BHA to be used for abandonment procedures based on corresponding simulation results, models, and performance data. Accordingly, the interfaces and systems of the present disclosure may enable a designer to select the optimized BHA for specific wellbore conditions and/or abandonment procedures. Then, once selected, the optimized BHA is then used for the particular abandonment procedure.
Embodiments of the present disclosure may generally be performed by a computing device or system, and more particularly performed in response to instructions provided by one or more applications or modules executing on one or more computing devices within a system. In other embodiments of the present disclosure, hardware, firmware, software, computer program products, other programming instructions, or any combination of the foregoing, may be used in directing the operation of a computing device or system.
Embodiments of the present disclosure may thus utilize a special purpose or general-purpose computing system including computer hardware, such as, for example, one or more processors and system memory. Embodiments within the scope of the present disclosure also include physical and other computer-readable media for carrying or storing computer-executable instructions and/or data structures, including applications, tables, data, libraries, or other modules used to execute particular functions or direct selection or execution of other modules. Such computer-readable media can be any available media that can be accessed by a general purpose or special purpose computer system. Computer-readable media that store computer-executable instructions (or software instructions) are physical storage media. Computer-readable media that carry computer-executable instructions are transmission media. Thus, by way of example, and not limitation, embodiments of the present disclosure can include at least two distinctly different kinds of computer-readable media, namely physical storage media and/or transmission media. Combinations of physical storage media and transmission media should also be included within the scope of computer-readable media.
Both physical storage media and transmission media may be used temporarily store or carry, software instructions in the form of computer readable program code that allows performance of embodiments of the present disclosure. Physical storage media may further be used to persistently or permanently store such software instructions. Examples of physical storage media include physical memory (e.g., RAM, ROM, EPROM, EEPROM, etc.), optical disk storage (e.g., CD, DVD, HDDVD, Blu-ray, etc.), storage devices (e.g., magnetic disk storage, tape storage, diskette, etc.), flash or other solid-state storage or memory, or any other non-transmission medium which can be used to store program code in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer, whether such program code is stored as or in software, hardware, firmware, or combinations thereof.
A “communication network” may generally be defined as one or more data links that enable the transport of electronic data between computer systems and/or modules, engines, and/or other electronic devices. When information is transferred or provided over a communication network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a computing device, the computing device properly views the connection as a transmission medium. Transmission media can include a communication network and/or data links, carrier waves, wireless signals, and the like, which can be used to carry desired program or template code means or instructions in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer.
Further, upon reaching various computer system components, program code in the form of computer-executable instructions or data structures can be transferred automatically or manually from transmission media to physical storage media (or vice versa). For example, computer-executable instructions or data structures received over a network or data link can be buffered in memory (e.g., RAM) within a network interface module (NIC), and then eventually transferred to computer system RAM and/or to less volatile physical storage media at a computer system. Thus, it should be understood that physical storage media can be included in computer system components that also (or even primarily) utilize transmission media.
Computer-executable instructions comprise, for example, instructions and data which, when executed at one or more processors, cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. The computer-executable instructions may be, for example, binaries, intermediate format instructions such as assembly language, or even source code. Although the subject matter of certain embodiments herein may have been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter of the present disclosure, is not limited to the described features or acts described herein, nor performance of the described acts by the components described herein. Rather, the described features and acts are disclosed as example forms of implementing the some aspects of the present disclosure.
In the description herein, various relational terms are provided to facilitate an understanding of various aspects of some embodiments of the present disclosure. Relational terms such as “bottom,” “below,” “top,” “above,” “back,” “front,” “left,” “right,” “rear,” “forward,” “up,” “down,” “horizontal,” “vertical,” “clockwise,” “counterclockwise,” “upper,” “lower,” “uphole,” “downhole,” and the like, may be used to describe various components, including their operation and/or illustrated position relative to one or more other components. Relational terms do not indicate a particular orientation for each embodiment within the scope of the description or claims. For example, a component of a BHA that is described as “below” another component may be further from the surface while within a vertical wellbore, but may have a different orientation during assembly, when removed from the wellbore, or in a deviated or other lateral borehole. Accordingly, relational descriptions are intended solely for convenience in facilitating reference to various components, but such relational aspects may be reversed, flipped, rotated, moved in space, placed in a diagonal orientation or position, placed horizontally or vertically, or similarly modified. Certain descriptions or designations of components as “first,” “second,” “third,” and the like may also be used to differentiate between identical components or between components which are similar in use, structure, or operation. Such language is not intended to limit a component to a singular designation. As such, a component referenced in the specification as the “first” component may be the same or different than a component that is referenced in the claims as a “first” component.
Furthermore, while the description or claims may refer to “an additional” or “other” element, feature, aspect, component, or the like, it does not preclude there being a single element, or more than one, of the additional or other element. Where the claims or description refer to “a” or “an” element, such reference is not be construed that there is just one of that element, but is instead to be inclusive of other components and understood as “at least one” of the element. It is to be understood that where the specification states that a component, feature, structure, function, or characteristic “may,” “might,” “can,” or “could” be included, that particular component, feature, structure, or characteristic is provided in some embodiments, but is optional for other embodiments of the present disclosure. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with,” or “in connection with via one or more intermediate elements or members.” Components that are “integral” or “integrally” formed include components made from the same piece of material, or sets of materials, such as by being commonly molded or cast from the same material, or machined from the same one or more pieces of material stock. Components that are “integral” should also be understood to be “coupled” together.
Any element described in relation to an embodiment herein may be combinable with any element (or any number of other elements) of any other embodiment(s) described herein. Although a few specific example embodiments have been described in detail herein, those skilled in the art will readily appreciate in view of the disclosure herein that many modifications to the example embodiments are possible without materially departing from the disclosure provided herein. Accordingly, such modifications are intended to be included in the scope of this disclosure. Likewise, while the disclosure herein contains many specifics, these specifics should not be construed as limiting the scope of the disclosure or of any of the appended claims, but merely as providing information pertinent to one or more specific embodiments that may fall within the scope of the disclosure and the appended claims. In addition, other embodiments of the present disclosure may also be devised which lie within the scopes of the disclosure and the appended claims. All additions, deletions, and modifications to the embodiments that fall within the meaning and scopes of the claims are to be embraced by the claims.
Certain embodiments and features may have been described using numerical examples, including sets of numerical upper limits and sets of numerical lower limits. It should be appreciated that ranges including the combination of any two values, are contemplated, or that any single value may be selected as a lower or upper value. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 10%, within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.
A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.
While embodiments disclosed herein may be used in oil, gas, or other hydrocarbon exploration or production environments, such environments are merely illustrative. Systems, interfaces, storage devices, computer-readable media, computer program products, and methods of simulating wellbore abandonment procedures, of the present disclosure may also be used in other applications and environments, including but not limited to automotive, aquatic, aerospace, hydroelectric, manufacturing, other industries, or even in other downhole environments. The terms “well,” “wellbore,” “borehole,” and the like are therefore also not intended to limit embodiments of the present disclosure to a particular industry. A wellbore or borehole may, for instance, be used for oil and gas production and exploration, water production and exploration, mining, utility line placement, or myriad other applications.
This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 61/922,405 filed on Dec. 31, 2013, entitled “METHODS FOR ANALYZING AND OPTIMIZING DOWNHOLE MILLING OPERATIONS,” and to United States Provisional Patent Application Serial No. 62/097,362 filed on Dec. 29, 2014, entitled “COMPUTING SYSTEMS, TOOLS, AND METHODS FOR SIMULATING DOWNHOLE OPERATIONS.” This application is also related to U.S. patent application Ser. No. 14/584,424, filed on Dec. 29, 2014, entitled “COMPUTING SYSTEMS, TOOLS, AND METHODS FOR SIMULATING WELLBORE DEPARTURE,” and U.S. patent application Ser. No. 14/584,477, filed Dec. 29, 2014, entitled “COMPUTING SYSTEMS, TOOLS, AND METHODS FOR SIMULATING WELLBORE RE-ENTRY.” Each of the foregoing applications is expressly incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61922405 | Dec 2013 | US | |
| 62097362 | Dec 2014 | US |
