A circulating sub apparatus can be installed in a drill pipe to provide a bypass flow path, e.g., to enable pumping of lost circulation material (LCM) slurry into a well without risk of clogging downhole tools.
In an aspect, a method for operating a circulating sub in a well includes opening a port of the circulating sub, including: dropping a ball into a drill pipe containing a downhole fluid, in which a port is defined in a wall of the drill pipe; and seating the ball on an actuator slidably disposed concentrically within the drill pipe, in which seating the ball on the actuator causes motion of the actuator relative to the drill pipe to open the port. The method includes closing the port of the circulating sub, including: introducing a solvent different from the downhole fluid into the drill pipe, in which a solubility of the ball in the solvent is greater than a solubility of the ball in the downhole fluid; and degrading the ball in the solvent, in which the degrading of the ball causes motion of the actuator relative to the drill pipe to close the port.
Embodiments can include one or any combination of two or more of the following features.
The ball is insoluble in the downhole fluid.
The ball comprises a core coated with a shell, and in which a solubility of the shell in the solvent is greater than a solubility of the shell in the downhole fluid. A solubility of the shell in the solvent is greater than a solubility of the core in the solvent, and in which the core is insoluble in the downhole fluid. Degrading the ball in the solvent comprises: dissolving or eroding the shell in the solvent; and receiving the core in a ball collector disposed in the drill pipe downhole from the actuator. The method includes retrieving the core. The method includes coating the retrieved core with a new shell for reuse.
Degrading the ball in the solvent comprises completely degrading the ball in the solvent.
The ball comprises a metal. The ball comprises a magnesium based alloy or an aluminum based alloy.
The ball comprises a polymer. The ball comprises polyglycolic acid or polylactic acid.
Introducing the solvent comprises introducing a fluid having an acidity higher than an acidity of the downhole fluid, introducing a fluid having a brine concentration higher than a brine concentration of the downhole fluid, or both.
Seating the ball on the actuator causes the actuator to slide within the drill pipe in a downhole direction to open the port.
Degrading the ball causes the actuator to slide within the drill pipe in an uphole direction to close the port.
16. The method of claim 1, comprising, when the port is open, flowing a lost circulation material slurry through the open port of the circulating sub and into an annular space exterior to the drill pipe.
The method includes, when the port is closed, flowing the downhole fluid through the drill pipe to a bottom hole assembly.
In an aspect, a circulating sub system includes a drill pipe, in which a port is defined in a wall of the drill pipe, and in which the drill pipe contains downhole fluid; an actuator slidably disposed concentrically within the drill pipe; and a ball seated in a seat of the actuator. The ball comprises a core coated with a shell, and in which the shell of the ball is insoluble in the downhole fluid. An outer diameter of the shell is larger than a diameter of a bore of the actuator and a diameter of the core is smaller than the diameter of the bore of the actuator. The actuator with the ball seated therein is disposed downhole of the port defined in the wall of the drill pipe such that a fluid can flow from a bore of the drill pipe, through the port, and into an annular space exterior to the drill pipe. The system also includes a ball collector disposed in the drill pipe downhole from the actuator.
Embodiments can include one or any combination of two or more of the following features.
The core of the ball is insoluble in the downhole fluid.
The ball collector is configured to receive the core of the ball when the shell of the ball is degraded. The actuator is configured to slide within the drill pipe to close the port when the shell of the ball is degraded.
The shell of the ball is soluble in a solvent different from the downhole fluid and in which the core of the ball is insoluble in the solvent. The solvent comprises a fluid having an acidity higher than an acidity of the downhole fluid, a fluid having a brine concentration higher than a brine concentration of the downhole fluid, or both.
The ball comprises a metal. The ball comprises a magnesium based alloy or an aluminum based alloy.
The ball comprises a polymer. The ball comprises polyglycolic acid or polylactic acid.
The approaches described here can have one or more of the following advantages. Actuation of a circulating sub apparatus using a ball that is insoluble in a downhole fluid but soluble in a different solvent provides a well operator control over the timing of the dissolving of the ball; the ball does not dissolve in the downhole fluid, but rather begins dissolving only after the operator has introduced the solvent. Use of a core-shell ball in which the shell is soluble in the solvent and the core is insoluble in the solvent means that balls of a relatively small diameter are collected in a ball collector of the circulating sub apparatus. Thus, more balls can fit in the ball collector before the ball collector needs to be emptied, enabling more activation-deactivation cycles to be performed before interruption of drilling activities. When the entire ball is soluble in the solvent, no ball collector is needed, and an indefinite number of activation-deactivation cycles can be performed without interruption of drilling activities to empty the ball collector.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
We describe here an approach to activation and deactivation of a circulating sub apparatus in a drill pipe using a ball that is insoluble in a downhole fluid used for well drilling, but soluble in a solvent different from the downhole fluid. Insertion of the ball into the drill pipe activates the circulating sub apparatus, opening up a bypass flow path that can be used, e.g., for pumping of lost circulation material slurry (LCM). When the solvent is introduced into the drill pipe, the solvent degrades (e.g., dissolves or erodes) the ball, deactivating the circulating sub apparatus and closing the bypass flow path. In some examples, the ball has a uniform composition and is formed of material that is insoluble in the downhole fluid and soluble in the solvent. In these examples, the entirety of the ball is degraded when the solvent is introduced into the drill pipe. In some examples, the ball is a core-shell ball that has a shell formed of a material that is insoluble in the downhole fluid and soluble in the solvent, and an inner core formed of a different material that is insoluble in both the downhole fluid and the solvent. In these examples, the shell of the ball is degraded when the solvent is introduced into the drill pipe, and the core remains intact and is collected in a ball collector of the circulating sub apparatus.
The circulating sub 100 includes an actuator 120 disposed within the inner bore 108 of the drill pipe 102. The actuator 120 is a generally cylindrical tube that is concentric with the drill pipe 102. An inner bore 122 of the actuator 120 has a smaller diameter than the diameter of the inner bore 108 of the drill pipe 102. The actuator 120 is configured to slide within the drill pipe 102. The actuator 120 can slide upwards (toward the top end 106 of the circulating sub 100) to a deactivated position and downwards (toward the bottom end 104 of the circulating sub 100) to an activated position. When the actuator 120 is in the deactivated position (
A circulating sub apparatus can be useful for managing lost circulating material (LCM) slurry containing particulates, fibrous materials, or a combination thereof. Lost circulation can be encountered when drilling through fractured or vugular formations. In some cases, lost circulation is mitigated by pumping LCM slurry. However, the particulates or fibrous materials in the LCM slurry can clog tools of the bottom hole assembly (BHA), such as a mud motor, measurement while drilling (MWD) tools, logging while drilling (LWD) tools, or other downhole tools. With a circulating sub apparatus assembled with a BHA, fluid flow can be switched from the interior of the drill column (e.g., the inner bore 108 of
As discussed in more detail in the following paragraphs, the circulating sub 100 is activated by dropping a ball 116 into the inner bore 108 of the drill pipe 102. The ball 116 rests on a seat 126 defined at a top of the actuator 120, where the weight of the ball causes the actuator 120 to slide downwards into the activated position, thereby opening the ports 110. When the ball 116 is removed from the seat 126 of the actuator 120, the actuator 120 slides upwards into the deactivated position, thereby closing the ports 110. In the example of
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The shell material of the core-shell ball 200 is insoluble (e.g., resistant to degradation by dissolving or eroding) a downhole fluid 202, such as a drilling fluid, that is present in and around the circulating sub 100, e.g., in the inner bore 108 and in the annular space 124 exterior to the circulating sub 100. When the core-shell ball 200 is seated on the actuator 120, the circulating sub 100 is activated and the ports 110 are open. To close the ports 110, a solvent capable of degrading (e.g., dissolving or eroding) the shell of the core-shell ball is pumped into the circulating sub 100. The shell of the ball dissolves or erodes, leaving the core, which is small enough to pass through the inner bore 122 of the actuator 120, thereby freeing the actuator to slide upwards and deactivate the circulating sub 100.
Use of a solvent that is different from the downhole fluid to degrade the ball provides a well operator with control over the timing of deactivation of the circulating sub apparatus 100. Degradation of the ball begins only once the operator introduces the solvent into the drill pipe 102.
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In the example of
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By activating and deactivating the circulating sub 100 using the core-shell ball 200, only a single ball is used for each round of activation and deactivation; no additional balls are used to deactivate the sub. In addition, the diameter of the ball 200 can be smaller than balls used in other approaches to activation and deactivation of circulating subs, meaning that the ball catcher 212 can hold more balls 200. For instance, in some examples the circulating sub 100 can be used for more than five rounds of activation and deactivation before the ball catcher 212 becomes full.
The shell 304 of the core-shell ball 200 is formed from a material that is more soluble in the solvent 210 than in the downhole fluid 202. In some examples, the shell 304 is formed of a metal-based material, such as a magnesium based alloy or an aluminum based alloy. The solvent 210 can be an acid (e.g., a fluid with a higher acidity than that of the downhole fluid 202) or a brine (e.g., a fluid with a higher brine concentration than that of the downhole fluid 202). With an acid as the solvent, the shell of the ball dissolves into ions fully dissolved in the solvent. With a brine as the solvent, the shell of the ball breaks down into a metal hydroxide powder, which has low solubility in brine.
The rate of degradation (e.g., erosion or dissolution) a metal alloy, such as a magnesium based alloy or an aluminum based alloy, depends on parameters such as downhole temperature and downhole pressure, and on the composition of the solvent 210. In some examples, the composition of the metal alloy of the shell 304 of the core-shell ball 200 is selected to achieve a desired rate of degradation, given an expected downhole temperature and pressure and given a particular composition of the solvent 210. In some examples, an operator selects an solvent 210 to use to achieve a desired rate of degradation given a particular composition of the shell and an actual downhole temperature and pressure. For instance, the operator can select the solvent 210 to expedite or delay the degradation of the shell of the ball 200, e.g., the operator can select a concentration or brine, with higher concentrations generally causing a faster rate of degradation.
In some examples, the shell 304 of the core-shell ball 200 is formed of a polymer, such as polyglycolic acid (PGA) or polylactic acid (PLA). Polymers are degraded by hydrolysis, in which the long polymer chains are broken down into smaller polymers or monomers when exposed to water or humidity, thereby losing structural integrity and mechanical properties. Over time, or as temperature increases, the smaller-chain polymers or monomers become acids, after which no solid shell remains. For instance, PGA degrades into glycolic acid, and PLA degrades into lactic acid. The dissolving or degrading rate of the polymer shell depends mainly on the temperature and on the composition of the solvent 210.
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In the approach of
In some examples, the ball 500 is formed of a metal-based material, such as a magnesium based alloy or an aluminum based alloy and the solvent can be an acid or a brine. With an acid as the solvent, the shell of the ball dissolves into ions fully dissolved in the solvent. With a brine as the solvent, the shell of the ball breaks down into a metal hydroxide powder (e.g., the powder 514 of
Referring to
A lost circulation material slurry is flowed through the open port and into an annular space exterior to the drill pipe (605).
A solvent that is different from the downhole fluid is introduced into the drill pipe (606). A solubility of the ball in the solvent is greater than a solubility of the ball in the downhole fluid. In some examples, the ball includes a core coated with a shell, and a solubility of the shell in the solvent is greater than a solubility of the shell in the downhole fluid, and a solubility of the shell in the solvent is greater than a solubility of the core in the solvent, and the core is insoluble in the downhole fluid. In some examples, the solubility of the entire ball in the solvent is greater than the solubility of the entire ball in the downhole fluid.
The ball is degraded (e.g., dissolved or eroded) in the solvent (608). When the ball is a core-shell ball, degrading the ball includes degrading the shell in the solvent (610) and receiving the core in a ball collector disposed in the drill pipe downhole from the actuator (612). When the ball is formed of a uniform composition, the ball is completely degraded in the solvent (614).
Degrading the ball the ball causes motion of the actuator in the uphole direction relative to the drill pipe to close the port (616) and the downhole fluid is flowed through the drill pipe to a bottom hole assembly (618).
Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims.