In the drilling and completion industry, the formation of boreholes for the purpose of production or injection of fluid is common. The boreholes are used for exploration or extraction of natural resources such as hydrocarbons, oil, gas, water, and alternatively for CO2 sequestration.
Composite frac plugs generally have an open inner diameter that is occluded by a ball dropped from the surface. The reason for this arrangement is that if the guns don't fire after the plug is set, then the open inner diameter will permit pumping another set of guns downhole without mobilizing coiled tubing to open a flow path. In a “plug and perf” operation, a bottom hole assembly (“BHA”) is run on wircline into a borchole that is typically cased and cemented and could include both horizontal and vertical sections. The BHA includes an isolation tool (the frac plug), a setting tool, and one or more perforation guns. The setting tool is actuated for packing off a production zone with the isolation tool. The one or more perforation guns are then positioned in the borehole and triggered by a signal sent down the wireline. Typically, balls are used for the isolation tools as such ball-accepting isolation tools provide fluid communication with lower zones, which enables sufficient fluid flow for redeploying the perforation guns in the event that they do not fire properly. After perforation, the BHA (excluding the isolation tool) is pulled out and a ball is dropped from surface for engaging a seat of the isolation tool for impeding fluid flow therethrough. While the process works adequately, it requires a significant amount of time and fluid to pump a ball downhole. Bridge plugs are occasionally used instead of ball type frac plugs, but these bridge plugs do not enable the aforementioned redeployment of failed perforation guns.
The art would be receptive to improved devices and methods for occluding a frac plug after firing of perforating guns.
A downhole assembly includes an isolation tool disposable downhole of a perforation gun. The isolation tool includes a tubular body having a seat, and an occluding device supported on the tubular body in an unseated position, and movable to a seated position on the seat in response to at least one of a firing operation of the perforation gun and a selected fluid velocity through the isolation tool. Fluid communication through the isolation tool is allowed in uphole and downhole directions in the unseated position of the occluding device, and blocked in the downhole direction in the seated position of the occluding device.
A method of completing a borehole includes running a downhole assembly having an isolation tool into the borehole, the isolation tool including a tubular body having a seat, and an occluding device supported on the tubular body in an unseated position, firing a perforation gun, and moving the occluding device from the unseated position to a seated position upon the seat only if the perforation gun is fired.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring now to
In one embodiment, the assembly 10 is a bottom hole assembly (“BHA”) for a “plug and perf” operation. The assembly 10 is positioned downhole and the isolation tool 14 is set in the structure 12 by the setting tool 16 for packing off a production zone 22. The isolation tool 14 could be retrievable, drillable, etc., and may be formed from composites, metals, polymers, etc. After a setting operation, the setting tool 16 may then be uncoupled from the isolation tool 14 and the perforation gun 18 positioned within the structure 12 for perforating the zone 22. Multiple perforation guns 18 could be included in the assembly 10 for forming multiple perforated sections in the zone 22 and other production zones.
With additional reference to
The assembly 10 includes the occluding device 24 during run-in and disposed in a pre-seated or unseated position within the isolation tool 14 so that the isolation tool 14 does not require an occluding device, such as a ball, to be subsequently dropped hundreds or thousands of feet from surface, thereby saving substantial time. In the unseated position of the occluding device 24, the isolation tool 14 still allows fluid communication therethrough in both uphole and downhole directions 28, 30. However, in the seated condition, the occluding device 24 seated within the isolation tool 14 will stop fluid communication from further flow in the downhole direction 30 through the isolation tool 14. The isolation tool 14 may serve as a one-way check valve that seals pressure, or at least substantially prevents fluid flow, from above the tool 14 in the downhole direction 30, but allows flow through the tool 14 from a downhole location in the uphole direction 28. In accordance with the above, the isolation tool 14 is shown in
As will be shown in
As further shown in
In a method of operating the isolation tool 14 shown in
Turning now to
In a method of operating the isolation tool 14 shown in
Turning now to
In a method of operating the isolation tool 14 shown in
Turning now to
In a method of operating the isolation tool 14 shown in
The isolation tool 14, or frac plug, is thus allowed to have an open bore, but will self-occlude in response to gun shock or fluid velocity (which can occur after the guns 18 are fired). This eliminates the “ball drop” from surface to occlude the isolation tool as is currently done. Also, this eliminates the use of water and time to get the ball down to the isolation device, resulting in substantial savings for the operator. This also eliminates the need to provide any additional ball drop device. The isolation tool 14 incorporates a self-occluding mechanism to self occlude in response to gun shock or other communication from the gun bottom hole assembly (“BHA”). The occluding device may be a ball 34, poppet 36, sleeve valve, flapper 32, or any other manner of occlusion. The communication could be pressure wave inertia, sound, fluid velocity. The occlusion device 24 remains unseated until sufficient velocity is pumped through the isolation device 14 or a sensor 88 indicates that the guns 18 have fired.
In an embodiment, the isolation tool 14 includes occluding devices 24 and related components at least partially formed of a disintegratable material that would disintegrate or dissolve after, or as a result of, a fracturing operation. In one embodiment, the disintegrateable material is a controlled electrolytic metallic (“CEM”) material. One example of a CEM material is commercially available from Baker Hughes, Inc. under the tradename IN-Tallic®, and is further described in U.S. Pat. Publication No. 2011/0135953 to Xu et al., herein incorporated by reference in its entirety. IN-Tallic® material is a controlled electrolytic metallic (“CEM”) nanostructured material that is lighter than aluminum and stronger than some mild steels, but disintegrates when it is exposed to the appropriate fluid through electrochemical reactions that are controlled by nanoscale coatings within the composite grain structure of the material. The occluding devices 24 made of the disintegratable material maintain shape and strength during the fracturing process and then disintegrate before or shortly after the well is put on production. IN-Tallic® material disintegrates over time by exposure to brine fluids, so that the disintegration occurs with most fracturing and wellbore fluids and no special fluid mixture is required. Disintegration rates depend on temperature and the concentration of the brine. Also, acids disintegrate the occluding devices 24 at a much higher rate. This allows the flexibility to pump acid on the occluding device 24 after the fracture is complete, to speed up the disintegration process if desired.
Other components of the isolation tool 14 may be made from composite materials which hold high pressure differentials, have a short lifespan due to temperature degradation in the borehole, and may be drilled out after use in order to put the well on production.
With further reference to
A selected fluid velocity through the isolation tool 14, or gun shock, will close the isolation tool 14, allowing all, or at least a substantial portion of, frac fluid to enter the perforations in the structure. If guns 18 fail to fire, the BHA 10 can be pulled from the structure 12, and the isolation tool 14 remains un-occluded. A second BHA (including at least new perforation gun 18) is pumped into the borehole at a slow enough rate such that the already-set isolation tool 14 will not close. New guns 18 are fired and the method returns to the procedure involving pumping into the well such that fluid will flow into perforations. The occluding device 24 of the isolation tool 14 will be moved to the seated position upon successful firing of the guns 18, or subsequent fluid velocity after the guns 18 are fired.
Set forth below are some embodiments of the foregoing disclosure:
Embodiment 1: A downhole assembly comprising: an isolation tool disposable downhole of a perforation gun, the isolation tool comprising: a tubular body having a seat; and, an occluding device supported on the tubular body in an unseated position, and movable to a seated position on the seat in response to at least one of a firing operation of the perforation gun and a selected fluid velocity through the isolation tool; wherein fluid communication through the isolation tool is allowed in uphole and downhole directions in the unseated position of the occluding device, and blocked in the downhole direction in the seated position of the occluding device.
Embodiment 2: The downhole assembly of embodiment 1, wherein fluid communication through the isolation tool is allowed in the uphole direction in the seated position of the occluding device.
Embodiment 3: The downhole assembly of embodiment 1, further comprising the perforation gun disposed uphole of the isolation tool, wherein the occluding device is only movable to the seated position after a firing operation of the perforation gun.
Embodiment 4: The downhole assembly of embodiment 3, wherein the isolation tool includes a sensor configured to sense the firing operation of the perforation gun.
Embodiment 5: The downhole assembly of embodiment 4, wherein the sensor includes at least one of an inertial sensor and an acoustic sensor.
Embodiment 6: The downhole assembly of embodiment 4, further comprising a release device configured to restrain the occluding device in the unseated position, wherein the release device is operatively disposed to release the occluding device upon receipt of a signal from the sensor.
Embodiment 7: The downhole assembly of embodiment 1, wherein the occluding device is a flapper member.
Embodiment 8: The downhole assembly of embodiment 1, wherein the occluding device is a poppet.
Embodiment 9: The downhole assembly of embodiment 1, wherein the occluding device is a ball.
Embodiment 10: The downhole assembly of embodiment 1, wherein the isolation tool includes a ported section between the seat and the occluding device in the un-seated position.
Embodiment 11: The downhole assembly of Embodiment 10, wherein the occluding device is connected to the ported section with at least one defeatable member in the un-seated position, the at least one defeatable member is defeated in the seated position of the occluding device.
Embodiment 12: The downhole assembly of embodiment 11, wherein the at least one defeatable member includes a shear pin.
Embodiment 13: The downhole assembly of embodiment 1, wherein the isolation tool further includes a settable member configured to set the isolation tool within an outer downhole structure.
Embodiment 14: The downhole assembly of embodiment 1, wherein movement of the occluding device from the unseated position to the seated position is velocity activated by the selected fluid velocity in a downhole direction through the isolation tool.
Embodiment 15: The downhole assembly of embodiment 1, further comprising a longitudinally movable sleeve disposed within the tubular body, the sleeve including an orifice, wherein a first position of the sleeve supports the occluding device in the unseated position, and fluid flow through the orifice moves the sleeve to a second position and enables movement of the occluding device to the seated position.
Embodiment 16: The downhole assembly of embodiment 1, wherein the occluding device is made of a disintegrateable material.
Embodiment 17: The downhole assembly of embodiment 16, wherein the disintegrateable material is a controlled electrolytic metallic nanostructured material.
Embodiment 18: A method of completing a borehole, the method comprising: running a downhole assembly having an isolation tool into the borehole, the isolation tool including a tubular body having a seat, and an occluding device supported on the tubular body in an unseated position; firing a perforation gun; and, moving the occluding device from the unseated position to a seated position upon the seat only if the perforation gun is fired.
Embodiment 19: The method of embodiment 18, wherein the isolation tool includes a sensor sensing the firing of the perforation gun, and the occluding device is moved to the seated position in response to a signal from the sensor.
Embodiment 20: The method of embodiment 18, further comprising pumping fluid through the borehole after the perforation gun is fired, and using fluid velocity of the fluid pumped through the borehole to move the occluding device from the unseated position to the seated position.
Embodiment 21: The method of embodiment 18, wherein fluid communication through the isolation tool is enabled in uphole and downhole directions in the unseated position of the occluding device, and blocked in the downhole direction in the seated position of the occluding device.
Embodiment 22: The method of embodiment 18, further comprising, in an event where the perforation gun fails to fire, pulling the perforation gun from the well and running a replacement perforation gun in the well, wherein the occluding device in the unseated position enables fluid communication in a downhole direction for redeployment of the replacement perforation gun.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).
The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.
This application claims the benefit of an earlier filing date from U.S. Provisional Application Ser. No. 62/092,421 filed Dec. 16, 2014, the entire disclosure of which is incorporated herein by reference.
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