This application is the National Stage of, and therefore claims the benefit of, International Application No. PCT/US2020/020379 filed on Feb. 28, 2020, entitled “DOWNHOLE ZONAL ISOLATION ASSEMBLY,” which was published in English under International Publication Number WO 2021/173155 on Sep. 2, 2021. The above application is commonly assigned with this National Stage application and is incorporated herein by reference in its entirety.
The process of induced hydraulic fracturing involves injecting a fracturing fluid at a high pressure into a fracturing zone of interest. Small fractures are formed, allowing fluids, such as gas and petroleum to migrate into the wellbore for producing to the surface. Often the fracturing fluid is mixed with proppants (e.g., sand) and chemicals in water so that once the pressure is removed, the sand or other particles hold the fractures open. Other fracturing fluids use concentrated acid to dissolve parts of the formation so that once the pressure is removed, dissolved tunnels are formed in the formation. Hydraulic fracturing is a type of well stimulation, whereby the fluid removal is enhanced, and well productivity is increased.
Multi-stage hydraulic fracturing is an advancement to produce fluids along a single wellbore or fracturing string. Multiple stages allow the fracturing fluid to be targeted at individual zones. Zones are typically fractured in a sequence. Previously fractured zones are isolated from the next zones to be fracture.
In a multi-stage fracturing process, previously fractured zones must be isolated from the zones that are going to be stimulated. Traditionally, isolation is performed with a ball that lands either on a ball seat or on a fracturing plug. The ball seats or fracturing plugs are positioned within zones of interest in the wellbore. Hydraulic fracturing can be performed in stages by selectively activating sleeves by the ball landing on a ball seat which also isolates the particular zones of interest from the previously fractured zones. Each target zone can be hydraulically fractured, stage by stage (e.g., toe to heal).
What are needed in the art are improved apparatus, systems, and methods for fracturing multi-stage zones.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms.
Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.
Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally toward the surface of the ground; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis. In some instances, a part near the end of the well can be horizontal or even slightly directed upwards. In such instances, the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be used to represent the toward the surface end of a well. Unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.
The term “proximate,” as used herein with regard to the placement of two features relative to one another, means that the two features are located within about 150 meters (e.g., about 500 feet) of one another. The term “substantially proximate,” as used herein with regard to the placement of two features relative to one another, means that the two features are located within about 30 meters (e.g., about 100 feet) of one another. The term “ideally proximate,” as used herein with regard to the placement of two features relative to one another, means that the two features are located within about 10 meters (e.g., about 30 feet) of one another.
Referring initially to
A subsea conduit 145 extends from the platform 115 to a wellhead installation 150, which may include one or more subsea blow-out preventers 155. A wellbore 160 extends through the various earth strata including formation 110. In the embodiment of
In accordance with one embodiment of the disclosure, the downhole fracturing tool assembly 190 includes a fracturing port cover coupleable to an interior of the wellbore casing 165. The wellbore casing 165, in the example embodiment, would have one or more fracturing ports therein. The downhole fracturing tool assembly 190, in accordance with this embodiment, additionally includes a fracturing port cover actuator coupled to the fracturing port cover, the fracturing port cover actuator operable to move the fracturing port cover between a first position sealing the one or more fracturing ports from an interior of the wellbore casing 165 and a second position exposing the one or more fracturing ports to the interior of the wellbore casing 165. The downhole fracturing tool assembly 190, in accordance with this embodiment, further includes fracturing port cover electronics coupled to the fracturing port cover actuator proximate the fracturing port cover, the fracturing port cover electronics operable (e.g., programmed in one embodiment) to activate the fracturing port cover actuator.
In accordance with one embodiment of the disclosure, the downhole zonal isolation assembly 195 includes a rotating fracturing valve positionable within the wellbore casing 165 proximate one or more fracturing zones of interest 175a, 175b. The downhole zonal isolation assembly 195, in accordance with this embodiment, additionally includes a rotating fracturing valve actuator coupled to the rotating fracturing valve, and rotating fracturing valve electronics coupled to the rotating fracturing valve actuator, the rotating fracturing valve electronics operable (e.g., programmed in one embodiment) to activate the rotating fracturing valve actuator to move the rotating fracturing valve from a first wellbore casing 165 open position to a second wellbore casing 165 closed position.
When it is desired to fracture a particular subterranean zone of interest, such as fracturing zones of interest 175a, 175b, the downhole fracturing tool assembly 190 and downhole zonal isolation assembly 195 may be appropriately actuated, for example opening and closing certain ones of the fracturing port covers, as well as opening and closing certain ones of the rotating fracturing valves. Thereafter, pressure within the wellbore 160 may be increased using the fracturing pump 135 and one or more different types of fracturing fluid and/or proppants, thereby forming fractures 180.
Referring now to
In the embodiment illustrated in
In accordance with one embodiment of the disclosure, the wellbore casing 270, at each of the fracturing zones of interest 295a, 295b, includes one or more fracturing ports 275a, 275b therein. The fracturing ports 275a, 275b, in this embodiment, provide a fluid path through the wellbore casing 270, as might be required to hydraulically fracture each of the fracturing zones of interest 295a, 295b. The number and location of the one or more fracturing ports 275a, 275b may vary greatly, for example based upon the design of the well system 200a.
In accordance with one embodiment of the disclosure, each of the first and second downhole fracturing tool assemblies 210a, 210b includes a fracturing port cover 215a, 215b coupled to an interior of the wellbore casing 270 proximate the one or more fracturing ports 275a, 275b. In accordance with this embodiment, the fracturing port covers 215a, 215b are operable to move between a first position sealing the one or more fracturing ports 275a, 275b from an interior of the wellbore casing 270 (see, for example fracturing port cover 215a) and a second position exposing the one or more fracturing ports 275a, 275b to the interior of the wellbore casing 270 (see, for example fracturing port cover 215b).
In accordance with one embodiment, the fracturing port covers 215a, 215b are sleeves lining at least a portion of the interior of the wellbore casing 270. For example, the sleeves may be sliding sleeves operable to linearly slide along a length of the wellbore casing 270, such as shown in
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The fracturing port cover actuators 220a, 220b may comprise many different designs and remain with the scope of the disclosure. Essentially, any actuator that is capable of moving the fracturing port covers 210a, 210b between the first, second and possibly third positions may be used. In certain embodiments, the fracturing port cover actuators 220a, 220b may be capable of moving the fracturing port covers 210a, 210b back and forth between the first, second and possibly third positions. In one specific embodiment, the fracturing port cover actuators 220a, 220b are electric actuators, such as for example a motor with a ball screw, among others. In another embodiment, the fracturing port cover actuators 220a, 220b are hydraulic or pneumatic actuators, and in yet another embodiment the fracturing port cover actuators 220a, 220b are chemical reaction actuators (e.g., gas generator). In yet another embodiment, an electronic rupture disc and an atmospheric chamber could be used as the fracturing port cover actuators 220a, 220b. Again, while only a few example embodiments of fracturing port cover actuators 220a, 220b have been given, those skilled in the art understand that many other fracturing port cover actuators 220a, 220b are within the scope of the disclosure. The downhole fracturing tool assemblies 210a, 210b illustrated in
In the embodiment of
In yet another embodiment, the fracturing port cover electronics 225a, 225b may be programmed to activate the fracturing port cover actuators 220a, 220b based upon receiving a signal. For example, the fracturing port cover electronics 225a, 225b may be programmed to activate the fracturing port cover actuators 220a, 220b based upon receiving a signal encoded on the wellbore casing 270 or within fluid within the wellbore casing 270. In yet another embodiment, the fracturing port cover electronics 225a, 225b are programmed to activate the fracturing port cover actuators 220a, 220b based upon receiving a signal from a drop ball or drop plug traversing down the wellbore casing 270. In yet other embodiments, combinations of the above may be used. While a handful of different embodiments have been given regarding the fracturing port cover electronics 225a, 225b, and specifically what they activate the fracturing port cover actuators 220a, 220b based upon, unless otherwise required the present disclosure should not be limited to such. The downhole fracturing tool assemblies 210a, 210b illustrated in
In accordance with the disclosure, the power sources 230a, 230b are operable to power the fracturing port cover electronics 225a, 225b. In accordance with one embodiment, the power sources 230a, 230b are downhole battery sources. In one embodiment, the downhole battery source is a primary battery. In a second embodiment, the downhole battery is a secondary battery. In a third embodiment, the downhole battery is a combination of primary and secondary batteries. In this embodiment, the downhole battery sources would have enough power to move the fracturing port covers 210a, 210b between the first, second and optionally third positions at least one time, if not a handful of times or longer. In other embodiments, the downhole battery sources are a first power source, and the downhole fracturing tool assemblies 210a, 210b each include a second power source 235a, 235b. In accordance with this example, the second power sources 235a, 235b could be fluid flow power sources, such as a turbine generator. The second power sources 235a, 235b have the added benefit that they can continue to power the fracturing port cover electronics 225a, 225b, even after the downhole battery sources have been depleted.
In those embodiments wherein the second power sources 235a, 235b are fluid flow power sources, one or more fluid ports 240a, 240b may couple a throat of the fracture proximate the one or more fracturing ports 275a, 275b and the fluid flow power sources. Accordingly, fluid from the fracture may be used to generate power for the fracturing port cover electronics 225a, 225b, among other powered devices. Furthermore, the fracturing port covers 215a, 215b may be operable to redirect fluid to the fluid flow power source via the fluid port 240a, 240b, and thus determine when and how much energy is generated by the second power sources 235a, 235b.
In accordance with one embodiment of the disclosure, the first and second downhole zonal isolation assemblies 250a, 250b include rotating fracturing valves 255a, 255b positionable within the wellbore casing 270 proximate the fracturing zones of interest 295a, 295b. The rotating fracturing valves 255a, 255b, in contrast to many downhole valves that may exist today, are operable to isolate fluid from travelling downhole, as opposed to seal fluid from travelling uphole. Moreover, the rotating fracturing valves 255a, 255b are located proximate a fracturing zone of interest, as opposed to proximate an uppermost portion of the wellbore 280.
The rotating fracturing valves 255a, 255b, in accordance with the disclosure, are operable to move from a first wellbore casing 270 open position (e.g., as shown with the rotating fracturing valve 255a) to a second wellbore casing 270 closed position (e.g., as shown with the rotating fracturing valve 255b). The rotating fracturing valves 255a, 255b may embody many different designs and remain within the scope of the disclosure. In the embodiment illustrated in
In certain embodiments, the rotating fracturing valves 255a, 255b, are operable to move back and forth between the wellbore casing 270 open position and the wellbore casing 270 closed position, for example using a spring or another power source. In other embodiments, the rotating fracturing valves 255a, 255b may only move between the wellbore casing 270 open position and the wellbore casing 270 closed position a single time, or vice versa. In those embodiments wherein the rotating fracturing valves 255a, 255b may not return to the wellbore casing 270 open position, they may comprise a dissolvable material. Alternatively, the rotating fracturing valves 255a, 255b may be physically removed, for example by being drilled out, in those embodiments wherein the rotating fracturing valves 255a, 255b may not return to the wellbore casing 270 open position.
In accordance with one embodiment of the disclosure, the first and second downhole zonal isolation assemblies 250a, 250b include rotating fracturing valve actuators 260a, 260b coupled to the rotating fracturing valves 255a, 255b, respectively. The rotating fracturing valve actuators 260a, 260b may comprise many different designs and remain within the scope of the disclosure. In one embodiment, the rotating fracturing valve actuators 260a, 260b are release mechanisms, that when released allow fluid within the wellbore casing 270 to move the rotating fracturing valves 255a, 255b from the first wellbore casing 270 open position to the second wellbore casing 270 closed position. In another embodiment, a combination of the release mechanism and a spring moves the rotating fracturing valves 255a, 255b from the first wellbore casing 270 open position to the second wellbore casing 270 closed position. In other embodiments, the rotating fracturing valve actuators 260a, 260b are electric actuators, such as for example a motor with a ball screw among others. In another embodiment, the rotating fracturing valve actuators 260a, 260b are hydraulic or pneumatic actuators, and in yet another embodiment the rotating fracturing valve actuators 260a, 260b are chemical reaction actuators (e.g., gas generators), among others.
In the embodiment of
In accordance with the disclosure, the power sources 264a, 264b are operable to power the rotating fracturing valve electronics 262a, 262b. In accordance with one embodiment, the power sources 264a, 264b are downhole battery sources. In this embodiment, the downhole battery sources would have enough power to move the rotating fracturing valves 255a, 255b from the first wellbore casing 270 open position to the second wellbore casing 270 closed position at least a single time. In another embodiment, the rotating fracturing valve electronics 262a, 262b are powered by the second power sources 235a, 235b.
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In the illustrated embodiment shown in
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The second fracturing port cover 215b and second rotating fracturing valve 255b may be moved from their respective first positions to their respective second positions using the second fracturing port actuator 220b and second rotating fracturing valve actuator 260b, respectively. Moreover, the second fracturing port actuator 220b and second rotating fracturing valve actuator 260b may be activated by the fracturing port cover electronics 225b and rotating fracturing valve electronics 262b, respectively, based upon any of the criteria discussed above, among other criteria.
It should be apparent that the second rotating fracturing valve 255b is optional. The well system of
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While not discussed in detail above, the first and second downhole fracturing tool assemblies 210a, 210b may be operated as a flow restrictor, such as an inflow control device (ICD), autonomous inflow control device (AICD), or autonomous inflow control valve (AICV). Accordingly, after fracturing, and during or after production, the first and second downhole fracturing tool assemblies 210a, 210b may be used to control the production from the first and second fracturing zones of interest 295a, 295b. For example, not only can the first and second downhole fracturing tool assemblies 210a, 210b completely close one or both of the first and second fracturing zones of interest 295a, 295b, in certain other embodiments the first and second downhole fracturing tool assemblies 210a, 210b may squeeze the production from one or both of the first and second fracturing zones of interest 295a, 295b. Furthermore, as this process may occur many months if not years after fracturing the first and second fracturing zones of interest 295a, 295b, the second fluid flow power sources 235a, 235b may be used to provide power to the first and second downhole fracturing tool assemblies 210a, 210b.
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Aspects disclosed herein include:
A. A downhole zonal isolation assembly, the downhole zonal isolation assembly including: 1) a rotating fracturing valve positionable within wellbore casing proximate a fracturing zone of interest, 2) a rotating fracturing valve actuator coupled to the rotating fracturing valve; and 3) rotating fracturing valve electronics coupled to the rotating fracturing valve actuator, the rotating fracturing valve electronics operable to activate the rotating fracturing valve actuator to move the rotating fracturing valve from a first wellbore casing open position to a second wellbore casing closed position.
B. A well system, the well system including: 1) a wellbore extending into one or more subterranean formations; 2) wellbore casing located within the wellbore; and 3) a first downhole zonal isolation assembly positioned within the wellbore casing proximate a first fracturing zone of interest, and a second downhole zonal isolation assembly positioned within the wellbore casing proximate a second fracturing zone of interest, each of the first and second downhole zonal isolation assemblies including; a) a rotating fracturing valve positioned within the wellbore casing, b) a rotating fracturing valve actuator coupled to the rotating fracturing valve; and c) rotating fracturing valve electronics coupled to the rotating fracturing valve actuator, the rotating fracturing valve electronics operable to activate the rotating fracturing valve actuator to move the rotating fracturing valve from the first wellbore casing open position to the second wellbore casing closed position.
C. A method for fracturing a well system, the method including: 1) positioning a first downhole zonal isolation assembly within wellbore casing and proximate a first fracturing zone of interest, and a second downhole zonal isolation assembly within the wellbore casing proximate a second fracturing zone of interest, each of the first and second downhole zonal isolation assemblies including; a) a rotating fracturing valve positioned within the wellbore casing, b) a rotating fracturing valve actuator coupled to the rotating fracturing valve; and c) rotating fracturing valve electronics coupled to the rotating fracturing valve actuator, the rotating fracturing valve electronics operable to activate the rotating fracturing valve actuator to move the rotating fracturing valve from the first wellbore casing open position to the second wellbore casing closed position; and 2) moving the rotating fracturing valve of the second downhole zonal isolation assembly from its first wellbore casing open position to the second wellbore casing closed position while the rotating fracturing valve of the first downhole zonal isolation assembly remains within its first wellbore casing open position.
Aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: wherein the rotating fracturing valve is a rotating flapper valve. Element 2: wherein the rotating fracturing valve is a rotating ball valve. Element 3: wherein the rotating fracturing valve actuator is a release mechanism, and further wherein fluid within the wellbore casing is operable to move the rotating fracturing valve from the first wellbore casing open position to the second wellbore casing closed position. Element 4: wherein the rotating fracturing valve electronics are operable to activate the rotating fracturing valve actuator based upon changes in at least one of time, temperature, pressure or flow. Element 5: wherein the rotating fracturing valve electronics are operable to activate the rotating fracturing valve actuator based upon a signal encoded on the wellbore casing or within fluid within the wellbore casing. Element 6: wherein the rotating fracturing valve electronics are operable to activate the rotating fracturing valve actuator based upon a signal received from a drop ball or drop plug traversing down the wellbore casing. Element 7: wherein at least a portion of the rotating fracturing valve is dissolvable. Element 8: wherein the rotating fracturing valve is a rotating flapper valve. Element 9: wherein the rotating fracturing valve is a rotating ball valve. Element 10: wherein the rotating fracturing valve actuator is a release mechanism, and further wherein fluid within the wellbore casing is operable to move the rotating fracturing valve from the first wellbore casing open position to the second wellbore casing closed position. Element 11: wherein the rotating fracturing valve electronics are operable to activate the rotating fracturing valve actuator based upon changes in at least one of time, temperature, pressure or flow. Element 12: wherein the rotating fracturing valve electronics are operable to activate the rotating fracturing valve actuator based upon a signal encoded on the wellbore casing or within fluid within the wellbore casing. Element 13: wherein the rotating fracturing valve electronics are operable to activate the rotating fracturing valve actuator based upon a signal received from a drop ball or drop plug traversing down the wellbore casing. Element 14: wherein at least a portion of the rotating fracturing valve is dissolvable. Element 15: further including a first downhole fracturing tool assembly positioned uphole of the first downhole zonal isolation assembly and proximate the first fracturing zone of interest, and a second downhole fracturing tool assembly positioned between the first and second zonal isolation assemblies and proximate the second fracturing zone of interest, wherein each of the first and second downhole fracturing tool assemblies include: a fracturing port cover coupleable to an interior of a wellbore casing having one or more fracturing ports therein; a fracturing port cover actuator coupled to the fracturing port cover, the fracturing port cover actuator operable to move the fracturing port cover between a first position sealing the one or more fracturing ports from an interior of the wellbore casing and a second position fully exposing the one or more fracturing ports to the interior of the wellbore casing; and fracturing port cover electronics coupled to the fracturing port cover actuator proximate the fracturing port cover, the fracturing port cover electronics operable to activate the fracturing port cover actuator. Element 16: wherein the second downhole zonal isolation assembly is located downhole of the first downhole zonal isolation assembly, and further including a first downhole fracturing tool assembly positioned uphole of the first downhole zonal isolation assembly and proximate the first fracturing zone of interest, and a second downhole fracturing tool assembly positioned between the first and second zonal isolation assemblies and proximate the second fracturing zone of interest, wherein each of the first and second downhole fracturing tool assemblies include: a fracturing port cover coupleable to an interior of a wellbore casing having one or more fracturing ports therein; a fracturing port cover actuator coupled to the fracturing port cover, the fracturing port cover actuator operable to move the fracturing port cover between a first position sealing the one or more fracturing ports from an interior of the wellbore casing and a second position fully exposing the one or more fracturing ports to the interior of the wellbore casing; and fracturing port cover electronics coupled to the fracturing port cover actuator proximate the fracturing port cover, the fracturing port cover electronics operable to activate the fracturing port cover actuator. Element 17: further including moving the fracturing port cover of the first downhole fracturing tool assembly to its first position sealing its one or more fracturing ports, moving the fracturing port cover of the second downhole fracturing tool assembly to its second position fully exposing its one or more fracturing ports, and then fracturing the second fracturing zone of interest after moving the rotating fracturing valve of the second downhole zonal isolation assembly from its first wellbore casing open position to the second wellbore casing closed position.
Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.
Filing Document | Filing Date | Country | Kind |
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PCT/US2020/020379 | 2/28/2020 | WO |
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WO2021/173155 | 9/2/2021 | WO | A |
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