Patent Grant
11761275
The present disclosure relates to subterranean developments, and more specifically, the disclosure relates to deploying solids within a subterranean well during drilling operations.
During the drilling of subterranean wells, such as subterranean wells used in hydrocarbon development operations, drilling mud and other fluids can be pumped into the well. In certain drilling operations, the wellbore of the subterranean well can pass through a zone that has induced or natural fractures, are cavernous, or otherwise have an increased permeability, which is known as a lost circulation zone. In such a case, the drilling mud and other fluids that are pumped into the well can flow into the lost circulation zone and become irretrievable.
Lost circulation can be encountered during any stage of hydrocarbon development operations. Lost circulation can be identified when drilling fluid that is pumped into the subterranean well returns partially or does not return to the surface. While some fluid loss is expected, excessive fluid loss is not desirable from a safety, an economical, or an environmental point of view. Lost circulation can result in difficulties with well control, borehole instability, pipe sticking, unsuccessful production tests, poor hydrocarbon production after well completion, and formation damage due to plugging of pores and pore throats by mud particles. In extreme cases, lost circulation problems may force abandonment of a well.
When unacceptable drilling fluid losses are encountered, conventional lost circulation materials are deployed with the drilling fluid from the surface. The revised fluid that includes the lost circulation materials is pumped downhole as part of the standard well circulation system. The revised fluid plugs and pressure seals the exposed formation at the point where losses are occurring. Once sealing has occurred and acceptable fluid loss control is established, drilling operations can resume. Conventional methods of delivering the revised fluid into the wellbore include passing the revised fluid through the standard charge pump. In some current systems the standard charge pump cannot accommodate objects within the revised fluid that are large, such as objects larger than 10 mm in diameter. In systems where the size of the objects will allow the objects to pass through the standard charge pump, the objects could still be damaged by the pumping or valve mechanism of the mud pumping system.
Embodiments of this disclosure provide systems and methods for downhole drill string deployment of large lost circulation or other large object, such as an object larger than 10 mm in diameter, that cannot pass through a standard charge pump or mud circulation pump. Such pumps can be, for example, centrifugal or positive displacement pumps. The systems and methods of this disclosure may also be used where objects can pass through the pumping system, but may become damaged by the associated pumping or valve mechanisms.
In an embodiment of this disclosure, a system for delivering objects formed of a solid material into a circulation fluid of a subterranean well includes a drilling assembly having a drill string that extends into the subterranean well. The drill string has a central bore defining an interior portion of a fluid flow path for the circulation fluid. An annulus is located between an outer diameter surface of the drill string and an inner diameter surface of the subterranean well. The annulus defines an annular portion of the fluid flow path for the circulation fluid. A mud tank is in fluid communication with the annuls by way of a mud return line, the mud tank having a storage space for the circulation fluid. A pump assembly is in fluid communication with the mud tank by way of a suction line. The pump assembly is operable to draw fluids from the mud tank through the suction line. A discharge line extends from the pump assembly to a volume transfer container. The volume transfer container has an inlet port, an outlet port, and a charge access opening sized to provide for the filling of the volume transfer container with the objects. A transfer line extends from the volume transfer container to the drilling assembly, providing a fluid flow path from the volume transfer container to the drilling assembly that is free of any pump.
In alternate embodiments, the outlet port of the volume transfer container can be in selective fluid communication with the transfer line. The inlet port can be in selective communication with a pump output. The pump output can be a high pressure pump output of the pump assembly. Alternately, the pump output can be a low pressure pump output of a low pressure pump.
In other alternate embodiments, the volume transfer container can be a tank containing a baffle labyrinth located between the inlet port and the outlet port. Alternately, the volume transfer container can be a tank containing an internal piston assembly with a piston head operable to move in a direction from the inlet port towards the outlet port. Alternately, the volume transfer container can be a pipe assembly containing one or more tubular members secured in line with both the discharge line and the transfer line.
In an alternate embodiment of this disclosure, a method for delivering objects formed of a solid material into a circulation fluid of a subterranean well includes extending a drill string of a drilling assembly into the subterranean well. The drill string has a central bore defining an interior portion of a fluid flow path for the circulation fluid, and defines an annulus located between an outer diameter surface of the drill string and an inner diameter surface of the subterranean well. The annulus defines an annular portion of the fluid flow path for the circulation fluid. The method further includes circulating the circulation fluid into the subterranean well with a circulation system. The circulation system includes a mud tank in fluid communication with the annuls by way of a mud return line. The mud tank has a storage space for the circulation fluid. A pump assembly is in fluid communication with the mud tank by way of a suction line. The pump assembly draws fluids from the mud tank through the suction line. A discharge line extends from the pump assembly to a volume transfer container. The volume transfer container has an inlet port, an outlet port, and a charge access opening sized to provide for the filling of the volume transfer container with the objects. A transfer line extends from the volume transfer container to the drilling assembly, providing a fluid flow path from the volume transfer container to the drilling assembly that is free of any pump.
In alternate embodiments, the method can further include circulating circulation fluid out of the volume transfer container through the outlet port to the transfer line and into the central bore of the drill string. Circulation fluid can be pumped into the volume transfer container from a pump output into the inlet port of the volume transfer container. The pump output can be a high pressure pump output of the pump assembly. Alternately, The pump output can be a low pressure pump output of a low pressure pump.
In other alternate embodiments, the volume transfer container can be a tank containing a baffle labyrinth located between the inlet port and the outlet port, and the method can further includes sweeping the circulation fluid through the baffle labyrinth and out of the outlet port. Alternately, the volume transfer container can be a tank containing an internal piston assembly with a piston head, and the method can further include sweeping the circulation fluid out of the outlet port by moving the piston head in a direction towards the outlet port. Alternately, the volume transfer container can be a pipe assembly containing one or more tubular members secured in line with both the discharge line and the transfer line, and the method can further include sweeping the circulation fluid out of the outlet port of the pipe assembly.
So that the manner in which the features, aspects and advantages of the embodiments of this disclosure, as well as others that will become apparent, are attained and can be understood in detail, a more particular description of the disclosure may be had by reference to the embodiments that are illustrated in the drawings that form a part of this specification. It is to be noted, however, that the appended drawings illustrate only certain embodiments of the disclosure and are not to be considered limiting of the disclosure's scope, for the disclosure may admit to other equally effective embodiments.
The disclosure refers to particular features, including process or method steps. Those of skill in the art understand that the disclosure is not limited to or by the description of embodiments given in the specification. The subject matter of this disclosure is not restricted except only in the spirit of the specification and appended Claims.
Those of skill in the art also understand that the terminology used for describing particular embodiments does not limit the scope or breadth of the embodiments of the disclosure. In interpreting the specification and appended Claims, all terms should be interpreted in the broadest possible manner consistent with the context of each term. All technical and scientific terms used in the specification and appended Claims have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs unless defined otherwise.
As used in the Specification and appended Claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly indicates otherwise.
As used, the words “comprise,” “has,” “includes”, and all other grammatical variations are each intended to have an open, non-limiting meaning that does not exclude additional elements, components or steps. Embodiments of the present disclosure may suitably “comprise”, “consist” or “consist essentially of” the limiting features disclosed, and may be practiced in the absence of a limiting feature not disclosed. For example, it can be recognized by those skilled in the art that certain steps can be combined into a single step.
Where a range of values is provided in the Specification or in the appended Claims, it is understood that the interval encompasses each intervening value between the upper limit and the lower limit as well as the upper limit and the lower limit. The disclosure encompasses and bounds smaller ranges of the interval subject to any specific exclusion provided.
Where reference is made in the specification and appended Claims to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously except where the context excludes that possibility.
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A system for sealing lost circulation zone 22 associated with subterranean well 10 includes a circulating port to provide downhole fluid circulation. The circulating port provides fluid communication between an inner bore of drill string 16 and annulus 26.
Annulus 26 is the elongated annular shaped space that extends a length of drill string 16 and is defined between an outer diameter surface of drill string 16 and an inner diameter surface of wellbore 12 of subterranean well 10. Annulus 26 defines an annular portion of the fluid flow path for the circulation fluid. Drill string 16 has a central bore defining an interior portion of a fluid flow path for the circulation fluid. During downhole fluid circulation, fluids can flow downhole through the inner bore of drill string 16 and uphole through annulus 26. In reverse circulation, fluids can flow downhole through annulus 26 and uphole through the inner bore of drill string 16.
In the example embodiment of
The system for sealing lost circulation zone 22 can be used to seal the entry of cavity 30 of lost circulation zone that has a cross sectional dimension X that is too large to be sealed with some currently available lost circulation material. Cavity 30 can be, for example, vugular or cavernous faults. After bottom hole assembly 20 has reached or passed through lost circulation zone 22, a combination of lost circulation shape 32 and lost circulation material 34 can be used to seal cavities 30 of lost circulation zone 22.
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Mud tank 42 is in fluid communication with annulus 26 by way of return line 44. Return line 44 caries circulation fluid and solids, including objects, to mud tank 42 after the circulation fluid has been circulated through subterranean well 10. Mud tank 42 is sized to provide storage space for the circulation fluid. Mud tank 42 can be associated with a shale shaker, which can be a vibrating screen device for screening cutting and other solids from the circulation fluid. The circulation fluid can drain into mud tank 42 from the shale shaker to be recirculated into subterranean well 10.
Pump assembly 46 is in fluid communication with mud tank 42 by way of suction line 48. Pump assembly 46 can draw circulation fluids from mud tank 42 and provide sufficient pressure for pumping the circulation fluids back into subterranean well 10. Pump assembly 46 is includes a high pressure pump and has a high pressure pump output 64. As an example, the high pressure pump of pump assembly 46 can have a pressure of up to 7,500 pounds per square inch (psi).
Discharge line 50 extends from pump assembly for delivery of circulation fluids to subterranean well 10. Transfer line 52 extends to drilling assembly 36. Discharge line 50 and transfer line 52 can both include, for example, portions of a standpipe 54. Transfer line 52 can further include rotary hose 56.
Volume transfer container 58 is shown schematically in
Discharge line 50 extends from pump assembly 46 to volume transfer container 58. Transfer line 52 extends from volume transfer container 58 to drilling assembly 36. Where discharge line 50 and transfer line 52 both include parts of standpipe 54, then volume transfer container 58 is located along standpipe 54. Transfer line 52 provides a fluid flow path from volume transfer container 58 to drilling assembly 36 that is free of any pump. In alternate embodiments, volume transfer container 58 can be secured in line along mud circulating pipe work upstream of standpipe 54.
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In certain embodiments, such as the embodiment of
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There may be times when the delivery of objects 68 that are formed of solid material are required to be delivered into wellbore 12, such as for example, upon the occurrence of severe or total lost circulation. Looking at
After pump assembly 46 is turned back on, because discharge line 50 and inlet valve 66 are in fluid communication with high pressure pump output 64 of pump assembly 46 (
Because volume transfer container 58 in such an embodiment is subjected to high pressure pump output 64 of pump assembly 46, volume transfer container 58 and associated valves and connections will be pressure rated and protected, such as with pressure relief valves, to the maximum pressure capacity of pump assembly 46.
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There may be times when the delivery of objects 68 are required to be delivered into wellbore 12, such as for example, upon the occurrence of severe or total lost circulation. Looking at
Charge pump 72 can pump circulation fluids into volume transfer container 58 that is free of objects 68 to flush objects 68 out of volume transfer container 58. Objects 68 that were contained within volume transfer container 58 are carried out of volume transfer container 58 through outlet port 62 and into transfer line 52 for delivery into wellbore 12.
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Inlet valve 66 can be operated to control the flow of fluids from discharge line 50 into inlet port 60. Outlet valve 74 can be operated to control the flow of fluids and objects 68 from volume transfer container 58 to intermediate line 76. Both inlet valve 66 and outlet valve 74 can be flow direction valves.
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Intermediate pump 78 can then be used to pump circulation fluid that was previously located within intermediate line 76 into volume transfer container, displacing fluids and objects 68 that were within volume transfer contain so that such fluids and objects flow into intermediate line 76. As can be seen in
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In embodiments of this disclosure, volume transfer container 58 can be a tank. Volume transfer container 58 has a charge access opening sized to provide for the filling of volume transfer container 58 with objects 68. In embodiments where volume transfer container 58 is a tank, the tank can have tank lid 82 that can be used as the charge access opening for filling volume transfer container 58 with liquids and objects 68. Tank lid 82 can be pressure rated and can be removable or hinged.
The tank can alternately have charge port 84. Charge port 84 can be an opening through a sidewall of the tank. Charge port 84 can also be sized so that charge port 84 can used as the charge access opening for filling volume transfer container 58 with objects 68.
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Example embodiments of this disclosure show volume transfer container 58 as a tank or a pipe. In alternate embodiments, volume transfer container 58 can be a feed hoppers or a mobile tanker.
In an example of operation, a method for delivering objects 68 formed of a solid material into a circulation fluid of subterranean well 10 includes extending drill string 16 into wellbore 12. During drilling operations, if there is a severe or total loss of circulation fluids, an operator can determine that it would be beneficial to deliver lost circulation materials into wellbore 12.
Objects 68 can include lost circulation shapes that can be too large to pass through mud pumps. In addition, passing objects 68 through a mud pump would damage the shape of the lost circulation shape, destroying the loss curing properties of the lost circulation shape. Instead of passing objects 68 through mud pumps, objects 68 can be loaded into volume transfer container 58 for delivery into wellbore 12 to plug and pressure seal the formation at the point where losses are occurring.
With fluid and objects 68, such as lost circulation shapes, loaded within volume transfer container 58, inlet valve 66 or outlet valve 74, or both inlet valve 66 and outlet valve 74 as applicable, can be manipulated to provide a fluid flow path from volume transfer container 58 to drilling assembly 36. When traveling from volume transfer container 58 to drilling assembly 36 and into wellbore 12, objects 68 do not pass through a pump.
When a sufficient volume of fluids and objects 68 have been delivered into wellbore 12 to address the lost circulation, inlet valve 66 or outlet valve 74, or both inlet valve 66 and outlet valve 74 as applicable, can be manipulated so that drilling fluids once again circulate into wellbore 12 without mixing with the contents of volume transfer container 58. Volume transfer container 58 can be refilled with fluid and objects and the process can be repeated as needed to address lost circulation concerns as drilling operations continue.
Embodiments of this disclosure provide systems and methods for downhole drill string deployment of large lost circulation or other large object, such as an object larger than 10 mm in diameter, that cannot pass through a standard charge pump or mud circulation pump. Such pumps can be, for example, centrifugal or positive displacement pumps. The systems and methods of this disclosure may also be used where objects can pass through the pumping system, but may become damaged by the associated pumping or valve mechanisms.
Embodiments of this disclosure, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others that are inherent. While embodiments of the disclosure has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present disclosure and the scope of the appended claims.
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