Patent Application
20200232295
The present invention relates to methods and apparatus for well abandonment and in particular, though not exclusively, to an apparatus and method for removing a portion of a tubular across a longitudinal section of the well to enable the placement of a cement plug.
When a well has reached the end of its commercial life, the well is abandoned according to strict regulations in order to prevent fluids escaping from the well on a permanent basis. In meeting the regulations it has become good practise to create the cement plug over a predetermined length of the well. As a well is constructed by locating conduits such as casing, lining, pipe and tubing (herein collectively referred to as tubulars) into the well, the cement plug must extend over all annuli present in the well. In many cases all conduits are removed leaving the outer casing, including the annulus bounded by the formation.
The integrity of the casing and in particular, the cement in an annulus will determine if a cement plug can just be located in the tubular. Steel casing can leak at the connections or corrode from acids. Cement can deteriorate with time too, but leaks also happen when cement shrinks, develops cracks or channels, or is lost into the surrounding rock when applied. If integrity fails, gases and liquids can leak out of the casing or, just as importantly, move into, up, and out of the well through faulty cement between the casing and the rock wall. These issues affect the ability to plug a well for abandonment but also for ensuring zonal isolation in unconventional reservoirs. Cement bond logging (CBL) can be used to log the quality of the cement bond but if the CBL shows the bond to be poor intervention is required with access needed to the outermost tubular.
One method of creating or repairing the cement plug is to mill away the inner tubular to expose the annulus behind the tubular and then pump cement into the enlarged area to create the cement plug. This is achieved using a rotatable section mill run on a work string and typically operated downwardly to remove the tubular section. In milling downwardly, the weight of the work string is used to apply downward force to the section mill to cause it to progress through the tubular being milled. This application of force to the mill by weight applied from above creates a wobble in the milling work string, which has a tendency to fracture the cutting inserts on the section mill blades. This, in turn, causes the mill to wear out sooner, resulting in the removal of less tubular footage before replacement of the mill is required. Further, since milling progresses downwardly, cuttings must be removed from the well bore as they are formed, to avoid forming a ball of cuttings around the mill and reducing its effectiveness. Specialized formulation of milling fluid, and maintenance of proper fluid flow rates, are required in order to circulate the cuttings out of the hole.
To overcome these disadvantages an alternative method has been developed which perforates the tubular and pumps cement through the perforations to travel up the annulus and thereby create a plug within the annulus. This ‘perf and plug’ arrangement, sometimes referred to as cement squeeze, has disadvantages in that by forcing the cement through narrow apertures there is no guarantee that the cement fully contacts the surrounding formation as the cement may not reach all areas in the annulus. As a result, the cement plug may be compromised and rendered at least partially ineffective. This method does provide a major advantage in that it can be performed from a floating vessel to offer what is referred to as a ‘rigless’ method of abandonment. By removing the requirement for a drilling rig, significant time and therefore costs can be made in the well abandonment procedure. In a rigless method the work string is anchored to the tubular and as such sea swell will place tension and/or weight on the work string. Even with the use of heave compensators, this variable load means that a section mill, reliant on using controlled weight to operate, cannot be used.
U.S. Pat. No. 6,679,328 discloses a method and apparatus for milling a section of casing in an upward direction, utilizing a downhole hydraulic thrusting mechanism for pulling a section mill upwardly. A downhole motor and torque anchor can be used to rotate the section mill, or the mill can be rotated by a work string. A stabilizer above the section mill can be used to stabilize the mill relative to the casing being milled. A spiral auger below the section mill can be used to move the cuttings downwardly.
In U.S. Pat. No. 6,679,328 the method of operation first sets the anti-torque anchor against the innermost casing as the milling fluid pressure is increased, which also starts the mud motor running and exerts an upward force on the section mill with the up-thruster. Fluid pressure extends the arms and blades of the mill, and the mill is rotated by the downhole motor. The section mill can be set to extend its arms at a relatively low pressure, so that the arms will extend before the up-thruster begins to lift the arms into cutting contact with the casing. Additionally, the motor can be designed to bypass fluid before it begins to rotate. The cutter arms extend, then the torque anchor blades contact the casing wall, then the mud motor begins to rotate, and finally, the up-thruster begins to lift the section mill. On the first cut, the casing is cut through, and then a portion of the 7″ casing is milled out, until the up-thruster reaches its full travel, or “bottoms out”. This opens piston valves, and a pressure drop will be noted in the milling fluid at this time. Then, the milling fluid pressure is reduced, to stop rotation of the mud motor, release the anti-torque tool, retract the mill arms, and allow the up-thruster to extend to its original length. The work string is then lifted to raise the section mill until its arms are positioned next to the milled lower end of the casing, at the top of the milled window. Pressure is then increased to extend the mill arms, reset the anti-torque anchor, rotate the mud motor, apply upward pressure to the mill, and resume milling. This process is then repeated as required. In this way, a window of desired length, for example, 250 feet, is cut out of the casing. The advantages of this arrangement are in the reduced wear to the blades due to constant tension applied and automatic removal of cuttings as they fall into the well.
A disadvantage of this method is that the mill arms are retracted every time the upthruster needs to be extended to its original length. The stopping and starting of milling produces the most wear on the mill and thus in this disclosure the apparatus must still be removed from the well regularly to replace the cutting blades. A further disadvantage is that the upthruster extends to its original length before the work string is lifted to raise the section mill. In this way the section mill must be re positioned at the bottom of the cut section of casing. The distance that the section mill requires to be raised is determined at surface which is difficult to judge. This is particularly difficult when the well is a horizontal well and the work string may be lying on the low side. In these circumstances raising the work string may only vertically lift the section mill across the diameter of the borehole rather than pull the string through the casing and thus raising the work string at surface will not reposition the section mill further up the wellbore at the bottom of the casing.
It is therefore an object of the present invention to provide a method of removing a section of well tubing which obviates or mitigates at least some of the disadvantages of the prior art.
It is a further object of the present invention to provide apparatus for removing a section of well tubing which obviates or mitigates at least some of the disadvantages of the prior art.
According to a first aspect of the present invention there is provided a method for removing a section of well tubing comprising the steps:
In this way, a substantially or near constant load is applied to the section mill and there is no requirement to reposition the section mill on each stroke of the hydraulic tensioning device. This makes the invention available for use in a rigless method.
Preferably, step (f) is performed before the hydraulic tensioning device bottoms out. When the hydraulic tensioning device ‘bottoms out’ which occurs when the portion of the device being raised towards the work string completes a stroke and can move no further, the load applied to the section mill is unpredictable. Thus in the present invention the work string is raised to extend the hydraulic tensioning device before this occurs. In this way, the mill is operated in a near continuous operation which saves wear on the cutter blades.
Preferably the method includes cycling through steps (e) to (f) repeatedly until a desired length of tubing has been removed.
As the wear on the cutter blades is reduced desired lengths of tubing such as 100-200 feet can be removed in a single trip.
Preferably, the method includes performing steps (e) and (f) together so that the work string is raised gradually to keep the device in a mid-stroke position so that a constant load is applied to the mill and continuous milling is achieved over a desired length of tubing.
Preferably a first signal is provided when the hydraulic tensioning device is near the end of its stroke before bottoming out so that the work string can be raised. In this way, a user is notified at surface to raise the work string before bottoming out occurs so as to maintain a constant tension on the section mill. The first signal may be a pressure change in the fluid at surface.
Preferably a second signal is provided when the hydraulic tensioning device is fully extended. In this way, a user is notified that they have raised the work string by a sufficient distance and excess load is not placed on the section mill. The second signal may be a pressure change in the fluid at surface.
Advantageously, the work string is lowered from a floating vessel. In this way, a section of tubing can be removed in a rigless arrangement.
Preferably the method includes the step of rotating the work string to rotate the section mill. Alternatively the method may include the step of actuating a downhole motor to rotate the section mill.
The method may include the step of cutting through the tubing prior to milling the tubing. In this way the tubing can be cut and milled on a single trip. Advantageously, the cut can be made by the cutter blades which are also used to mill the tubing.
The method may include the step of disposing of cuttings downhole. In this way, cuttings do not have to be circulated to surface and disposed of.
The method may include the step of inserting a seal in the well tubing at a location below the section of well tubing to be removed. The seal may be a bridge plug, a cement plug or a packer. The method may include the further step of conducting a cement bond log (CBL) over the length of well in which the section of well tubing has been removed. This would allow a test on cement bond integrity behind an outer tubular in the well. The method may further include cementing over the length of well in which the section of well tubing has been removed.
According to a second aspect of the present invention there is provided apparatus for removing a section of well tubing comprising:
a work string;
a hydraulic tensioning device having an upper end and a lower end, the upper end being attachable to the work string, the hydraulic tensioning device being adapted to stroke and selectively pull the lower end upwardly towards the work string;
a section mill attachable to a lower end of the hydraulic tensioning device, the section mill including a plurality of blades, the blades being arranged to move from a first position within the section mill to a second position being extended to contact the well tubing and thereby mill the tubing in an upward direction;
characterised in that:
the hydraulic tensioning device includes at least one indicator, the at least one indicator providing a first signal and a second signal when the hydraulic tensioning device is towards each end of its stroke, respectively.
In this way, the user at surface knows when the hydraulic tensioning device is fully extended and can stop raising the work string and is notified as the stroke is ending and can raise the work string to prevent the device bottoming out. Thus by raising the work string gradually, ideally the user keeps the device in a mid stroke position so that a constant tension is applied to the mill without obtaining either signal.
Preferably the work string has a through bore for the passage of fluid from surface to extend the cutter blades and stroke the hydraulic tensioning device upwards. In this way, the apparatus can be operated from surface. More preferably, the indicator comprises a variable fluid flow restrictor. In this way, variations in the pressure of fluid can be used as the first and second signals. Alternatively, the indicator may comprise an electronic switch which detects the position of relative parts of the hydraulic tensioning device. In this way, an electronic signal can be generated for the first and second signal. Those skilled in the art will appreciate that such electronic signals can be transmitted to surface using telemetry.
The apparatus may include a downhole motor. In this way, the section mill can be rotated downhole instead of via rotation of the work string. The work string may be threaded pipe, being right or left-handed. Alternatively the work string may be coiled tubing. In this way, the section mill can be arranged to be left-hand turned so as to prevent to unthreading of sections of the pipe being milled. The apparatus may include an anchor to prevent rotation of the work string. In this way, the work string above the motor is prevented from winding. The anchor may be an anti-torque anchor which includes friction elements to prevent undesired rotation of the work string.
A spiral auger may be located below the section mill to assist in moving cutting downhole. In this way, cuttings do not have to be circulated to surface and disposed of.
In the description that follows, the drawings are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form, and some details of conventional elements may not be shown in the interest of clarity and conciseness. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce the desired results.
Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as “including,” “comprising,” “having,” “containing,” or “involving,” and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term “comprising” is considered synonymous with the terms “including” or “containing” for applicable legal purposes.
All numerical values in this disclosure are understood as being modified by “about”. All singular forms of elements, or any other components described herein including (without limitations) components of the apparatus are understood to include plural forms thereof.
Additionally the terms “above”, “below”, “upper” and “lower” are relative and take their standard meaning when considering a standard vertical will with “lower” being upstream and “upper” being downstream in the well.
There will now be described, by way of example only, various embodiments of the invention with reference to the drawings, of which:
Referring initially to
Like the arrangement of U.S. Pat. No. 6,679,328, incorporated herein by reference, the section mill 12 is designed for upward milling, in combination with an up-thruster tool, the hydraulic tensioning device 14, an anti-torque anchoring tool 16, and a downhole motor 18, which are mounted to a work string 20. In the present invention, the work string 20 is coiled tubing. The apparatus 10 is tripped into the hole to position the section mill 12 at the lower end of the interval where a section 22 or window is to be cut. For clarity,
The hydraulic tensioning device 14 may be considered as a load control sub or a pressure balanced weight transfer sub. The purpose of the hydraulic tensioning device 14 is to supply a constant upward load on the section mill 12. When operated from a floating vessel 25 in a rigless arrangement, upward milling would be impossible unless the constant load can be maintained on the mill as an operator would be unable to raise the work string to provide a constant load in the presence of heave from the floating vessel 25.
Referring now to
Inner mandrel 34 is part of a top sub 40 which includes a standard box section 42 for attachment of the hydraulic tensioning device 14 to the work string 20. The inner mandrel 34 contains the ports 44 through the body of the mandrel 34 to access a chamber 46 between the mandrels 32,34. The inner mandrel 34 has the nozzle 38 located within the central bore 36 attached at a lower end 48. The box section 42 at the upper end 50 of the top sub 40 has a first diameter with the inner mandrel 34 having a smaller diameter than the first diameter.
Arranged over the inner mandrel 34 is the outer mandrel 32. At an upper end 52 of the outer mandrel 32 there is a locking sub 54. This provides sliding seals 56 between the mandrels 32,34 and a wall 58 of the chamber 46. The chamber 46 is otherwise formed by inner wall 60 of the outer mandrel 32, the outer wall 62 of the inner mandrel 34 and a wall 64 of a piston 66 fixed to the wall 62 of the inner mandrel 34. The ports 44 are arranged to access the chamber 46 beside the wall 64 of the piston 66. The distance between the piston 66 and the box section 42 determines the stroke length for the hydraulic tensioning device. This distance may be set to one to two metres. However it may be set to shorter lengths if desired.
At a lower end 68 of the outer mandrel 32 there is a bottom sub 70 including a standard pin connection 72 for attachment to another tool such as the section mill 12. The outer diameter of the outer mandrel 32 and pin section 72 matches the outer diameter of the box section 42 of the top sub 40 to ensure there are no parts to catch in the well bore. Mounted on the upper end 74 of the bottom sub 70 is a prong 76. Prong 76 forms the indicator, generally indicated by reference numeral 30, used to provide the first and second signals to indicate the position of the outer mandrel 32 relative to the inner mandrel 34 in relation to the stroke distance. The prong 76 lies on the central axis of the bore 36 within the outer mandrel 32 and is sized to locate within and slide through the nozzle 38. Through ports 78 are arranged through the bottom sub 70 to provide a fluid pathway through the central bore 36 around the prong 76.
The inner wall 60 of the outer mandrel 32 and the outer wall 62 of the inner mandrel 34 will have splined sections, typically around the nozzle 38, so that rotation of the top sub 40 via the work string 20 and, if present a downhole motor 18, is transmitted through the entire hydraulic tensioning device 14 to the section mill 12 located on the bottom sub 70.
Returning now to
The section mill 12 may be as shown in U.S. Pat. No. 6,679,328 having a plurality of arms each pivoted around a point, mounted in longitudinal slots, which are held in the open position by an upward moving wedge block moved by a piston to support the arms and prevent them from collapsing under heavy loading. Actuation of the section mill 12 is achieved by pumping fluid through the work string 20 which acts on the piston. Release of hydraulic pressure will allow the arms to retract back into the body of the mill 12. The section mill arm can be fitted with a casing cutter type blade for penetration of the tubing, or the arm can be fitted with the square type blades typically found on a pilot mill, to provide for milling an extended length of tubing. In this embodiment, the section mill 12 can first be operated to penetrate the tubing with the casing cutter type blade, then the arms can be exchanged for arms having the pilot mill type blades, for the remainder of the procedure.
An alternative section mill 12 is described in Applicants co-pending patent application GB1713525.2, incorporated herein by reference. This section mill 12 includes elongate blades 80 which have a cutting structure extending along at least a portion of a length from a first edge and at least a portion of a width from a second edge of the elongate cutter blade, the second edge being longer than the first edge, the first and second edges being perpendicular to each other. The blades are moved axially and radially relative to the tubular body to arrange the second edge parallel to the central longitudinal axis for milling. As the blades are moved out the apex, where the first edge meets the second edge, acts as a cutter and will cut the tubing thereby opening up a window in the tubing as the blades are extended. Consequently this means that the initial cutting and subsequent milling of the tubing does not require a change of blades and the elongate blades allow an entire section of tubing in excess of 200 feet to be removed on a single trip in the well. This section mill can also be operated by fluid pressure acting on a piston and is thus operable from surface.
Also shown in
In use, the apparatus 10 is run into the inner tubular 24, in the arrangement shown in
Pumping fluid through the central bore 36 will also operate the hydraulic tensioning device 14. A back pressure will occur as fluid is pumped through the nozzle 38. This will result in fluid entering the ports 44 to fill the chamber 46. As the piston 66 is fixed in position on the inner mandrel 34 which in turn is fixed to the work string, the chamber 46 will expand by fluid pressure against the wall 58 of the locking sub 54. The locking sub 54 will therefore be forced upwards relative to the inner mandrel 34, taking the outer mandrel 32 with it. As the section mill 12 is connected to the outer mandrel 32 via the bottom sub 70, it will be raised relative to the work string 20 at a rate equal to the rate fluid enters the chamber 46. If the pump rate of fluid at surface through the central bore 36 is held constant then a constant load is applied to the section mill 12. This provides for even milling of the tubular 24 in the upward direction. It will be realised that a truly constant load cannot be achieved due to friction in the system and we may therefore consider the load to be substantially or near constant.
The work string 20 can be raised during filling of the chamber 46. This will have the effect of moving the piston 66 upwards and keep the chamber 46 from entirely filling. If the rate of raising the work string 20 is balanced against the pump rate of fluid filling the chamber 46 then a constant load or tension is applied to the section mill 12 and any length of section 22 can be milled continuously. However, it will be apparent that keeping this balance will be difficult.
If the outer mandrel 32 is raised faster than the work string 20, then the locking sub 54 risks hitting the box section 42 of the top sub 40. This will mean that the hydraulic tensioning device 14 has fully stroked and ‘bottoming out’ has occurred. At this point the load on the section mill 12 is unpredictable as it is entirely dependent on the load on the work string 20. When operated from a floating vessel 25 this would be undesirable as chattering could occur between the blades 80 and the tubular 24 causing potential damage to the section mill 12. In the present invention, a user is warned that the device 14 is near the end of the stroke so remedial action can be taken before bottoming out occurs.
Referring now to
It is noted that milling of the tubular 24 is continued throughout this operation. In this way, the blades 80 are never stopped and thus overwear of the blades is prevented. This position of approaching the end of the stroke is illustrated in
When the string 20 is raised at a faster rate than the rate of fill of the chamber 46, the chamber 46 will reduce in volume as the piston 66 is brought up to meet the wall 58 of the locking sub 54. As this occurs the device 14 is stroked outwardly into its extended position again,
The pressure (from the nozzle 38) and the size of the piston 66 are chosen along with an appropriate flow rate to give the correct force on the mill to get efficient rate of cutting but without damaging the cutting structure or else creating too much cuttings which could block the hole and cause the mill to get stuck in the ground.
Thus the process can be performed as:
In an embodiment, the string 20 is raised at the same time as the device 14 is stroked. In this way you can balance the operation and attempt to keep the device 14 in mid-stoke so that neither the first 84 or second 86 signal is detected. This is as illustrated in
While the indicator 30 provides first 84 and second 86 signals in the form of a pressure drop recordable at surface, it will be appreciated that the parts could be arranged to provide a pressure increase at surface instead or one of each depending on which end of the stroke you are at. Additionally while a prong used to form restrictions in the central bore is used to provide the indicator 30, electronic switches could be used which would provide a signal to be relayed by known telemetry techniques to surface.
The apparatus 10 and method find particular use in a rigless method for well abandonment as described in WO 2016/156862 to the present applications. The steps in this well abandonment procedure are illustrated in
An alternative approach which can be used in a rigless arrangement i.e. from a floating vessel which does not require the expense of a rig, is described in WO 2016/156862. In
If desired the procedure can include the steps of spotting sand 110 on top of the cement plug 108 acting as the primary barrier. The production tubing 24 can be cut together with the control lines so as to free the completion below the uppermost hanger 96a. This is illustrated in
The principal advantage of the present invention is that it provides a method for removing a section of well tubing in rigless arrangement were milling is near continuous.
A further advantage of an embodiment of the present invention is that it provides a method for removing a section of well tubing on a single trip in a well.
A still further advantage of an embodiment of the present invention is that it provides apparatus that indicates when a hydraulic tensioning device is towards an end of a stroke so that adjustments can be made to maintain a constant load on a continuously rotating section mill.
The foregoing description of the invention has been presented for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. The described embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilise the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Therefore, further modifications or improvements may be incorporated without departing from the scope of the invention herein intended. For example, while the section mill is described for upward movement to mill the tubular, the section mill could be adapted to operate in a downward fashion also.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1716096.1 | Oct 2017 | GB | national |
| 1811289.6 | Jul 2018 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB2018/052767 | 9/28/2018 | WO | 00 |
