This specification relates to a completion device and method for wellbores, and in particular, to a device and method for installing completion tools in a wellbore.
Oil well completion is the process of making a well ready for production in an oil-bearing reservoir/formation. Completion includes drilling a wellbore in the formation, preparing the bottom of the wellbore, running in a liner, cementing a casing in the wellbore around the liner, and stimulating (“fracking”) the formation.
Stimulation processes (including a fracking treatment, or a “frack”) have the function of creating an effective flow path between the reservoir and the wellbore to increase the flow of hydrocarbons through the formation.
One method to complete an oil well is called “plug-and-perf”. In this method, a liner is placed into the wellbore, and the annular space between the liner and wellbore, may be cemented through most of the length of the wellbore. The wellbore is segmented into zones that are each defined by running a fracking plug into the liner and locating the plug at a part of the wellbore corresponding to a target zone. Once a fracking plug is located in its zone, it is set with a plug setting tool, which locks the plug into the liner at a selected place in the wellbore. A perforating tool (gun) is also pumped into the wellbore and is located in the same zone as the plug. Generally, the perforation gun is run into the liner towards a target zone attached to a wireline (e.g. an E-line), which enables the use of electrical signals originating from the surface to trigger the discharge of the perforation gun. The wireline also allows two-way transmission of data, thus enabling the transmission to surface of information regarding wellbore conditions such as pressure, temperature and seismic responses. Wireline also enables the use of electrical signals to locate the plug in the correct position, to set the plug and release it, and to move the guns into the correct position before firing them.
When the plug is set, a seal is created that fluidically isolates the parts of the liner that are uphole from the plug from the parts of the liner that are downhole from the plug. After the plug is set, the gun is fired to create holes and cracks in the wall of the liner and the cemented casing at that zone, and into the formation around the wellbore. In some cases, the plug and gun (perforation tool) are deployed at the same time; the plug and gun are pumped down to the target zone from surface attached together until they reach the target zone, at which time the plug is set, and then the gun is fired. Each resulting perforation will extend from the inner bore through the liner and cement casing, and deep into the surrounding formation at that zone, creating openings between the inner bore of the wellbore and the formation. The perforation gun might then be moved uphole within the target zone in which the plug has been set, and fired again to create additional perforations at the target zone, until all the charges on the perforation gun are utilized at that target zone. The perforation gun and plug setting tool are then pulled out from the wellbore.
Fracking then occurs at the target zone by pumping fracturing (frack) fluid from the surface. The frack fluid is injected into the wellbore under pressure and passes through the created perforations in the liner and casing, and into the formation. The frack fluid flows into the perforations since the set plug prevents fluid from moving downhole of the target zone.
Fracturing fluids usually contain water, surfactants, friction reducers, proppant (sand) and other additives designed to maintain fractures (“fracks”) in the formation, which improves the flow of hydrocarbons trapped in the formation, through the fracks, and into the wellbore.
After fracking of the target zone, another plug is sent downhole on a plug setting tool and is placed in the next zone uphole from the previous target zone. The foregoing process is then repeated, until all the zones of the well have been fracked.
Since there may be well over 50 zones in a wellbore, this process can be repeated more than 50 times for each wellbore, and therefore is typically time consuming, including the steps in which plugs need to be placed and set. In addition to being time consuming, repeating the process so many times for each wellbore can be very costly, since each fracking plug needs to be removed from its respective target zone after the zone has been fracked, and the removal of each plug is also a costly operation. A plug can be removed by milling it out, which involves running a mill attached to a motor into the wellbore on coiled tubing, milling out the plug, and then using the coiled tubing to pull the mill back up to surface for future reuse.
In some more recent plug-and-perf completion operations, shaped profiles are placed at pre-selected locations in the interior of the liner, which are used to place the plugs. The plugs securely engage with the profiles by, for example, latching into the profiles. For perforating a zone, a perforation assembly including a perforation gun, a plug setting tool and a fracking plug comprising a latch, is lowered into the liner towards a target zone, using a wireline. The latch has a physical feature that is designed to correspond to the shaped profile of the target zone. The plug setting tool actuates the latch to engage with the profile of the liner at the respective target zone. Each profile in the liner thus acts as a marker that enables the setting of a perforation gun at a target zone corresponding to that profile. In this type of operation, one must mill out the plug after use.
U.S. Pat. No. 9,145,744 (Jordan) describes a completion solution that attempts to avoid milling of the plugs after fracking is completed. This patent describes using plugs that are fixed in the casing using dogs. A fracking assembly (the perforation gun, the setting tool, and the fracking plug) is then raised causing the dogs in the fracking plugs to release and allowing the entire assembly to be raised. An alternative solution described in this patent requires the operator to run back into the casing assembly with a retrieving tool to lock into the upper end of the fracking plug, which is then dragged up, forcing release of the dogs and thus enabling free movement of the plug towards surface. However, removal of the plug using force may cause damage since plugs are designed to withstand great forces applied to their uphole side (i.e., the side of the plug closest to the surface) in order to achieve their function of setting a fluid seal between the zone of interest and all parts of the wellbore downhole from that zone. High costs are incurred if the plugs need to be milled because they cannot be easily retrieved.
There is a need in the art for a more retrievable plug in completion operations that involve the setting of plugs and firing of perforation guns.
The perforation-gun completion device described in this specification (latch-and-pea device) is designed to minimize the above-mentioned drawbacks of prior art plug-and-pea devices. The device includes a latch for securely engaging with the liner and a seat attached to the latch for hosting a ball. The liner into which these latch-and-perf devices are lowered has identical profiles designed to engage with the devices throughout the liner, regardless of the zone. This means that the latch-and-perf devices to be deployed into a given liner can all be identical, regardless of the zone to which a given latch-and-pea device is assigned. The latch-and-pea device is secured to the liner using the latch. The latch by itself is not a seal that isolates the uphole part of the liner from the downhole part of the liner, Instead, the latch-and-pea device described in this specification uses a ball as a seal, in place of the plug of prior art systems. Once the latch is set into engagement with the liner in its target zone, a ball landed on the seat of the latch creates a seal in the liner. Fracking may occur when the seal is in place.
In one embodiment, the ball is designed to dissolve after fracking is completed. In another embodiment, the seat against which the ball seals, is designed to dissolve after fracking. In this other embodiment, the ball can be pumped downhole and away from the rest of the latching seal after the seat dissolves. Whether the ball dissolves, or the seat dissolves and the ball moves downhole, the disappearance of the ball and/or seat, allows ready access from surface to the downhole side of the latch, without any milling or otherwise removing the seal, as in previous embodiments. Specifically, the downhole side of the set latch is easily accessible from the surface, after dissolution of the ball and/or seat, through the space previously occupied by the ball and/or seat. By providing easy access to a set latch at its downhole end, the latch can be more easily retrieved without damaging the latch-and-pea device.
According to one embodiment described in this specification, a latch and pea assembly for completion of a wellbore is provided, comprising: a setting tool comprising an explosive charge and a wireline connector; a run-in tool installed on the setting tool; a latch installed on the run-in tool and adapted to assume a retracted state during run-in of the assembly and an expanded state when the latch arrives at a predetermined depth in the wellbore; and a seal adapted to seal against hydraulic pressure applied from surface to enable fracking of the wellbore, the assembly being adapted to be run into the wellbore attached to a wireline, and at least a predetermined part of the seat being adapted to dissolve after fracking of the wellbore.
This specification also describes a fracturing plug for completion of a wellbore, comprising: a latch adapted to assume a retracted state during run-in of the fracturing plug in the wellbore and an expanded state when the fracturing plug arrives at a predetermined depth in the wellbore; a seat confined inside the latch when the latch is in the retracted state, and adapted to seal the wellbore under hydraulic pressure, when the plug is in the expanded state, wherein the latch has an internal profile adapted to keep the seat inside the latch.
According to a further aspect, this specification is directed to a plug-and-pea method of stimulating production of hydrocarbons from a wellbore having a casing, comprising: running in a latch and pea assembly attached to a wireline, the assembly including a setting tool, a run-in tool installed on the setting tool, and a fracturing plug with a dissolvable seat attached to the run-in tool, with the fracturing plug in a retracted state; at a predetermined depth in the wellbore, disengaging the fracturing plug from the run-in tool causing the fracturing plug to assume an expanded state; displacing the fracturing plug downhole using fluid pumped down the liner; installing the fracturing plug at a target location in the expanded state, to pressure-isolate a target zone of the wellbore from a zone downhole the target location; retrieving the run-in tool from the wellbore; running-in at the target stage a perforating gun installed on wireline, forming a plurality of perforations in the casing along the target zone, and fracking the target zone; and then once the dissolvable seal has dissolved, retrieving the fracturing plug using a retrieving tool.
It should be noted that the terms “upper”, “uphole”, “lower”, “downhole” are relative terms used to refer to an entity located in the wellbore with respect to the surface (wellhead). For example, an “upper” feature generally refers to the feature closer to the wellhead than a corresponding “lower” feature. Position of a tool that may be referred to as “uphole” relative to a “downhole” tool, again relative to the wellhead. These terms have this meaning even in a horizontal well.
The drawings accompanying and forming part of this specification are included to depict certain aspects of the invention. A clearer impression of the invention, and of the components and operation of devices provided with the invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting, embodiments illustrated in the drawings, wherein identical reference numerals designate the same components. Note that the features illustrated in the drawings are not necessarily drawn to scale.
The latch-and-perf assembly 10 described in this specification comprises a latching seal 5 (which itself comprises in an embodiment a latch 23 and a ball 21), a run-in tool 7, a wireline setting tool 9 (which may itself comprise an E-4™ setting tool) for setting the latching seal 5, and a perforating gun 40. The assembly 10 is lowered in the well toward a target location in a target zone, using a wireline 30. The wireline setting tool 9 is used to deploy the latching seal 5 in the vicinity of the target zone.
Once the latch-and-pea assembly 10 arrives at a predetermined depth in the wellbore in the vicinity of the target location, but uphole by a relatively short distance from the target location, a small power charge in the wireline setting tool 9 is used to free the latching seal 5 from the run-in tool 7. In some embodiments, the run-in tool 7 comprises a wireline adapter kit (not shown) provided at the downhole end of the wireline 30 to connect the wireline 30, and the wireline setting tool 9, to the latching seal 5. When the small charge carried by the wireline setting tool 9 is discharged, it creates a motion that allows the latching seal 5 to be released from the wireline 30, run-in tool 7, and wireline setting tool 9. Other means of attaching the setting tool 9 to the wireline 30 are envisaged.
Once the latching seal 5 is released from the run-in tool 7, it is pumped down a relatively short distance of 1 to 10 meters towards the locator sub 11 placed at the target location, using a small volume of fluid. The locator sub 11 is part of the liner 12 and has, in this embodiment, one or more profiles 16 with which the latching seal 5 can engage. There is a locator sub 11 for each stage of the wellbore. When the latching seal 5 latches against the profiles of the locator sub 11, the latching seal 5 is captured inside the locator sub 11 and seals up-hole portions of the the locator sub 11, from downhole portions of the locator sub 11.
As shown in
In one embodiment, the ball 21 is located inside the latching seal 5 as the latching seal 5 is run into the liner 12 toward the locator sub 11. In another embodiment, the latching seal 5 is run into the liner 12 toward the locator sub 11 without a ball 21, and a ball is later pumped into the liner 11 for landing on a seat 32 inside latching seal 5. Once the latching seal 5 has latched into the locator sub 11, the ball 21 is pumped from surface into engagement with the seat 32 of the latching seal 5. In one embodiment, the ball 21 is trapped inside the latch 23.
When fluid is pumped into bore 18 of the liner 12, the latching seal 5 comprising as indicated above the ball seat 32, the ball 21 and the latch 23, will move through the liner 12 in the downhole direction. The internal profile of the fingers 25, namely the set of inward projections 28, is designed to facilitate run-in of the seat 32. The ball 21 remains in the latch 23 until, in this embodiment, the ball 21, or in another embodiment, the seat 32 holding the ball 21, dissolves. In this embodiment, the ball seat 32 is an integral part of the latch 23. In all embodiments, when the seat 32 hosts the ball 21, and pressure is applied from surface, a seal is formed between the ball 21 and seat 32 that fluidically isolates the portion of the liner 12 that is downhole from the latching seal 5, from the portion of the liner 12 that is uphole from the latching seal 5.
In an alternative embodiment, the ball seat 32 is adapted to dissolve after fracking, the seat 32 is trapped inside the latch along with the ball 21, which may be dissolvable or non-dissolvable. When fluid is pumped into the liner 12, the entire latching seal 5 (comprising the ball seat 32, the ball 21 and the latch 23) will move through the liner 12 in the downhole direction. The ball 21 can dissolve or flow back uphole as either the ball seat 32 and/or ball 21 can dissolve.
After the latch 23 with seal 21 is pumped into the engagement with the profile (as seen for example in
During run-in of the latch-and-perf assembly 10, the fingers 25 are in the retracted position, with the tips of the fingers 25 forced inwardly by a retaining sleeve 33, as better seen in
When the wireline setting tool 9 actuates by, for example, ignition of the E-4 charge carried by the setting tool 9, the highly pressurized gas that is generated, forces the inner mandrel 37 of the wireline setting tool 9 to retract in the uphole direction. As seen in
In operation, the latch-and-perf assembly 10 is deployed in the wellbore with the latch 23, and specifically its fingers 25, in a retracted state (see
In one embodiment, at the time of the outward radial movement of the fingers 25 of the latch 23 of the latch-and-perf assembly 10, the distance between the latch-and-perf assembly 10 and the target location (i.e., the profile 31 in the locator sub 11) is about three meters. The appropriate positioning of the plug-and-perf assembly 10 when the explosion by the wireline setting tool 9 is triggered, can be ensured from surface by noting the deployed length of the wireline 30. The wireline 30 is also used to send the detonation signal to the charge inside the wireline setting tool 9, when the device arrives at an appropriate depth.
Once the latching seal 5 is released from the run-in tool 7 and other parts of the latch-and-perf assembly 10, the latching seal 5 is pumped down so it lands on the locator sub 11 where it is captured in profile 31 as described above. As also described above, the ball 21 captured inside the latch 23, (or part of latch 23) sits on seat 32 and seals the internal bore 18 of the liner 12, so that the zone 70 (see
The wireline 30 is then used to move the wireline setting tool 9 and the run-in tool 7 further uphole from the latching seal 5. The perforating gun 40 is then discharged in the sealed zone 60, for perforating the liner 12, the casing 14 around the liner 12, and the formation in the vicinity of the zone 60. Specifically, the perforating gun 40, which is run-in with the latch-and-perf assembly 10 to zone 60 that has been targeted for perforation, is discharged. The gun 40 can be moved uphole to a next location in the zone 60, and discharged again to create additional perforations through the liner, casing and in the formation at zone 60. The process can be repeated until the zone 60 is fully perforated. Thereafter, the wireline 30 with the wireline setting tool 9, spent perforating gun 40, and the run-in tool 7, are pulled out of the liner, and the zone 60 is fracked, with the latching seal 5 sealing the zone 60 against fracking fluid going downhole to for example downhole zone 70.
After fracking of zone 60 is completed, the dissolvable ball 21 and/or ball seat 32 dissolve. The latch 23 can now be easily retrieved, if the operator wishes, by running-in a retrieving tool 67, as shown in
In another embodiment, latching seal 5 can be used to land in an internal profile of a sliding sleeve (not shown) covering a port, (not shown) when pressure is applied uphole from latching seal 5. When it lands, latching seal 5 closes the bore 18. When the resulting force of the applied pressure crosses a threshold level, the sliding sleeve shifts to open the port, and a hydraulic frack can then be performed through the open port. This embodiment does not require perforating guns 40.
This patent application claims priority from the U.S. provisional Patent Application 62/690,310 filed Jun. 26, 2018.
Number | Date | Country | |
---|---|---|---|
62690310 | Jun 2018 | US |