Patent Application
20230193745
Drilling a wellbore typically includes pumping a fluid, such as “drilling mud”, down a string of connected hollow pipes, called a drillstring, and out of a drill bit attached to the lower end of the drillstring. The drilling mud then circulates out of the hole to the surface carrying pieces of drilled rock, known as “cuttings”. The density of the drilling mud is carefully controlled to provide a wellbore pressure on the earth formation that is specifically designed for a given application. In most cases, the wellbore pressure is designed to be greater than the pressure of the formation fluids (e.g., water, hydrocarbons) contained in the drilled rock. As a result, the wellbore pressure prevents formation fluids from entering the annulus and being transported to surface.
In drilling operations, a fluid loss event can occur in situations where the hydrostatic pressure inside a wellbore is not maintained in a particular range, where the hydrostatic pressure may be greater than the formation pressure, but less than the fracture pressure. If the hydrostatic pressure in the wellbore exceeds the fracture pressure, fractures may be formed in the formation, leading to leakage of drilling mud or other fluids. Leakage of drilling mud is commonly referred to as “lost circulation”. Lost circulation is a major cause of non-productive time (NPT) during drilling and increases the cost of drilling, since drilling fluid lost to the formation must be replaced.
The drilling industry has developed several techniques to fight losses. Lost circulation materials (LCM) may refer to any substance added to drilling fluids when drilling fluids are actively being lost to the formation to prevent or mitigate further loss. For example, the LCM may include gels, fibers, cement, or chemicals.
A fluid loss event is typically detected when the flow rate or pressure of returning drilling mud is less than expected. In some extreme lost circulation cases, there can be total mud loss, where there is no returning mud. Flow rate and pressure in returning pipes may be measured continuously, which can alert operators to a partial or total mud loss. If a total loss is not mitigated in a timely fashion, there is risk of the wellbore collapsing.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
In one aspect, embodiments disclosed herein relate to a method. The method includes creating a chamber within an annulus between a wellbore casing and a drillpipe, wherein an upper boundary of the chamber comprises a seal and a lower boundary of the chamber comprises a liquid surface and determining a volume of the chamber at a first time. Determining the volume of the chamber includes measuring, using a pressure gauge, a first pressure within the chamber, changing an amount of a gas in the chamber, measuring, using the pressure gauge, a second pressure within the chamber, and determining a first volume of gas within the chamber based on the first and second pressure measurements and the change in the amount of gas. The method further includes determining a first fluid level based on the first volume of the chamber.
In another aspect, embodiments disclosed herein relate an apparatus, which includes a casing disposed within a wellbore and a drillpipe disposed within the casing, wherein an annulus is created between the casing and the drillpipe. The apparatus further includes a seal disposed in the annulus, a chamber, wherein an upper boundary of the chamber comprises the seal and a lower boundary of the chamber comprises a surface of a liquid, and a pressure gauge connected to the chamber.
Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.
Specific embodiments of the disclosed technology will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency. The size and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements and have been solely selected for ease of recognition in the drawing.
In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.
In the following description of
Disclosed herein are embodiments of apparatus and methods for measuring a downhole fluid level in an annulus. Such apparatus and methods may be used during a fluid loss event in order to assess the effectiveness of fluid loss mitigation methods. More specifically, embodiments disclosed herein relate to creating a chamber within an annulus, such that the amount of gas within the chamber may be changed and a corresponding pressure change may be calculated. From such a pressure change, a chamber volume may be calculated, which can, in turn, be used to calculate a fluid level.
As the wellbore 116 is drilled, sections of the wellbore 116 may be cased. At intervals during the drilling of the wellbore 116, drilling may be paused, the drill bit 108 and drillstring may be removed from the wellbore 116 and casing 102 may be inserted into the wellbore 116. Casing 102 is composed of sections of pipe with outer diameters slightly smaller than the diameter of the wellbore 116. The sections of casing 102 may be screwed together at the surface as they are inserted into the wellbore 116. Depending on the depth of the wellbore 116 and other operating parameters, multiple strings of casing 102 may be used to case the wellbore 116. Each successive string of casing 102 may be lowered into the wellbore 116 and connected to an end of a previously installed casing 102 or extend to the surface 122. Each successive string of casing 102 decreases in both outer diameter and inner diameter. After a string of casing 102 is lowered into the wellbore 116, cementing operations may be performed where liquid cement 104 is pumped down the interior of the casing to the depth at which drilling has halted, which may refer to the bottom of the wellbore 116. At this point, drill mud is pumped down the interior of the casing to displace the cement into the annulus. The annulus may refer to either the space between a casing 102 and the wellbore 116, or the space between two casings 102. A cement plug may be deployed between the liquid cement and the displacing drill mud to prevent mixing of the drilling mud and the cement. Once in the annulus, the liquid cement 104 may solidify and set.
A blowout preventer (BOP) 110 may be installed at the top of the wellbore 116. A blowout preventer 110, as one skilled in the art will be aware, refers to an array of one or more large valves at the top of the wellbore 116 that may be closed if the drilling crew loses control of formation fluids. Closing the valve may allow the drilling crew to regain control of the reservoir and mud density can be increased until the BOP may be safely opened, and pressure control of the formation may be retained.
Turning now to
The uncased portion 218 of the wellbore 116 may be called the openhole section 218 of the wellbore 116, and the lower surface 220 of the wellbore 116 may be called the bottom hole 220. If the formation is particularly porous, fluid loss may occur in openhole 218 portions of the wellbore 116, where drilling mud 215 may leak into the formation through the formation pores. Further, fractures 222 may be present in the formation. Fractures 222 may be preexisting natural fractures or may be created if the pressure within the wellbore 116 exceeds the formation fracture pressure. When fractures 222 form in the formation, drilling mud 215 may be lost to the formation through the fractures 222.
In one or more embodiments, as shown in
In other embodiments, the seal 206 may be formed by a blowout preventer (BOP) 110, as shown in
In some embodiments, as depicted in
Turning now to
Initially, in S702, a chamber 216 is created within an annulus 214. The annulus 216 may refer to the space between a casing 212 and a drillpipe 210, where the drillpipe 210 is set within the casing 212. However, the method described in flowchart 700 may be applied to any wellbore 116 where one casing string is set within another casing string, creating an annular region between the two strings. A seal 206 may be disposed within the annulus 216, where the seal 206 serves as an upper boundary of the chamber 216. In one or more embodiments, the seal 206 may be an inflatable packer 302. In other embodiments, a blowout preventer (BOP) 110 may provide the seal 206. A liquid surface 209 may serve as a lower boundary of the chamber 216.
In S704, in accordance with one or more embodiments, the volume of gas within the chamber 216 may be determined at a first time. In step S704a, a first pressure of the chamber 216 may be measured with a pressure gauge 202. In S704b, an amount of gas within the chamber 216 may be changed, such that a pressure change occurs. In some embodiments, the amount of gas may be changed by pumping gas into the chamber 216. In other embodiments, the amount of gas may be changed by pumping gas out of the chamber 216. In one or more embodiments, gas may be pumped into the chamber 216 through conduit 204 penetrating the seal 206. In other embodiments, where a blowout preventer 110 serves as the seal 206, gas may be pumped into the chamber 216 via a kill line 432. In further embodiments, a first specialized drillpipe section 502 may be coaxially connected to the drillpipe 210, such that a flexible gas hose 504 may be attached to the first specialized drillpipe section 502 at one location and gas may be pumped directly into the chamber. In further embodiments, a second specialized drillpipe section 602 may be coaxially connected to the drillpipe 210 and a hard conduit 604 may be attached to the second specialized drillpipe section 602 in two locations. In such embodiments, gas may be pumped into the chamber 216 directly through the hard conduit 604. In one or more embodiments, changing an amount of gas may refer to pumping gas out of the chamber 216. In some embodiments, the pressure gauge 202 may be disposed on the seal 206. In other embodiments, where a blowout preventer 110 serves as the seal 206, the pressure gauge 202 may be installed on a choke line 438. In some embodiments, the pressure gauge 202 may be a digital, high-frequency gauge. However, any type of pressure gauge 202 may be used without departing from the scope of this disclosure. In further embodiments, including those where a first specialized drillpipe section 502 and a flexible gas hose 504 are implemented, the pressure gauge 202 may be disposed on the flexible gas hose 504.
In S704c, a second pressure change within the chamber 216 may be measured at a second time, which may be separated from the first time by a non-zero time interval. The second pressure change may be measured using a pressure gauge 202, which may be installed in the system in a variety of locations. In some embodiments, this may be the same pressure gauge 202 used to measure the first pressure.
In S704d, a volume of gas within the chamber 216 may be determined based on the first and second pressure measurements and the change in the amount of gas. Pressure, as one skilled in the art will be aware, may be calculated using the ideal gas equation:
where P is the pressure within the chamber 216, R is the universal gas constant, T is the ambient atmospheric temperature, V is volume of gas within the chamber 216, and n is the moles of gas in the chamber 216. n may be defined as:
n=n
0
+Δn, Equation (2)
where
where Δn is the moles of gas pumped into or out of the chamber 216, n0 is the initial moles of gas in the chamber 216 before the amount of gas is changed, t is time during which the amount of gas is changed, Q is the volumetric pump rate, and P0 is ambient atmospheric pressure.
Combining Equations 2 and 3 gives:
that may be further simplified to:
In situations, such as embodiments which method 700 applies to, where a pressure change over a given period of time is required in place of a discrete pressure value, P may be replaced by ΔP, where ΔP is the pressure change. Similarly, t may be replaced with Δt, where Δt is the non-zero time interval over which the pressure change occurred. Making these substitutions and rearranging in order to find volume, Equation 5 becomes:
In S704d, in accordance with one or more embodiments, Equation 6 may be used to determine the volume of gas in the chamber 216. From the volume of gas, a fluid level 208 may be determined, where the fluid level 208 is the axial distance between the upper boundary and lower boundary of the chamber 216. As such, the following general equation for the volume of a cylinder may be applied to determine the fluid level 208:
V
C
=πr
2
h, Equation (7)
where VC is the volume of a cylinder, r is the radius of the cylinder, and h is the height of the cylinder. Applying Equation 7 to the chamber 216, the following equation may provide the fluid level 208:
where h is the fluid level 208, rC is the radius of the casing 212, rD is the radius of the drillpipe, and V is the volume of the chamber 216.
Steps S704 and S706 may be repeated throughout a fluid loss event to monitor changes in fluid level 208 and to determine if a fluid loss, which may be the difference between two fluid level values, has occurred. In S708, continuous monitoring of fluid level 208 allows for the creation and execution of a fluid loss control plan, as well as allowing operators to assess the success of implemented mitigation methods. In one or more embodiments, a fluid loss control plan may involve pumping a substance, which may be a plugging material, downhole. In some embodiments, the plugging material may be a gel. In other embodiments, the plugging material may be a powdered agent. A plugging material may create a blockage such that fluid is unable to escape to the formation. Plugging may be temporary or permanent. In one or more embodiments, control of fluid loss for a mud may be achieved by altering the mud chemistry to improve the effectiveness of already present material in preventing fluid loss. For example, adding a clay deflocculant to freshwater mud, as one skilled in the art will be aware, may improve fluid loss control. Though method 700 has been described as specifically applying to embodiments wherein a drillpipe is set within a casing, method 700 may also be applied to any embodiment where a casing is set within a casing.
Embodiments of the present disclosure may provide at least one of the following advantages. In fluid loss events, it is prudent for operators to determine a fluid level within an annular space in order to assess the severity of the fluid loss event. A pressure change apparatus may be implemented into an existing wellbore, such that a chamber may be created within the annular space. By changing the amount of gas within the chamber, a pressure change may be measured which can be used to calculate the volume of gas within the chamber, and a fluid level within the annular space. The information garnered from determining the fluid level may be used to develop a drilling fluid loss control plan which may work to mitigate the effects of the fluid loss event on the drilling operation. The pressure change apparatus may be used continuously, alerting operators to changes in fluid level throughout the fluid loss event and, therefore, to the effectiveness of implemented mitigation methods. This continuous monitoring of fluid level allows operators to quickly address fluid loss events, such that drilling efficiency and wellbore safety may be preserved and maintained.
Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
