Patent Grant
11519258
The field relates to pressure testing a casing string during reverse cementing in an oil or gas operation. A fluid flow path through the casing string can be closed before, during, or after the conclusion of the reverse cementing operation to allow pressure testing of the casing string to occur.
The features and advantages of certain embodiments will be more readily appreciated when considered in conjunction with the accompanying figures. The figures are not to be construed as limiting any of the preferred embodiments.
Oil and gas hydrocarbons are naturally occurring in some subterranean formations. In the oil and gas industry, a subterranean formation containing oil and/or gas is referred to as a reservoir. A reservoir can be located under land or off shore. Reservoirs are typically located in the range of a few hundred feet (shallow reservoirs) to a few tens of thousands of feet (ultra-deep reservoirs). In order to produce oil or gas, a wellbore is drilled into a reservoir or adjacent to a reservoir. The oil, gas, or water produced from a reservoir is called a reservoir fluid.
As used herein, a “fluid” is a substance having a continuous phase that can flow and conform to the outline of its container when the substance is tested at a temperature of 71° F. (22° C.) and a pressure of one atmosphere “atm” (0.1 megapascals “MPa”). A fluid can be a liquid or gas. A homogenous fluid has only one phase; whereas a heterogeneous fluid has more than one distinct phase. A colloid is an example of a heterogeneous fluid. A heterogeneous fluid can be: a slurry, which includes a continuous liquid phase and undissolved solid particles as the dispersed phase; an emulsion, which includes a continuous liquid phase and at least one dispersed phase of immiscible liquid droplets; a foam, which includes a continuous liquid phase and a gas as the dispersed phase; or a mist, which includes a continuous gas phase and liquid droplets as the dispersed phase. As used herein, the term “base fluid” means the solvent of a solution or the continuous phase of a heterogeneous fluid and is the liquid that is in the greatest percentage by volume of a treatment fluid.
A well can include, without limitation, an oil, gas, or water production well, an injection well, or a geothermal well. As used herein, a “well” includes at least one wellbore. A wellbore can include vertical, inclined, and horizontal portions, and it can be straight, curved, or branched. As used herein, the term “wellbore” includes any cased, and any uncased, open-hole portion of the wellbore. A near-wellbore region is the subterranean material and rock of the subterranean formation surrounding the wellbore. As used herein, a “well” also includes the near-wellbore region. The near-wellbore region is generally considered to be the region within approximately 100 feet radially of the wellbore. As used herein, “into a subterranean formation” means and includes into any portion of the well, including into the wellbore, into the near-wellbore region via the wellbore, or into the subterranean formation via the wellbore.
A wellbore is formed using a drill bit. A drill string can be used to aid the drill bit in drilling through the subterranean formation to form the wellbore. The drill string can include a drilling pipe. During drilling operations, a drilling fluid, sometimes referred to as a drilling mud, may be circulated downwardly through the drilling pipe, and back up the annulus between the wellbore and the outside of the drilling pipe. The drilling fluid performs various functions, such as cooling the drill bit, maintaining the desired pressure in the well, and carrying drill cuttings upwardly through the annulus between the wellbore and the drilling pipe.
A portion of a wellbore can be an open hole or cased hole. In an open-hole wellbore portion, a tubing string can be placed into the wellbore. The tubing string allows fluids to be introduced into or flowed from a remote portion of the wellbore. In a cased-hole wellbore portion, a casing is placed into the wellbore that can also contain a tubing string. A wellbore can contain an annulus. Examples of an annulus include, but are not limited to: the space between the wellbore and the outside of a tubing string in an open-hole wellbore; the space between the wellbore and the outside of a casing in a cased-hole wellbore; and the space between the inside of a casing and the outside of a tubing string in a cased-hole wellbore.
During well completion, it is common to introduce a cement composition into an annulus in a wellbore. For example, in a cased-hole wellbore, a cement composition can be placed into and allowed to set in the annulus between the wellbore and the casing in order to stabilize and secure the casing in the wellbore. By cementing the casing in the wellbore, fluids are prevented from flowing into the annulus. Consequently, oil or gas can be produced in a controlled manner by directing the flow of oil or gas through the casing and into the wellhead. Cement compositions can also be used in primary or secondary cementing operations, well-plugging, or squeeze cementing. As used herein, a “cement composition” is a mixture of at least cement and water, and possibly other additives.
As used herein, a “cement composition” is a mixture of at least cement and water. A cement composition can include additives. As used herein, the term “cement” means an initially dry substance that develops compressive strength or sets in the presence of water. Some examples of cements include, but are not limited to, Portland cements, gypsum cements, high alumina content cements, slag cements, high magnesia content cements, sorel cements, and combinations thereof. A cement composition is a heterogeneous fluid including water as the continuous phase of the slurry and the cement (and any other insoluble particles) as the dispersed phase. The continuous phase of a cement composition can include dissolved substances.
A spacer fluid can be introduced into the wellbore after the drilling fluid and before the cement composition. The spacer fluid can be circulated down through a drill string or tubing string and up through the annulus. The spacer fluid functions to remove the drilling fluid from the wellbore.
In traditional cementing operations, a spacer fluid is typically introduced after the drilling fluid into the casing. The spacer fluid pushes the drilling fluid through the casing and up into an annular space towards a wellhead. A cement composition is then introduced after the spacer fluid into the casing.
A cement composition should remain pumpable during introduction into a wellbore. A cement composition will ultimately set after placement into the wellbore. As used herein, the term “set,” and all grammatical variations thereof, are intended to mean the process of becoming hard or solid by curing. As used herein, the “setting time” is the difference in time between when the cement and any other ingredients are added to the water and when the composition has set at a specified temperature. It can take up to 48 hours or longer for a cement composition to set. Some cement compositions can continue to develop compressive strength over the course of several days. The compressive strength of a cement composition can reach over 10,000 psi (69 MPa).
Reverse cementing operations were developed to overcome some of the disadvantages to traditional cement operations. For example, in traditional cementing operations, the setting time of the cement composition is longer in order for the cement slurry to travel through the casing or an inner tubing string and back up into the annulus before setting. Additionally, the amount of cement slurry that is pumped is generally greater than in reverse cementing. In reverse cementing, the cement slurry is pumped directly into the annulus instead of into the annulus via the casing string or tubing string. Accordingly, reverse cementing generally requires less of the cement slurry, faster setting times, and lower pump pressures because gravity assists the cement slurry in being placed in the annulus.
After the cement composition has been placed at the desired location in an annulus, it is common to pressure test the casing to verify the structural integrity of the casing. During the pressure testing, the casing string tends to radially expand from the pressure inside the casing string. In cementing operations, the cement slurry may begin to set before pressure testing can be performed. If the cement slurry is beginning to set and not in liquid form, then a micro-annulus can form along the outer diameter of the casing string due to the expansion of the casing during the pressure testing and retraction after the pressure testing is concluded. The mostly- to partially-set cement slurry is unable to flow back into the void created by the expansion and retraction of the casing string. If a micro-annulus forms, then fluid can undesirably flow through the micro-annulus. Therefore, pressure testing of the casing is typically performed days after the cement slurry has been placed to allow the cement slurry to completely set and prevent formation of a micro-annulus.
The inability to perform pressure testing during or shortly after a cementing operation undesirably leads to increased costs due to downtime waiting for the cement composition to fully set and delays the pressure testing and other wellbore operations. Thus, there is a need for improved ways to pressure test a casing string in a reverse cementing operation that requires less time and money.
A downhole tool can be used to perform a reverse cementing operation and pressure test a casing string before, during, or shortly after the conclusion of the reverse cementing operation. The downhole tool can include a fluid flow path through the inner diameter of the tool. The fluid flow path can be closed before, during, or after a reverse cementing operation. Closure of the fluid flow path allows for pressure testing of the casing string to be performed. The pressure testing is performed while the cement composition is in a fluid state and is less likely to form a micro-annulus.
Methods of pressure testing a casing string in a reverse cementing operation in a wellbore comprises: introducing the casing string and a downhole tool installed within the casing string into the wellbore, wherein the downhole tool comprises a fluid flow path defined by an inner diameter of the downhole tool; introducing a cement composition into an annulus located between a wall of the wellbore and an outside of the casing string; causing the fluid flow path of the downhole tool to close against fluid flow from the annulus into the downhole tool; and increasing pressure within the casing string.
It is to be understood that the discussion of any of the embodiments regarding the downhole tool is intended to apply to all of the method embodiments. Any reference to the unit “gallons” means U.S. gallons.
Turning to the figures,
The downhole tool 100 can include an inner sleeve 130 and a valve connector housing 160. The inner sleeve 130 can be releasably attached to the valve connector housing 160 by a frangible device 147. The frangible device 147 can be any device that is capable of withstanding a predetermined amount of force and capable of releasing at a force above the predetermined amount of force. The frangible device 147 can be, for example, a shear pin, a shear screw, a shear ring, a load ring, a lock ring, a pin, or a lug. There can also be more than one frangible device 147 that connects the inner sleeve 130 to the valve connector housing 160. The frangible device 147 or multiple frangible devices can be selected based on the force rating of the device, the total number of devices used, and the predetermined amount of force needed to release the device. For example, if the total force required to break or shear the frangible device is 15,000 pounds force (lbf) and each frangible device has a rating of 5,000 lbf, then a total of three frangible devices may be used.
The downhole tool 100 can include a valve 141. The valve 141 can be a flapper valve. As shown in
The methods include closing the fluid flow path through the downhole tool 100. As shown in
With reference to
The sleeve 130 can be shifted via a variety of mechanisms. By way of example and as shown in
Turning now to
As can also be seen in
With continued reference to
By way of another example, electro-mechanical sifting of the sleeve can be used. A magnetic permeability sensing apparatus (“sensing apparatus”) can be used for activating devices downhole based on magnetic permeability sensing, including shifting the sleeve 130 during reverse cementing operations. At designated stages of reverse cementing operations, a material with high magnetic permeability can be added to the cement composition to be sent downhole to enable a magnetic sensor to detect the magnetic permeability of the slurry. The sensing apparatus is situated downhole near a flow port to detect the presence of the cement composition with known magnetic permeability corresponding to the cement composition sent downhole and to send a signal to close a valve (e.g., a sliding sleeve, ball valve, etc.) either at the flow port or across the cross section of the casing string 112. Once the known cement composition is detected, an additional signal (e.g., a wired signal through electric line or fiber optics, or a wireless signal such as a pressure rise, an acoustic signal, etc.) is sent by the sensing apparatus to a controller of the reverse cementing operations at the surface to stop flow of the current slurry and/or commence flow of a different slurry. In one application, the additional signal is a pressure rise associated with the increased flow resistance from the valve closing. The sensing apparatus can include a magnet source (e.g., a permanent magnet or an electromagnet) and a magnetic sensor. The sensing apparatus can be configured to detect specific ranges of magnetic permeability by inducing a magnetic field in the cement composition to be read by the magnetic sensor. The magnetic sensor can detect different cement compositions downhole based on different concentrations of the high magnetic permeability material in the cement composition, which results in magnetic fields with different strengths at the sensor. This sensing apparatus can detect multiple types of cementing fluids using accurate measurements of magnetic permeability.
By way of yet another example, a valve, such as a ball valve or safety valve, can be programmed to close the fluid flow path through the casing string 112 at a predetermined time. For example, the valve can be programmed to close the fluid flow path at the conclusion of the reverse cementing operation.
It is to be understood that although
The components of the downhole tool can be made from a variety of materials including, but not limited to, metals, metal alloys, composites, plastics, and rubbers. Other components can also be included, for example, components required for safety and/or regulatory requirements.
The methods include introducing a cement composition 111 into an annulus located between a wall 110 of the wellbore and an outside of the casing string 112. The annulus and inside of the casing string 112 can contain a fluid. The fluid can be a run-in fluid, for example, a drilling mud. The methods can include introducing a first fluid into the annulus prior to introduction of the cement composition 111. The first fluid can be a spacer fluid. A spacer fluid can help separate a drilling mud from the cement composition 111. The cement composition 111 can then be introduced into the annulus. There can also be a second, third, etc. fluid, such as a tail cement composition or a cement composition containing a different concentration of the high magnetic permeability material, introduced into the annulus after the cement composition 111. Any of the fluids can be introduced into the annulus in the direction D3 and can enter the downhole tool in the direction D5.
The methods further include increasing pressure within the casing string from the surface via drilling rig pumps or other service provider pumps. One of the many advantages to the novel methods is that pressure testing can be performed before, during, or shortly after the cement composition(s) have been introduced into the wellbore annulus. The cement composition(s) can be in a fluid form. As used herein, the term “fluid form” means the cement composition can flow and conform to the outline of a container. It is to be understood that a cement composition in “fluid form” may begin to gel, develop compressive strength, and/or set; however, any gelation, development of compressive strength, and/or setting should not be so significant as to reduce the ability of the cement composition to flow and conform to the outline of a container. A cement composition in fluid form enables pressure testing to be performed at this stage of the reverse cementing operation without formation of a micro-annulus. This advantageous capability can significantly reduce costs and time.
According to any of the embodiments, an overbalanced wellbore is achieved after introduction of the cement composition 111. A wellbore segment can have a specific hydrostatic pressure. The hydrostatic pressure in the wellbore segment can be pre-determined. As used herein, “hydrostatic pressure” is the force per unit area exerted by a column of wellbore fluid at rest. In U.S. oilfield units, hydrostatic pressure is calculated using the equation: P=MW*Depth*0.052, where MW is the drilling fluid density in pounds per gallon, Depth is the true vertical depth or “head” in feet, and 0.052 is a unit conversion factor chosen such that P results in units of pounds per square inch (psi). The hydrostatic pressure is the force exerted on the wellbore components, such as a tubing string or casing, or a subterranean formation for an open-hole wellbore portion, via the fluid located in the wellbore or in a tubing string. According to these embodiments, an overbalanced wellbore exists when the hydrostatic pressure of the column of fluid in the annulus is less than the hydrostatic pressure of the column of fluid in the casing string.
The density of any fluids introduced before the cement composition as well as the density of the cement composition can be selected such that an overbalanced wellbore is achieved. There can also be a second cement composition that is introduced into the annulus. For example, a first cement composition, such as a lead cement slurry, can be introduced into the annulus—followed by a second cement composition, such as a tail cement slurry that has a different density. The following is one, non-limiting example of a density design of fluids to achieve hydrostatic equilibrium. A 9 pound per gallon (ppg) drilling mud can be located within the casing and annulus. A higher density spacer fluid, for example 12 ppg, can be pumped into the annulus when the reverse cementing operation begins. The heavier weight spacer fluid pushes the lighter weight drilling mud through the annulus in the direction D3. A lead cement slurry with a higher density than the drilling mud, but lighter than the spacer fluid, for example 11 ppg, can be pumped into the annulus. The lead cement will remain on top of the spacer fluid and allow the spacer fluid to continue pushing the drilling mud through the annulus and can enter the casing string 112 in the direction D4. A tail cement slurry can have a density equal to or less than the lead cement slurry, for example 10 ppg. After placement of all of the cement slurries in the annulus, hydrostatic equilibrium can be achieved with the column of fluid in the annulus having a combined average density of 10.5 ppg and the column of fluid in the casing string having a combined average density of 10.5 ppg. One of ordinary skill in the art will be able to select the density and volume of the fluids in order to achieve hydrostatic equilibrium or an overbalance.
An embodiment of the present disclosure is a method of pressure testing a casing string in a reverse cementing operation in a wellbore comprising: introducing the casing string and a downhole tool installed within the casing string into the wellbore, wherein the downhole tool comprises a fluid flow path defined by an inner diameter of the downhole tool; introducing a cement composition into an annulus located between a wall of the wellbore and an outside of the casing string; causing the fluid flow path of the downhole tool to close against fluid flow from the annulus into at least a portion of the casing string; and increasing pressure within the portion of the casing string that is closed against fluid flow from the annulus. Optionally, the method further comprises wherein the fluid flow path of the downhole tool is closed by shifting of an inner sleeve. Optionally, the method further comprises wherein shifting of the inner sleeve is accomplished via a ball and a ball seat, mechanical actuation of the inner sleeve, hydraulic actuation of the inner sleeve, or electro-mechanical actuation of the inner sleeve. Optionally, the method further comprises wherein the downhole tool further comprises: a flapper valve located on an inside of a body of the downhole tool, wherein the flapper valve is in an open position prior to shifting of the inner sleeve; or two or more flow ports located around a periphery of a body of the downhole tool, wherein the two or more flow ports are in an open position and the inner sleeve is located above the two or more flow ports prior to shifting of the inner sleeve. Optionally, the method further comprises wherein shifting of the inner sleeve causes a flapper of the flapper valve to move into a closed position or wherein shifting of the inner sleeve causes the two or more flow ports to move into a closed position. Optionally, the method further comprises wherein the downhole tool further comprises a ball seat located on an inner diameter of the inner sleeve. Optionally, the method further comprises dropping a ball from a wellhead onto the ball seat. Optionally, the method further comprises wherein the ball engages with the ball seat and a pressure differential is created after a seal is created by engagement of the ball with the ball seat. Optionally, the method further comprises wherein the pressure differential causes the inner sleeve to shift. Optionally, the method further comprises wherein the downhole tool further comprises a valve connector housing releasably connected to the inner sleeve by a frangible device, and wherein the pressure differential causes the frangible device to shear and releases the inner sleeve from connection with the valve connector housing. Optionally, the method further comprises wherein the downhole tool further comprises a valve located within the inner diameter of the downhole tool. Optionally, the method further comprises wherein the valve is programmed to close at a predetermined time, and wherein closure of the valve closes the fluid flow path. Optionally, the method further comprises wherein the downhole tool further comprises a ball seat located on an inner diameter of the inner sleeve. Optionally, the method further comprises dropping a ball from a wellhead onto the ball seat. Optionally, the method further comprises wherein the ball engages with the ball seat and closes the fluid flow path through the downhole tool. Optionally, the method further comprises wherein closure of the fluid flow path is accomplished using a bridge plug or a packer. Optionally, the method further comprises wherein the step of increasing pressure within the portion of the casing string comprises pumping a fluid from a wellhead into the portion of the casing string using a pump. Optionally, the method further comprises introducing a fluid into the annulus located between the wall of the wellbore and the outside of the casing string before introduction of the cement composition. Optionally, the method further comprises introducing a second cement composition into the annulus located between the wall of the wellbore and the outside of the casing string after introduction of the cement composition. Optionally, the method further comprises creating an overbalanced wellbore, wherein the hydrostatic pressure of a column of fluid located in the annulus is less than the hydrostatic pressure of a column of fluid in the portion of the casing string.
Therefore, the apparatus, methods, and systems of the present disclosure are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is, therefore, evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.
As used herein, the words “comprise,” “have,” “include,” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps. While compositions, systems, and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions, systems, and methods also can “consist essentially of” or “consist of” the various components and steps. It should also be understood that, as used herein, “first,” “second,” and “third,” are assigned arbitrarily and are merely intended to differentiate between two or more fluids, valves, etc., as the case may be, and does not indicate any sequence. Furthermore, it is to be understood that the mere use of the word “first” does not require that there be any “second,” and the mere use of the word “second” does not require that there be any “third,” etc.
Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a−b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
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