Patent Grant
11187044
This disclosure relates to systems and methods for to processing subterranean formations from which hydrocarbons can be produced.
Various techniques can be used to produce oil from a subterranean zone. Artificial lifting mechanisms, such as electrical submersible pumps and gas lifts, are often used to add energy to the fluid column in a wellbore in order to increase the amount of oil produced from a subterranean zone. However, the oil produced from a subterranean zone using artificial lifting techniques often results in the oil being lifted with other formation fluids, such as water.
This disclosure describes systems and methods for forming subterranean caverns.
In an example implementation, a method includes spraying acid onto an inner wall of a wellbore. The wellbore is formed in a subterranean zone with entrapped hydrocarbons that flow into the subterranean zone. Spraying the acid forms a subterranean cavern within a portion of the wellbore, the subterranean cavern being wider than the wellbore. The entrapped hydrocarbons flow into the subterranean cavern. The entrapped hydrocarbons include liquid hydrocarbons and water. The liquid hydrocarbons and the water separate under gravity within the subterranean cavern. The method also includes drawing the liquid hydrocarbons from the subterranean cavern to a surface of the wellbore.
This, and other implementations, can include one or more of the following features. The method can further include positioning an acidizing tool within the wellbore, supplying acid to the acidizing tool, rotating the acidizing tool about 360 degrees, and, in response to determining that a radius of a portion of the wellbore proximate the acidizing tool is about 300 percent to about 400 percent an initial radius of the wellbore, raising the acidizing tool within the wellbore towards the surface. Determining that the radius of the portion of the wellbore proximate the acidizing tool is about 300 percent to about 400 percent an initial radius of the wellbore can include measuring the radius of the portion of the wellbore proximate the acidizing tool using one or more ultrasonic sensors coupled to the acidizing tool. An upper portion of the subterranean cavern can be dome-shaped. The method can further include rotating the acidizing tool between a first position and a second position to form the upper portion of the subterranean cavern. The acidizing tool can include a center hub coupled to an end of a downhole conveyance, one or more projections extending radially from the center hub, and an opening through each of the one or more projections, wherein the one or more projections are positioned substantially perpendicular to a longitudinal axis of the downhole conveyance in the first position and are positioned substantially parallel to the longitudinal axis of the downhole conveyance in the second position. Drawing the liquid hydrocarbons from the subterranean cavern to a surface of the wellbore can include positioning a pump in an oil column formed in the subterranean cavern. Positioning a pump in an oil column formed in the subterranean cavern can include positioning a liquid level sensor in the subterranean cavern, wherein the liquid level sensor is configured to detect oil-water interfaces and oil-gas interfaces, based on detecting at least one of an oil-water interface and an oil-gas interface, determining a center of the oil column, and positioning the pump at the center of the oil column. Determining the center of the oil column can include receiving a signal from the liquid level sensor indicating a depth corresponding to an oil-gas interface in the subterranean cavern, receiving a signal from the liquid level sensor indicating a depth corresponding to an oil-water interface in the subterranean cavern, and calculating an average of the depth of the oil-gas interface and the depth of the oil-water interface. The liquid level sensor can be coupled to the pump, and positioning a liquid level sensor in the subterranean cavern can include lowering the pump into the subterranean cavern
In some implementations, a system for producing liquid hydrocarbons from a formation includes an acidizing tool configured to rotate and spray acid onto an inner wall of a wellbore to form a subterranean cavern, and a controller communicably coupled to the acidizing tool. The controller is configured to perform operations that include controlling the acidizing tool to rotate about a downhole conveyance coupled to the acidizing tool and spray acid onto an inner wall of a wellbore. The operations also include, in response to receiving a signal indicating that a radius of the wellbore is at least a threshold radius, causing the acidizing tool to be raised uphole within the wellbore. The operations also include, in response to determining that a depth of the subterranean cavern is at least a threshold depth, rotating the acidizing tool to form a dome-shaped upper portion of the subterranean cavern.
This, and other implementations, can include one or more of the following features. The depth of the subterranean cavern can be about 30 percent to about 50 percent a total depth of the wellbore. The depth of the subterranean cavern can be equal to a depth of an oil-bearing subterranean formation. The system can further include a submersible pump configured to draw liquid hydrocarbons from the subterranean cavern, and a liquid level sensor, and the controller can be communicably coupled to the submersible pump and the liquid level sensor. The operations can further include, in response to receiving a first signal from the liquid level sensor indicating an oil-water interface and a second signal from the liquid level sensor indicating an oil-gas interface, determining a center of an oil column formed by gravity separation in the subterranean cavern, and, in response to determining the center of the oil column, positioning the submersible pump in the center of the oil column. The liquid level sensor can be coupled to the submersible pump, and the operations can include lowering the submersible pump through the subterranean cavern. The system can include one or more ultrasonic sensors coupled to the acidizing tool, and the signal indicating that the radius of the wellbore is at least a threshold radius can be received by the controller from the one or more ultrasonic sensors. The system can include an acid source fluidly coupled to the acidizing tool, and controlling the acidizing tool to spray acid onto an inner wall of a wellbore can include pumping acid from the acid source to the acidizing tool. The acidizing tool can include one or more projections extending radially from a hub coupled to an end of a downhole conveyance, and an opening through each of the one or more projections. The operations can further include controlling the acidizing to rotate between a first position and a second position to form the upper portion of the subterranean cavern, wherein the one or more projections are positioned substantially perpendicular to a longitudinal axis of the downhole conveyance in the first position and the one or more projections are positioned substantially parallel to the longitudinal axis of the downhole conveyance in the second position.
Example implementations of the present disclosure can include one, some, or all of the following features. For example, a subterranean cavern formed by a system or method according to the present disclosure can improve downhole gravity separation of formation fluids. A subterranean cavern formed by a system or method according to the present disclosure can increase the inflow of formation fluids into the wellbore. A subterranean cavern formed by a system or method according to the present disclosure can reduce the cost and time required to produce oil from a subterranean zone by, for example, reducing or eliminating the need for water treatment operations at the surface to separate the oil from other subterranean fluids. A subterranean cavern formed by a system or method according to the present disclosure can be used to dispose of or store carbon dioxide and/or water produced from the surrounding subterranean formation.
The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.
The present disclosure describes a method and system for forming a subterranean cavern for oil production. In some implementations, the method and system provide for improved production of oil from a subterranean formation. This disclosure describes a system for forming a subterranean cavern in a wellbore and pumping oil from an oil column formed in the subterranean cavern to the surface. For example, an acidizing tool coupled to an acid source is lowered into a wellbore and is operated to spray acid onto an inner wall of the wellbore. The acid applied to the inner wall of the wellbore increases the radius of the portion of the wellbore proximate the acidizing tool to form a subterranean cavern. Formation fluid from the subterranean formation surrounding the subterranean cavern flows into the subterranean cavern. The formation fluid in the subterranean cavern separates under gravity separation into an oil column and water column. In order to pump oil from the subterranean cavern, a submersible pump is lowered into the subterranean cavern and positioned in the center of the oil column based on signals received from a liquid level sensor. Once positioned in the center of the oil column, the submersible pump is operated to pump the oil in the subterranean cavern to the surface while minimizing the water and other formation fluids pumped to the surface.
Although not shown, a drilling assembly deployed on the surface 102 can be used to form the wellbore 112 prior running the acidizing tool 116 into the wellbore 112 to form a subterranean cavern. The wellbore 112 is formed to extend from the surface 102 through one or more geological formations in the Earth. One or more subterranean formations, such as subterranean zone 114, are located under the surface 102. One or more wellbore casings, such as surface casing 106 and intermediate casing 108, can be installed in at least a portion of the wellbore 112. In some implementations, the well can be uncased.
Although shown as a wellbore 112 that extends from land, the wellbore 112 can be formed under a body of water rather than the surface 102. For instance, in some implementations, the surface 102 can be a surface under an ocean, gulf, sea, or any other body of water under which hydrocarbon-bearing, or water-bearing, formations can be found. In short, reference to the surface 102 includes both land and underwater surfaces and contemplates forming or developing (or both) one or more wellbores 112 from either or both locations.
The wellbore 112 can be formed by any appropriate assembly or drilling rig used to form wellbores or boreholes in the Earth. Although shown as a substantially vertical wellbore (for example, accounting for drilling imperfections), the wellbore 112, in alternative implementations, can be directional, horizontal, curved, multi-lateral, or other form other than merely vertical.
Once the wellbore 112 is formed (or in some cases during portions of forming the wellbore 112), one or more tubular casings can be installed in the wellbore 112. As illustrated, the wellbore 112 includes a conductor casing 104, which extends from the surface 102 shortly into the Earth. A portion of the wellbore portion 112 enclosed by the conductor casing 104 can be a borehole.
Downhole of the conductor casing 104 is the surface casing 106. The surface casing 106 can enclose a borehole that is smaller than the borehole enclosed by the conductor casing 104 and can protect the wellbore 112 from intrusion of, for example, freshwater aquifers located near the surface 102. The wellbore 112 then extends vertically downward. This portion of the wellbore 112 can be enclosed by the intermediate casing 108. In some implementations, the location in the wellbore 112 at which the acidizing tool 116 is moved to can be an open hole portion (for example, with no casing present) of the wellbore 112. As depicted in
As depicted in
As shown in
While the acidizing tool 116 has been described as including a pair of projections 120a, 120b extending from a hub 118, other shapes and designs can be used for the acidizing tool. For example, in some implementations, the acidizing tool 116 can include three or more projections extending from a hub. Further, in some implementations, the projections 120a, 120b can each include two or more of openings positioned along the length of each projection 120a, 120b.
In some implementations, the acidizing tool 116 does not include any projections 120a, 120b. For example, in some implementations, the acidizing tool includes a body with a plurality of openings extending through the body, and the body of the acidizing tool is configured to rotate about the downhole conveyance 110 and provide acid to the wellbore 112 through the opening in the body of the acidizing tool.
As depicted in
The system 100 also includes an array of sensors 128a, 128b used to measure the radius of the portion of the wellbore 112 proximate to and surrounding the acidizing tool 116. As depicted in
While the sensors 128a, 128b for detecting the radius of the wellbore 112 are depicted in
As shown in
The control system 124, in some implementations, can send and receive data between itself and the sensors 128a, 128b and the acidizing tool 116. The control system 124 includes a power source, such as a battery, and, in some implementations, the control system 124 provides electrical power to the acidizing tool 116. In addition, the control system 124 can control and provide electrical power to the pump 117. In some implementations, power is provided to the acidizing tool 116 via power cables extending from the surface 102 through the wellbore 112 to the acidizing tool 116. In some implementations, a single electrical line (such as control line 111) can be used to provide both power and data transmission to the acidizing tool 116, pump 117, and sensors 128a, 128b. In some implementations, separate electrical lines are used to provide data communication and power to the acidizing tool 116, pump 117, and sensors 128a, 128b. In some implementations, the sensors 128a, 128b are battery powered. The control system 124 can perform one or more operations described in the present disclosure to operate all or parts of the acidizing tool 116, the sensors 128a, 128b, and the pump 117.
Referring to
Once the wellbore 112 is formed, acid is sprayed onto an inner wall of the wellbore 112 to form a subterranean cavern (150). As depicted in
As depicted in
Acid pumped from the acid source 126 to the acidizing tool 116 by pump 117 exits the acidizing tool 116 and is sprayed onto the inner wall 132 of the wellbore 112. For example, the acid pumped from the acid source 126 to the acidizing tool 116 exits the acidizing tool 116 through the openings 122a, 122b of projections 120a, 120b of the acidizing tool 116. In some implementations, based on the radius of the wellbore 112 detected by sensors 128a, 128b, the control system 124 determines the pressure of the acid exiting the openings 122a, 122b of the acidizing tool 116 required for the acid to reach the inner wall 132 of the wellbore 112. Based upon this determination, the control system 124 controls the pump 117 to generate sufficient fluid pressure in the fluid line 115 to provide the necessary pressure for the acid exiting the acidizing tool 116 to reach the inner wall 132 of the wellbore 112.
While acid is being pumped from the acid source 126 to the acidizing tool 116, the control system 124 controls the acidizing tool 116 to rotate within the wellbore 112. For example, the control system 124 controls the hub 118 of the acidizing tool 116 to rotate 360 degrees about the end of downhole conveyance 110. By rotating the acidizing tool 116 within the wellbore 112, the acid exiting the openings 122a, 122b of the acidizing tool 116 is distributed substantially evenly onto the inner wall 132 of the wellbore 112. In some implementations, the control system 124 controls the rate of rotation of the acidizing tool 116 within the wellbore 112. In addition, the control system 124 controls the fluid pressure provided by the pump 117 in order to control the rate of ejection of acid from the acidizing tool 116
As acid is applied by the acidizing tool 116 to the inner wall 132 of the wellbore 112, the acid erodes the portion of the subterranean formation 114 forming the inner wall 132. As a result, the radius of the wellbore 112 proximate the acidizing tool 116 increases to form a portion of a subterranean cavern. For example, as depicted in
As the acidizing tool 116 applies acid to the inner wall 132 of the wellbore 112, the sensors 128a, 128b coupled to the acidizing tool 116 continually measure the radius of the wellbore 112 and transmit signals to the control system 124 indicating the current radius of the wellbore 112. In some implementations, the sensors 128a, 128b are configured to transmit signals to the control system 124 in realtime. Realtime monitoring allows continuous monitoring to better control the subterranean cavern formation process.
For the purposes of this disclosure, the terms “real-time,” “real time,” “realtime,” “real (fast) time (RFT),” “near(ly) real-time (NRT),” “quasi real-time,” or similar terms (as understood by one of ordinary skill in the art) mean that an action and a response are temporally proximate such that an individual perceives the action and the response occurring substantially simultaneously. For example, the time difference for a response to display (or for an initiation of a display) of data following the individual's action to access the data may be less than 1 ms, less than 1 sec., less than 5 secs., etc. While the requested data need not be displayed (or initiated for display) instantaneously, it is displayed (or initiated for display) without any intentional delay, taking into account processing limitations of a described computing system and time required to, for example, gather, accurately measure, analyze, process, store, or transmit (or a combination of these or other functions) the data.
In some implementations, as the radius of the wellbore 112 increases due to the acid etching performed by the acidizing tool 116, the control system 124 controls the pump 117 to adjust fluid pressure of the acid provided to the acidizing tool 116. For example, if the signals provided by the sensors 128a, 128b indicate that the radius of the wellbore 112 proximate the acidizing tool 116 has increased, the control system 124 can cause the pump 117 to provide an increased fluid pressure in the fluid line 115 such that the acid exits the openings 122a, 122b of the acidizing tool 116 at an increased rate of ejection. Continually increasing the fluid pressure of the acid provided to the acidizing tool 116 as the radius of the wellbore 112 increases ensures the acid exiting the acidizing tool 116 is still able to reach the inner wall 132 of the wellbore 112.
Referring to
The acidizing tool 116 is continually moved uphole through the wellbore 112 while spraying acid onto the inner wall 132 of the wellbore 112, as described above, in order to form a lower portion 152 of a subterranean cavern 150, as depicted in
Referring to
In some implementations, in order to form the dome-shaped upper portion 154 of the subterranean cavern 150 (as depicted in
While the acidizing tool 116 is moving between the first angular position 142 and the second angular position 144, the control system 124 continues to control the pump 117 to pump acid from the acid source 126 to the acidizing tool 116 via the fluid line 115. In addition, the acidizing tool 116 continues to rotate about the end of the downhole conveyance 110 and spray acid onto the inner wall 132 of the wellbore 112.
The sensors 128a, 128b continually measure the radius 206 of the dome-shaped upper portion 154 of the subterranean cavern 150 as it is being formed by the acidizing tool 116, and transmit signals to the control system 124 indicating the radius 206 of the upper portion 154. Once the control system 124 receives a signal from the sensors 128a, 128b indicating that the radius 206 of the dome-shaped upper portion 154 of the subterranean cavern 150 is equal to a target radius, the control system 124 ceases movement of the acidizing tool 116 and controls the pump 117 to stop the flow of acid to the acidizing tool 116.
In some implementations, the dome shape of the upper portion 154 of the subterranean cavern 150 is configured to prevent the subterranean cavern 150 from collapsing. For example, based on rock elasticity theory, the crown of the dome-shaped upper portion 154 (“roof”) of the subterranean cavern 150 experiences the maximum tangential stress of the upper portion 154. However, as depicted in
As depicted in
At 606, liquid hydrocarbons are drawn from the subterranean cavern to the surface. Referring to
As depicted in
As depicted in
While the liquid level sensor 706 is depicted in
As depicted in
Referring to
As formation fluids flow from the subterranean formation 114 into the subterranean cavern 150, the various types of fluids separate through gravity separation. For example, as depicted in
Once the oil and water in the subterranean cavern 150 have separated into an oil column 804 and a water column 802, the oil in the oil column 804 can be removed from the subterranean cavern 150 and pumped to the surface 102. Referring to
As depicted in
Based on the position of the liquid level sensor 706 at the time that the liquid level sensor 706 detects each of the interfaces 810, 812, the control system 124 can determine the location of the bottom surface of the oil column 804 and the top surface of the oil column 804 within the subterranean cavern 150. Based on determining the location (for example, the depth) of the bottom and top surfaces of the oil column 804 within the subterranean cavern 150, the control system 124 can determine a position equidistant between the bottom and top surfaces of the oil column 804 in order to determine the location of the center of the oil column 804 within the subterranean cavern 150.
In response to determining the location of the center of the oil column 804 within the subterranean cavern 150, the control system 124 engages the downhole conveyance 710 to position the submersible pump 704 at the location identified as the center of the oil column 804. In some implementations, the depth of the submersible pump 704 within the subterranean cavern 150 is determined by the control system 124 based on signals received from one or more sensors (not shown) that indicate the number of turns that a reel coupled to the downhole conveyance 710 has completed. Based on the number of turns completed by the reel coupled to the downhole conveyance 710, the control system 124 can determine the length of the downhole conveyance 710 within the wellbore 112, which indicates the depth of the submersible pump 704 within the subterranean cavern 150. Once the submersible pump 704 is positioned in the center of the oil column 804, the control system 124 engages the submersible pump 704 to begin pumping oil out of the subterranean cavern 150 to the surface 102.
In some implementations, the control system 124 controls the submersible pump 704 to continue pumping until the control system 124 detects that a predetermined amount of oil has been pumped from the subterranean cavern 150 to the surface 102. In some implementations, the control system 124 controls the submersible pump 704 to continue pumping until the control system 124 receives a signal from the liquid level sensor 706 indicating detection of a water-gas interface 814, which indicates that the entire oil column 804 has been pumped from the subterranean cavern, as depicted in
The controller 900 is intended to include various forms of digital computers, such as printed circuit boards (PCB), processors, digital circuitry, or other hardware. Additionally the system can include portable storage media, such as, Universal Serial Bus (USB) flash drives. For example, the USB flash drives can store operating systems and other applications. The USB flash drives can include input/output components, such as a wireless transmitter or USB connector that can be inserted into a USB port of another computing device.
The controller 900 includes a processor 910, a memory 920, a storage device 930, and an input/output device 940. Each of the components 910, 920, 930, and 940 are interconnected using a system bus 950. The processor 910 is capable of processing instructions for execution within the controller 900. The processor can be designed using any of a number of architectures. For example, the processor 910 can be a CISC (Complex Instruction Set Computers) processor, a RISC (Reduced Instruction Set Computer) processor, or a MISC (Minimal Instruction Set Computer) processor.
In one implementation, the processor 910 is a single-threaded processor. In another implementation, the processor 910 is a multi-threaded processor. The processor 910 is capable of processing instructions stored in the memory 920 or on the storage device 930 to display graphical information for a user interface on the input/output device 940.
The memory 920 stores information within the controller 900. In one implementation, the memory 920 is a computer-readable medium. In one implementation, the memory 920 is a volatile memory unit. In another implementation, the memory 920 is a non-volatile memory unit.
The storage device 930 is capable of providing mass storage for the controller 900. In one implementation, the storage device 930 is a computer-readable medium. In various different implementations, the storage device 930 can be a floppy disk device, a hard disk device, an optical disk device, or a tape device.
The input/output device 940 provides input/output operations for the controller 900. In one implementation, the input/output device 940 includes a keyboard, a pointing device, or both. In another implementation, the input/output device 940 includes a display unit for displaying graphical user interfaces.
The features described can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. The apparatus can be implemented in a computer program product tangibly embodied in an information carrier, for example, in a machine-readable storage device for execution by a programmable processor; and method steps can be performed by a programmable processor executing a program of instructions to perform functions of the described implementations by operating on input data and generating output. The described features can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. A computer program is a set of instructions that can be used, directly or indirectly, in a computer to perform a certain activity or bring about a certain result. A computer program can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment.
Suitable processors for the execution of a program of instructions include, by way of example, both general and special purpose microprocessors, and the sole processor or one of multiple processors of any kind of computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for executing instructions and one or more memories for storing instructions and data. Generally, a computer will also include, or be operatively coupled to communicate with, one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits).
To provide for interaction with a user, the features can be implemented on a computer having a display device such as a CRT (cathode ray tube) or LCD (liquid crystal display) monitor for displaying information to the user and a keyboard and a pointing device such as a mouse or a trackball by which the user can provide input to the computer. Additionally, such activities can be implemented via touchscreen flat-panel displays and other appropriate mechanisms.
The features can be implemented in a control system that includes a back-end component, such as a data server, or that includes a middleware component, such as an application server or an Internet server, or that includes a front-end component, such as a client computer having a graphical user interface or an Internet browser, or any combination of them. The components of the system can be connected by any form or medium of digital data communication such as a communication network. Examples of communication networks include a local area network (“LAN”), a wide area network (“WAN”), peer-to-peer networks (having ad-hoc or static members), grid computing infrastructures, and the Internet.
While certain implementations have been described above, other implementations are possible.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any claims or of what may be claimed, but rather as descriptions of features specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, example operations, methods, or processes described herein may include more steps or fewer steps than those described. Further, the steps in such example operations, methods, or processes may be performed in different successions than that described or illustrated in the figures. Accordingly, other implementations are within the scope of the following claims.
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