Patent Application
20160201414
Embodiments of the present disclosure relate generally to the field of drilling and processing of wells. More particularly, present embodiments relate to a system and method for launching a cement plug during casing operations.
Cement plugs are typically utilized during casing operations to substantially remove cement from an interior surface of wellbore tubulars. In conventional oil and gas operations, an annulus is formed around the wellbore tubulars and a formation. During completion operations, casing (e.g., wellbore tubulars) may be secured to the formation via cementing. The cement is pumped through the casing to fill the annulus and secure the casing to the formation. After cement pumping is complete, the cement plug is introduced into the casing to clear the cement from the interior surface of the casing. As a result, cementing operations may continue with little to no mixing of cement with the drilling/displacement fluids pumped through the casing.
In accordance with one aspect of the disclosure a system includes a plug launching assembly, including a housing. The system also includes a first flow assembly of the plug launching assembly including a first primary flow path configured to direct a fluid flow into a wellbore. Moreover, the first flow assembly is configured to transition from a first position to a second position within the plug launching assembly. Also, the first flow assembly is releasably coupled to the housing while in the first position. The system further includes a second flow assembly of the plug launching assembly coupled to the housing and positioned downstream of the first flow assembly. The first flow assembly engages the second flow assembly while the first flow assembly is in the second position. The system also includes a cement plug releasably coupled to the second flow assembly. Furthermore, the cement plug is positioned within a second primary flow path of the second flow assembly while the cement plug is coupled to the second flow assembly. The system also includes a cement plug launcher of the first flow assembly configured to release the cement plug from a stored position, in which the cement plug is coupled to the cement plug launcher, to a release position. Also, the system includes a bypass line of the plug launching assembly configured to direct the fluid flow from the first flow assembly to the second flow assembly while the first flow assembly is in the first position.
In accordance with another aspect of the disclosure a system includes a ball launcher configured to release a ball into a wellbore and a cement swivel positioned downstream of the ball launcher. The cement swivel is configured to direct a flow of fluid into the wellbore. The system also includes a plug launching assembly positioned downstream of and fluidly coupled to the cement swivel, a first flow assembly of the plug launching assembly, and a second flow assembly of the plug launching assembly positioned downstream of the first flow assembly. The first flow assembly of the plug launching assembly includes a cement plug launcher configured to release a cement plug into the wellbore upon activation. Moreover, the system includes a gap of the plug launching assembly positioned between the first flow assembly and the second flow assembly while the first flow assembly is in a first position. The system also includes a bypass line of the plug launching assembly extending between the gap and the second flow assembly. The bypass line is configured to direct the flow of fluid from the gap to the second flow assembly while the first flow assembly is in the first position. Furthermore, the system includes an auxiliary flow line fluidly coupled to the first flow assembly and the second flow assembly. The auxiliary flow line is configured to direct the flow of fluid from the first flow assembly to the second flow assembly while the first flow assembly is in a second position. Also, a geometry of the first flow assembly engages with a corresponding geometry of the second flow assembly such that the first flow assembly substantially fills a volume of the gap while the first flow assembly is in the second position.
In accordance with another aspect of the disclosure a system includes a first flow assembly. The first flow assembly includes a first primary flow path having a first section having a first diameter and a second section having a second diameter, the first diameter being greater than the second diameter. The first flow assembly is configured to transition from a first position to a second position. The system also includes a second flow assembly including a second primary flow path and a plurality of flow ports configured to receive a flow of fluid from upstream of the second flow assembly and bypassing at least a portion of the second primary flow path. Moreover, the first flow assembly is engaged with the second flow assembly in the second position. The system further includes a housing configured to align the first flow assembly with the second flow assembly within the housing. The first flow assembly is positioned upstream of the second flow assembly and the first flow assembly is releasably engaged with the housing in the first position.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Present embodiments provide a cement plug launching assembly configured to provide a flow of a fluid around a plug launcher. For example, a bypass line is configured to direct the flow from a first primary flow path to a second primary flow path via flow ports disposed in a first flow assembly and a second flow assembly. Furthermore, an auxiliary flow line is configured to redirect flow around a blocked first primary flow path via flow ports disposed in the first and second flow assemblies. The plug launching assembly is configured to receive a ball to activate the plug launcher and release a cement plug disposed within the second flow assembly. In certain embodiments, the ball blocks the flow of fluid through the first primary flow path, thereby generating sufficient force to fracture shear pins and release the first flow assembly. As a result, the first flow assembly is configured to engage the second flow assembly and release the cement plug.
Turning now to the drawings,
A tubular drive system 40, hoisted by the traveling block 22, positions the tubular 38 above the wellbore 30. In the illustrated embodiment, the tubular drive system 40 includes a top drive 42, a gripping device 44, and a tubular drive monitoring system 46 (e.g., an operating parameter monitoring system) configured to measure forces acting on the tubular drive system 40, such as torque, weight, and so forth. For example, the tubular drive monitoring system 46 may measure forces acting on the tubular drive system 40 via sensors, such as strain gauges, gyroscopes, pressure sensors, accelerometers, magnetic sensors, optical sensors, or other sensors, which may be communicatively linked or physically integrated with the system 46. The gripping device 44 of the tubular drive system 40 is engaged with a distal end 48 (e.g., box end) of the tubular 38. The tubular drive system 40, once coupled with the tubular 38, may then lower the coupled tubular 38 toward the stump 36 and rotate the tubular 38 such that it connects with the stump 36 and becomes part of the casing string 28.
The drilling rig 10 further includes a control system 54, which is configured to control the various systems and components of the drilling rig 10 that grip, lift, release, and support the tubular 38 and the casing string 28 during a casing running or tripping operation. For example, the control system 54 may control operation of the gripping device 44 and the power slips 34 based on measured feedback (e.g., from the tubular drive monitoring system 46 and other sensors) to ensure that the tubular 30 and the casing string 28 are adequately gripped and supported by the gripping device 44 and/or the power slips 34 during a casing running operation. In this manner, the control system 54 may reduce and/or eliminate incidents where lengths of tubular 38 and/or the casing string 28 are unsupported. Moreover, the control system 54 may control auxiliary equipment such as mud pumps, robotic pipe handlers, and the like.
In the illustrated embodiment, the control system 54 includes a controller 56 having one or more microprocessors 58 and a memory 60. For example, the controller 56 may be an automation controller, which may include a programmable logic controller (PLC). The memory 60 is a non-transitory (not merely a signal), tangible, computer-readable media, which may include executable instructions that may be executed by the microprocessor 56. The controller 56 receives feedback from the tubular drive monitoring system 46 and/or other sensors that detect measured feedback associated with operation of the drilling rig 10. For example, the controller 56 may receive feedback from the tubular drive system 46 and/or other sensors via wired or wireless transmission. Based on the measured feedback, the controller 56 regulates operation of the tubular drive system 46 (e.g., increasing rotation speed).
In the illustrated embodiment, the drilling rig 10 also includes a casing drive system 70. The casing drive system 70 is configured to reciprocate and/or rotate the tubular 38 (e.g., casing) during casing and/or cementing operations. In the illustrated embodiment, the casing drive system 70 is placed above the rig floor 12. However, in other embodiments the casing drive system 70 may be placed beneath the rig floor 12, at the rig floor 12, within the wellbore 30, or any other suitable location on the drilling rig 10 to enable rotation of the tubular 38 during casing and/or cementing operations. As mentioned above, in certain embodiments, the control system 54 may control the operation of the casing drive system 70. For example, the control system 54 may increase or decrease the speed of rotation of the tubulars 38 based on wellbore conditions.
The casing drive system 70 may be used during cementing operations to direct cement into the casing string 28. In the illustrated embodiment, the casing drive system 70 is coupled to a cement swivel 72 configured to supply cement for cementing operations. For example, the cement swivel 72 may receive cement from a pumping unit 74 via a supply line 76. Additionally, the casing drive system 70 may include an inner bore configured to direct the cement through the casing drive system 70 and into the casing string 28. Moreover, the illustrated embodiment includes a ball launcher 78 positioned in the supply line 76 between the cement swivel 72 and the pumping unit 74. As will be described below, the ball launcher 78 is configured to introduce a ball into the cement swivel 72 to activate a cement plug launcher positioned downstream of the casing drive system 70. However, as will be described below, in other embodiments the cement plug launcher may be integral with the casing drive system 70, integral with the casing string 28, or located near the bottom of the wellbore 30.
As shown in
It should be noted that the illustration of
In the illustrated embodiment, the first and second flow assemblies 82, 84 are positioned within a housing 88. The housing 88 is configured to align the first flow assembly 82 with the second flow assembly 84. As will be described below, alignment of the first and second flow assemblies 82, 84 enables the first flow assembly 82 to activate a plug launcher disposed within the second flow assembly 84. In certain embodiments, the housing 88 enables the plug launching assembly 80 to couple to the casing drive system 70 (e.g., via threads, via flanges). Moreover, in the illustrated embodiment, the first flow assembly 82 is secured to the housing 88 via shear pins 90. The shear pins 90 are configured to support the weight of the first flow assembly 82 and a flow 92 of fluid (e.g., cement, drilling fluid) traveling through the first flow assembly 82 as represented generally by the arrows. In the illustrated embodiment, the flow 92 is substantially in the downward direction 86. However, as will be described below, upon release of the ball the shear pins 90 are configured to fracture to enable the first flow assembly 82 to move in the downward direction 86 toward the second flow assembly 84. While the illustrated embodiment depicts shear pins 90 configured to position the first flow assembly 82 above the second flow assembly 84, in other embodiments different attachment mechanisms with modes of operation (e.g., attached, detached, actuated, unactuated) may be utilized. For example, the first flow assembly 82 may be positioned on tracks or guide rails with an actuator configured to move the first flow assembly 82 in the downward direction 86.
The first flow assembly 82 includes a first primary flow path 94 configured to enable the flow 92 of fluid through the first flow assembly 82 and toward the second flow assembly 84. In the illustrated embodiment, the first primary flow path 94 is generally cylindrical and disposed substantially through the center of the first flow assembly 82. However, in other embodiments, the first primary flow path 94 may be disposed in any suitable alignment relative to the first flow assembly 82 based on the expected flow conditions. As shown, the first primary flow path 94 is fluidly coupled to a first flow port 96. In the illustrated embodiment and mode of operation, the first flow port 96 is substantially blocked by the housing 88. That is, little or no flow continues through the first flow port 96. In certain embodiments, seals are arranged around an outlet of the first flow port 96 to further block flow out of the first flow port 96 while the housing 88 is positioned proximate to the first flow port 96. As will be described below, the first flow port 96 is configured to align with a first auxiliary flow port after the first primary flow path 94 is blocked by the ball.
As described above, the first primary flow path 94 receive the flow 92 of fluid from the casing drive system 70. The first primary flow path 94 has a first diameter 98 in a first section 100 and a second diameter 102 in a second section 104. As shown, the first diameter 98 is larger than the second diameter 102. In the illustrated embodiment, the change in diameter between the first and second sections 100, 104 forms a shoulder 106 configured to receive the ball. In certain embodiments, the shoulder 106 includes seals configured to substantially block flow around the ball while the ball is positioned on the shoulder 106. Furthermore, the second section 104 of the first flow assembly 82 has an outer diameter 108 configured to align with the second flow assembly 84. As will be described below, the second section 104 of the first flow assembly 82 is configured to engage the second flow assembly 84 to release the cement plug.
In the illustrated embodiment, a gap 110 is positioned between the first flow assembly 82 and the second flow assembly 84 while the first flow assembly 82 is in a first position 120. While the first flow assembly 82 is in the first position 120, the shear pins 90 are configured to secure the first flow assembly 82 to the housing 88. However, in other embodiments (e.g., in embodiments using an actuator instead of shear pins), the first position 120 may be referred to as the position in which the first flow assembly 82 is not engaged with the second flow assembly 84. In the illustrated embodiment, the gap 110 is configured to enable movement of the first flow assembly 82 in the downward direction 86. In certain embodiments, the distance between the first and second flow assemblies 82, 84 (and, thereby, the height of the gap 110) may be 1 inch, 2 inches, 4 inches, 6 inches, 8 inches, 10 inches, 12 inches, or any suitable distance depending on the design conditions of the drilling rig 10. For example, in certain embodiments, the gap 110 may be as small as possible to minimize the size and weight of the plug launching assembly 80.
Furthermore, as described above, the gap 110 is configured to receive the flow 92 of the fluid as the fluid passes through the first flow assembly 82 (e.g., via an outlet 112). As a result, the gap 110 is sized to enable the flow 92 of the fluid through the first flow assembly 82 and toward a first bypass port 122. In certain embodiments, the first bypass port 122 is formed in the housing 88. However, in other embodiments, the first bypass port 122 may extend out of the housing 88 or be disposed in an annulus formed between the first and second flow assemblies 82, 84 and the housing 88. The first bypass port 122 is fluidly coupled to a bypass line 124 configured to direct flow from the gap 110 to the second flow assembly 84. In the illustrated embodiment, the bypass line 124 is formed in the housing 88. However, in other embodiments the bypass line 124 may extend out of the housing 88. For example, the bypass line 124 may be flexible tubing coupling the first bypass port 122 to the second flow assembly 84. As will be described below, the bypass line 124 is configured to direct the flow 92 around the cement plug 128 and into a second primary flow path 138 of the second flow assembly 84.
In the illustrated embodiment, the first flow assembly 82 includes a cement plug launcher 126. The cement plug launcher 126 is configured to release a cement plug 128 from a stored position 130 (e.g., coupled to the second flow assembly 84) to a released position. In certain embodiments, the cement plug launcher 126 may include a piston that extends to drive the cement plug 128 down the casing string 28. However, in other embodiments, the cement plug launcher 126 may include shear pins that break to release the cement plug 128 or any other suitable system to release the cement plug 128. For example, the cement plug launcher 126 may be coupled to the control system 54 and the release of the cement plug 128 may be controlled by activation of a sensor. As shown, a third section 132 of the second flow assembly 84 is configured to receive the first flow assembly 82 when the first flow assembly 82 is released from the first position 120. That is, an inner diameter 134 of the third section 132 is approximately equal to the outer diameter 108 of the second section 104. As a result, the second section 104 of the first flow assembly 84 is configured to engage the third section 132 of the second flow assembly 84 to release the cement plug 128.
As described above, the bypass line 124 is configured to provide the flow 92 of the fluid around the cement plug launcher 126 from the gap 110 to the second flow assembly 84. In the illustrated embodiment, a second bypass port 136 fluidly couples the bypass line 124 to a second primary flow path 138 of the second flow assembly 84. As shown, the second bypass port 136 is positioned downstream of the cement plug 128, thereby enabling the flow 92 to enter the second primary flow path 138 while the cement plug 128 is in the stored position 130.
While the bypass line 124 is configured to fluidly couple the gap 110 and the second flow assembly 84, an auxiliary flow line 140 is configured to fluidly couple the first flow assembly 82 and the second flow assembly 84. The auxiliary flow line 140 is configured to fluidly couple to the first flow port 96 of the first flow assembly 82 while the first flow assembly 82 is in the second position. That is, the first flow port 96 aligns with a first auxiliary flow port 142 when the first flow assembly 82 activates the cement plug launcher 126. Additionally, a second auxiliary flow port 144 couples the auxiliary flow line 140 to the second primary flow path 138 of the second flow assembly 84. As shown, the auxiliary flow line 140 is disposed within the housing 88. However, in other embodiments, the auxiliary flow line 140 may extend out of the housing 88 or be disposed in an annulus formed between the first and second flow assemblies 82, 84 and the housing 88. For example, the auxiliary flow line may be flexible tubing or another suitable tubular configured to transfer the flow 92 from the first flow assembly 82 to the second flow assembly 84. In the illustrated embodiment, the second auxiliary flow port 144 is positioned downstream of the cement plug 128. However, in other embodiments, the second auxiliary flow port 144 may be positioned upstream of the cement plug 128.
As described above, during casing and/or drilling operations the flow 92 of the fluid may be directed through the first primary flow path 94 into the gap 110. The flow 92 is blocked from exiting the first flow port 96 due to the placement of the housing 88 blocking the outlet of the first flow port 96. Moreover, in certain embodiments, seals are placed about the first flow port 96 to further block or reduce the flow from the first flow port 96 while the first flow assembly 82 is in the first position 120. The flow 92 of the fluid exits the gap 110 via the first bypass 122 and enters the bypass line 124. The bypass line 124 directs the flow 92 of the fluid around the cement plug 128 and into the second primary flow path 138 of the second flow assembly 84 via the second bypass port 136. As a result, drilling, casing, and/or cementing operations may continue while the cement plug 128 is in the stored position 130.
The blockage in the first primary flow path 94 is configured to generate a downward force in the first flow assembly 82. For example, the pressure of the fluid blocked in the first flow assembly 82 generates a force on the shear pins 90. Furthermore, in certain embodiments, the flow 92 may continue toward the first flow assembly 82, even with the blockage in place. As a result, as mentioned above, the shear pins 90 are configured to fracture. In certain embodiments, the shear pins 90 may be designed to resist a predetermined amount of pressure or hold for a predetermined amount of time after the ball 150 blocks the first primary flow path 94. For example, the shear pins 90 may be designed and calibrated to fracture one minute after the ball 150 reaches the shoulder 106. As will be described in detail below, the first flow assembly 82 is configured to move in the downward direction 86 after the shear pins 90 break to engage the second flow assembly 84.
In the illustrated embodiment, the movement of the first flow assembly 82 into the second position 152 enables the flow 92 of the fluid through the auxiliary flow line 140. As shown, the first auxiliary flow port 142 is aligned with the first flow port 96, thereby enabling the flow 92 through the auxiliary flow line 140 from the first primary flow path 94. Accordingly, the flow 92 of the fluid is configured to travel through the auxiliary flow line 140 and enter the second primary flow path 138 via the second auxiliary flow port 144. In certain embodiments, the flow 92 drives the cement plug 128 through the casing string 28. As a result, drilling, cementing, and/or completion operations may continue without removing the casing string 28 from the wellbore 30.
Moreover, as shown in
As described in detail above, the plug launching assembly 80 is configured to launch the cement plug 128 during casing operations via the ball launcher 78. The ball launcher 78 is configured to introduce the ball 150 into the supply line 76 supplying cement and/or drilling fluid to the cement swivel 72. The cement swivel 72 directs the flow 92 to the casing drive system 70, which directs the flow to the plug launching assembly 80. While the first flow assembly 82 is in the first position, the flow 92 of the fluid is configured to flow through the first flow assembly 82 and through the bypass line 124, thereby bypassing the cement plug 128 positioned downstream of the first flow assembly 82. However, once the ball 150 is introduced, the ball 150 is configured to block the flow 92 through the first primary flow path 94 of the first flow assembly 82. Due to the blockage, the shear pins 90 are configured to fracture, thereby enabling the first flow assembly 82 to move in the downward direction 86 and engage the second flow assembly 84. As a result, the cement plug launcher 126 is configured to release the cement plug 128. Moreover, once the first flow assembly 82 engages the second flow assembly 84 and is positioned in the second position 152, the first flow port 96 of the first flow assembly 82 is aligned with the first auxiliary flow port 142. As a result, the flow 92 through the first primary flow path 94 is re-directed through the auxiliary flow line 140 and around blockage formed by the ball 150. Accordingly, drilling fluid can bypass the ball 150 and, via the auxiliary flow line 140, flow through the second primary flow path 138 of the second flow assembly 84.
While the present disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and tables and have been described in detail herein. However, it should be understood that the embodiments are not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Further, although individual embodiments are discussed herein, the disclosure is intended to cover all combinations of these embodiments.
