The invention generally relates to a technique and apparatus for drilling and completing a well in one half trip.
One way to drill a hydrocarbon well is to use the hydraulic power of drilling fluid (mud or water, as a few examples) to turn a drill bit. More specifically, a conventional drill string may include, among other components, a drill bit and a motor (called a “mud motor”) that is located near the bottom of the string above the drill bit. The drilling fluid typically flows from a mud pump at the surface of the well, through the central passageway of the drill string and returns to the mud pump via the annulus of the well. During drilling, the drill string remains stationary (as an example), and the drilling fluid exerts a rotational force on a rotor of the mud motor, which causes the drill bit (which is connected to the rotor) to turn. Besides driving the rotation of the drill bit, the drilling fluid may serve other functions, such as cooling off the drill bit, returning removed earth to the surface of the well and suppressing production.
A casing string may be installed as the well is being drilled. The installation of the casing string may be the first of many steps to complete the well, as typically, several downhole trips directed to well completion are made after the drilling operation. The downhole trips (defined as a round trip into and out of the wellbore) may include, for example, a trip to perforate the well and one or more trips to install production tubing, pumps, packers, liners, sand screens, etc. Each trip into the well typically increases the cost of completing the well.
Thus, there is a continuing need for better ways to reduce the number of downhole trips used to complete a well.
In an embodiment of the invention, a technique that is usable with a well includes running a motor into the well and actuating the motor to turn a drill bit. The motor is also used to pump well fluid from the well.
In another embodiment of the invention, an assembly that is usable with a well includes a tubular member, a shaft, a first actuator and a second actuator. The shaft is disposed in the tubular member. The first actuator is adapted to, in a motor mode of the assembly, turn the shaft in response to fluid that is communicated through the tubular member from the surface of the well. The second actuator is adapted to, in a pump mode of the assembly, turn the shaft to pump well fluid from downhole to the surface of the well.
In another embodiment of the invention, a system that is usable with a well includes a string, an isolation device, a drill bit and an assembly. The isolation device is adapted to be selectively activated to isolate an annular region outside of the string. The assembly is adapted to, in a first mode, turn the drill bit and, in a second mode, pump well fluid from downhole to the surface of the well.
Advantages and other features of the invention will become apparent from the following drawing, description and claims.
Referring to
The motor assembly 30 is constructed to operate in one of two different modes of operation. In a first mode of operation, the motor assembly 30 functions as a drilling fluid motor, or “mud motor,” for purposes of rotating a drill bit 34 of the bottom hole assembly 28. In a second mode of operation, the motor assembly 30 functions as a well fluid pump to pump well fluid through the string 20 to the surface of the well. Thus, in use, the motor assembly 30 is first operated in the first mode of operation for purposes of drilling a well and is then operated in the second mode of operation to pump well fluid from the well.
Therefore, the string 20 initially functions as a drill string, and as part of the drill string, the motor assembly 30 operates in its first mode of operation to rotate the drill bit 34 to extend the borehole, as depicted at reference numeral 14. The motor assembly's rotation of the drill bit 34 occurs in response to drilling fluid that circulates in a path, which includes the string's central passageway and an annulus 12 of the well. More specifically, the drilling fluid exits a mud pump (not shown) at the surface of the well to form a flow 16 through the central passageway of the string 20, and the flow 16 actuates the motor assembly 30 to cause the assembly 30 to rotate the drill bit 34. Upon exiting nozzles (not shown) near the drill bit 34, the drilling fluid forms a flow 18 (in the annulus 12) back to the surface of the well.
In addition to the bottom hole assembly 28, the string 20 may include various other components or tools, depending on the particular embodiment of the invention. For example, in accordance with some embodiments of the invention, the string 20 includes an isolation device 24 that may be activated, or “set,” to form an annular seal between the exterior of the string 20 and the surrounding wellbore or casing string 10, depending on whether the well is cased. More particularly, when the motor assembly 30 is in its first mode of operation (and therefore, used as a mud motor), the isolation device 24 remains de-activated, or unset, to leave the annulus 12 unrestricted and permit the return flow 18 of the drilling fluid to the surface of the well. However, as further described below, in its second mode of operation, the motor assembly 30 serves as a production fluid pump; and for this mode of operation, the isolation device 24 is activated to create a seal inside the annulus 12. More specifically, the activation of the isolation device 24 forms an annular seal to isolate the annular region below the isolation device 24 from the annular region above the isolation device 24.
Among its other features, in accordance with some embodiments of the invention, the bottom hole assembly 28 includes a circulation valve 38 that is closed in the first mode of operation of the motor assembly 30. However, for the second mode of operation of the motor assembly 30, the valve 38 is opened for purposes of facilitating well fluid flow into the central passageway of the string 20.
As depicted in
Thus, when operating in its second mode of operation, the motor assembly 30 functions to pump well fluid from the lower region 46 into the central passageway of the string 20, where the corresponding flow 50 is formed (due to the pumping by the motor assembly 30) to the surface of the well.
Due to the above-described two operational modes of the motor assembly 30, the well may be drilled and completed in only a half trip (i.e., the equipment is run into the well without being pulled out of hole), thereby potentially resulting in a substantial reduction in the cost of completing the well.
In accordance with other embodiments of the invention, a valve that is controlled by the pressure differential that is established by the motor assembly 30 may be substituted for the valve 38. This other valve may include radial ports that are designed (when the valve is open) to communicate fluid between the annulus and the central passageway of the string 20. Communication through the ports may be controlled by a rupture disk. During the drilling of the well, the pressure differential between the inside and the outside of the string 20 is not sufficient to rupture the disk. However, upon conversion of the motor assembly 30 into a production fluid pump, operation of the assembly 30 creates a local pressure depression (created by trying to pump the well fluid through nozzles of the bottom hole assembly 28, for example), which ruptures the disk and opens flow through the radial ports. Alternatively, the above-described pressure differential may be used in a valve (substituted for the valve) to shear a shear pin of the valve for purposes of freeing a mechanical sleeve (which is driven by the pressure differential) to open and allow communication through radial flow ports. Thus, many variations are possible and are within the scope of the appended claims.
Referring to
For purposes of simplifying the description of the dual modes of operation of the motor assembly 30, a simplified version of the bottom hole assembly 28 is depicted in
Referring to
In accordance with other embodiments of the invention, the string 20 may rotate during drilling. For example, in accordance with some embodiments of the invention, the string 20 may be formed from jointed tubing sections and may be rotated during drilling to increase the rate of penetration (ROP) and drilling operation's hole cleaning ability. Furthermore, in accordance with some embodiments of the invention, the bottom hole assembly 28 may include a bent sub for purposes of directional drilling, and as such, the string 20 may need to slide and rotate. Thus, many variations are possible and are within the scope of the appended claims.
In accordance with some embodiments of the invention, the motor assembly 30 also includes a pump actuator 150. The pump actuator 150 is connected to the shaft 170 for purposes of rotating the shaft 170 during the second mode of operation in which the motor assembly 30 functions as a well fluid pump. More specifically, the pump actuator 150 remains inactive during the first mode of operation, in which the assembly 30 functions as a drilling motor. At the conclusion of the first mode of operation, the flow of drilling fluid through the motor assembly 30 ceases, and the shaft 170 stops rotating. At this point, energy (hydraulic, mechanical or electrical, as examples) is supplied from the surface of the well to activate the pump actuator 150, an activation that causes the pump actuator 150 to turn the shaft 170.
More specifically, in accordance with some embodiments of the invention, when activated, the pump actuator 150 rotates the shaft 170 in an opposite direction from the rotation of the shaft 170 during the first mode. It is noted that the drill bit may or may not turn during the second mode of operation, depending on the particular embodiment of the invention.
The rotation of the shaft 170 by the pump actuator 150 causes the drilling actuator 160 to become a pump. In other words, due to the rotation of the shaft 170, the drilling actuator 160 creates a pressure drop that causes the motor assembly 30 to receive well fluid through the lower port 174 and communicate this well fluid through the upper port 151 into the central passageway of the string 20 to form the flow 50 (see
Although
Referring to
Referring to
As also depicted in
It is noted that an induction motor is one out of many different types of electrical motors that may be used as the pump actuator in accordance with some embodiments of the invention. Furthermore, actuators other than electrical-based actuators may be used in accordance with other embodiments of the invention. For example,
Alternatively, referring to
Referring back to
Referring to
In other embodiments of the invention, the packer 550 may include, for example, a downhole reservoir 560, which contains a triggering fluid to activate the swellable material 554. Thus, the swellable material 554 may be triggered by the release of the fluid in the reservoir 560 to swell, and this release may be initiated at the end of the drilling operation. The release of the triggering fluid may occur, for example, in response to a remotely-communicated command that is communicated via the drilling fluid, via an electrical cable, and acoustically, etc. Alternatively, the string 20 may include an isolation device that is formed from a combination of a compression-type packer and a swellable material.
Alternatively, in accordance with some embodiments of the invention, the swellable material 554 may have a controlled rate of swelling and also have the ability to shrink back again should an intervention be needed to retrieve the string 20 from the well. As yet another variation, a slug may be pumped through the string 20 from the surface of the well to initiate the swelling. In this regard, the inner diameter of the swellable material may be expanded by the slug. Once the swelling of the swellable material is initiated, the swelling may then be maintained by the produced flow.
As yet other examples, the isolation device 24 may be an inflatable packer or a combination of an inflatable packer with a swellable material, in accordance with other embodiments of the invention.
In accordance with some embodiments of the invention, the isolation device 24 may be alternatively installed on the casing string 10 instead of being part of the string 20. In this regard, the casing string 10 may include a special casing joint that contains the isolation device. As more specific examples (to name just a few), the joint may be lined with a swellable material or may include an inflatable packer.
The string 20 may include tools other than those described above in accordance with the various possible embodiments of the invention. For example, referring back to
The string 20 may also include a perforating gun that is fired prior to the beginning of the assembly's second mode of operation. As another example of a potential embodiment of the invention, the string 20 may include sensors for purposes of monitoring drilling and subsequent production from the well. Furthermore, in accordance with some embodiments of the invention, the string 20 may include chemical injection lines. Thus, many variations are possible and are within the scope of the appended claims.
The drilling operation may be an overbalanced or underbalanced drilling operation, depending on the particular embodiment of the invention. In this regard, underbalanced drilling may provide the advantages of time savings and the prevention of formation damage as the drilling nears the production zone. Additionally, the rate of penetration (ROP) may benefit as well from overburden drilling. In other embodiments of the invention, near balance, or managed pressure drilling, may be used in which some degree of pressure control is achieved via choking at the surface of the well.
Referring back to
Although the techniques and systems that are described herein are particularly advantageous for drilling and then subsequently pumping in a half trip, the techniques and systems may also be advantageous for operations that involve more than a half trip into the well. For example, during drilling, the string 20 may be retrieved for purposes of, for example, changing a drill bit for the case of a long borehole. Although more than one half trip is used, the string 20 is still ultimately used as a production pipe due to the dual use of the motor assembly 30, thereby saving additional trips into the well.
While the present invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
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Number | Date | Country | |
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20080029303 A1 | Feb 2008 | US |