The present invention relates to a downhole lost circulation while drilling remedial tool. More specifically, it relates to a tool arranged for detecting an undesired mud loss state, and, if such mud loss state is determined, to release from a drill string conveyed tank above the bottomhole assembly, a fluid which starts reacting with ambient water such as water from the drilling mud or the formation, and when entering cracks and fissures causing the mud loss, the reacting fluid will continue to react with water and expand to form a gel-like substance which blocks the cracks and fissures.
A major problem when a mud loss is detected, is the time it takes to circulate in remedial agents to stop the loss of mud or lost circulation if one is drilling at several kilometers depth in a well. Another problem is to introduce a remedial fluid such as cement or swelling material from the surface, which is known practice, because it is difficult to control in advance the time the remedial fluid shall use to set and cure. The amount of pumped remedial fluid may be tens of cubic metres.
The main purpose of the invention is, during drilling, to detect an undesired mud loss state and release a swellable sealant agent from a downhole tank to near the drilling bit and let it mix with water and cure the fracture causing the undesired mud loss. In an embodiment of the invention the mud loss state is detected downhole and action is automatically taken.
The U.S. Pat. No. 3,255,833A from 1966 identifies a problem regarding loss of the return circulation drilling fluid through so-called blind holes, and discloses a device and method to apply a wall-building paste around the drill bit for rotary well-drilling apparatus. Norwegian patent application NO20180753 discloses a device and a method for releasing a swellable agent from a drill pipe string conveyed annular tank near the drill bit in order to remedy loss of circulation. Further background art is mentioned in EP1653042A1, WO00/66878A1, US2007/0246225A1 and EP1653942A1.
The invention is defined in the attached claims.
Embodiments of the invention are illustrated in the attached drawing Figures.
The invention discloses a mud loss treatment drilling tool (1), please see
The purpose of the invention is that when an undesired mud loss is detected, either automatically or by the driller's observation of the drilling process, for flushing all or part of said swellable sealant agent (5) into said through channel (101), so as for a mixture (5, w) of said swellable agent (5) and said water (w) to start reacting to swell during the time it takes the mixture (5, w) to reach a fracture (f) extending from a well under drilling by said BHA, so as for continuing to swell and block said fracture (f) to stop said undesired mud loss.
In this way, part of the circulating mud is converted to a swellable pill, but the entire process takes place downhole near the drilling bit. In this way, the swelling mixture will reach the cause of undesired mud loss very fast because the swellable agent is stored near the drill bit and the transport path for the mixture is very short to the fracture or loss zone. In an embodiment the proportion is between 1:100 and 1:30, more preferably about 1:60.
An advantage of having a swelling agent which consumes the same water volume downhole as it “expands” to, there is no net volume increase, so the method should work under pressure and under varying pressure.
The sealing agent (5) may be dry, such as powder or small dried flakes or granulate or even extrusion rods, or wet, or wet, in a non-reacting fluid. In an embodiment the “tank” (10) may in an embodiment be a container (10) for push-out extrusion rods of solid swelling agent (5), not fluids. Equivalently, oppositely, the swellable sealant agent (5) arranged for mixing with oil (o) to swell; that would be the same, and is easily developed from this invention.
In an embodiment of the invention, please see
In an embodiment of the invention, the tool's (1) inlet (123) is arranged in an upper, inlet flow diverter sub (4) arranged on top of at least one of said tanks (10), and said inlet flow diverter sub (4) communicating from said through channel (101) via said inlet (123) to said tank (10). This provides displacement mud from the main bore (101) into the tank to displace the swelling agent (5) out of the opposite end through outlet (120). Having the inlet (120) arranged in a separate inlet flow diverter sub (4) makes it easier to assemble the tool (1) form a sub (4) component and one or more dual concentric pipes, and optionally a lower outlet flow diverter sub (6) forming together the tank (10) with a central bore/channel (101).
In an embodiment of the invention the tool (1) has a valve (12) (one or more) for opening the inlet (123) and/or sealing off said through channel (101) above said [lower] outlet (120), please see
In an embodiment the tool (1) further comprises said valve (12) being arranged at or below said inlet (123), preferably the inlet (123) is in the upper flow diverter sub (4), for closing said through bore (101) and opening the inlet (123) to the tank (10).
In an embodiment of the invention the tool (1), said valve (12) comprises an obturator seat (126S), see
In an embodiment of the invention the tool (1), wherein said inlet (123) it comprises an inlet rupture disc (129i) for sealing off said inlet (123) until a predefined differential pressure across said inlet rupture disc (129i) is exceeded.
The tool of the invention may comprise that said outlet (120) is arranged in an outlet flow diverter sub (6) arranged at a lower end of said tank (10), said flow diverter sub (6) communicating between said tank (10) via said outlet (120) to said through channel (101). This makes the assembly easy as one may only need to modify slightly a dual pipe sub being closed in the bottom of the annulus and having a through bore and a lateral port (120) in the inner pipe.
In an embodiment of the invention the tool (1)'s outlet (120) comprises an outlet rupture disc (129o) for sealing off said outlet (120) until a predefined differential pressure across the outlet rupture disc (129o) is exceeded.
In an embodiment of the invention the tool (1) comprises that said obuturator seat (126S) is part of a sliding sleeve valve (127) arranged in said through channel (101) wherein in a first position (P1) seals off said inlet (123) and when said sliding sleeve valve (127) is sled downhole by a force on said obturator seat (126S) into a second position (P2), said sliding sleeve valve (127) opens up said inlet (123). In an embodiment there is a burst disc at the outlet (120) and a ball operated sleeve valve at the inlet (123)
In an embodiment of the invention, the tool (1) comprises that an outlet obuturator seat (120S) is part of a sliding sleeve valve (120S) arranged in said through channel (101) wherein in a first position (O1) seals off said outlet (120) and when an outlet sliding sleeve valve (120o) is sled downhole by a force on said obturator seat (120S) into a second position (O2), said sliding sleeve valve (120o) opens up said outlet (120).
The general design of the outlet obturator seat (120S) in the lower part of e.g.
In an embodiment of the invention the tool (1) is comprising a ball valve (12, 124) and corresponding seat (preferably shear-out) for sealing off said through bore (101) below said inlet (123) and above said outlet (120), see e.g.
In an embodiment of the invention the tool (1), said through channel (101) being a through main bore (101) for said drilling fluid flow. Generally in this application the through channel (101) has been drawn axially, but this is no limitation and the through channel (101) may be excentrically arranged (or constituted by a partly plate-like separator structure through the tool such as a longitudinal partition wall between a through passage (101) and a tank (10)).
In an embodiment of the invention said through channel (101) is an axial through main bore (101) such as for dual drilling pipes. The outer wall has the mechanical structure sufficient to be used as drill pipe, the inner pipe shall only withstand the pressure difference between the tank (10) and the central bore (101)
In an embodiment of the invention, we have made an “inverted perforation gun”—release of the swellable sealing agent. Said valve (12) to said outlet (120) comprises one or more perforation charges (12C) arranged along a radially outer face of said central pipe (101i) and arranged for forming perforation holes (120C) inwardly radially between said tank (10) and said through channel (101). The perforation charges (12C) are ignited by a trigger mechanism (12Ct) which may comprise a ball seat and shear pin sleeve arranged in said central channel (101) and for being triggered by a ball landing and being pressurized in the ball seat, please see
In an embodiment of the invention we may use a so-called “slotted apertures central pipe” for the inner pipe wall of the tank. Please see
In an embodiment of the invention, a triggering mechanism constituted by a ball seat ( ) arranged below at least an upper of two or more of said slots (12S) with said slot plugs (12P), so as for a ball or dart or part-open dart (12B) to block said ball seat ( ) to increase pressure above said ball (12B). The partly or entirely blocked ball seat will result in an increasing pressure above it, and will trigger the release. The ball seat may be shearable so as to be caught below in a ball seat catcher. All ball catchers in the present invention have a bypass.
In an embodiment of the invention said tank (10) is annular about said through main bore (101). This is shown in all drawings, and optionally the tank is not annular but constitutes a sector parallel to the through bore which then also becomes a sector passage.
In an embodiment of the invention the tool (1) has arranged below said lower tooljoint (101L) one or more weight collars (2) with main bore (201) and a drill bit (3) forming part of said BHA assembly (2, 3). There may also be an MWD unit between the tool and the drill bit (3).
For drilling in a dominantly vertical direction, one usually has a series of weight collars (2) arranged behind the drill bit in order to have weight on the drill bit during drilling. Drill collars are similar to drill pipe string sections but have a thicker wall in order to provide weight on the bit. The series of weight collars (2) may be about 100 meters all together. These are connected in an upper end to the drill pipe string which is suspended in the drill rig, the drilling motor above the drilling deck. Another purpose of the drill collars is to provide rotational inertia directly connected to the drill bit. So above a neutral point (N) near or in the upper weight collar (2), there generally is axial tension in the drill pipe string which is suspended on the hook, and below the neutral point (N), there is compression in the weight collars (2) acting with an axially downward force on the rotating bit.
In an embodiment of the invention the tool (1) is arranged near above the neutral point (N) of the drill string, i.e. under drill pipe string axial tension or little axial tension, and above the drill weight collars (2). This is an advantage in case of suddenly occurring increased torsion moment resistance during rotational drilling, because the weight collars will have a large rotational inertia to temporarily meet the increased torsion moment resistance, allowing time for reducing the torque applied and/or weight on bit. Otherwise, the relatively thin-walled tank (10) section would directly meet and transfer the torsion moment resistance at the bit, and the main body (1) would risk torsional deformation and damage.
In an embodiment of the invention the tool (1) is arranged without drill weight collars (2) below it (such as illustrated in
In an embodiment of the invention said drill bit (3) has drilling fluid nozzles (301). The swelling of the swelling material (5) absorbing water from the drilling mud while passing from the outlet (120) toward the drill bit should not form so large or solid swollen lumps that they block the drilling fluid nozzles (301) in the bit. This is a task to manage for the chemist manufacturing the swelling agent (5).
In an embodiment of the invention the said upper flow diverter sub (4) comprises said valve (12) arranged for operating with two flow modes;
In an embodiment of the invention, said tank (10) comprises a pressure equalizer mechanism (9) for equalizing a pressure inside the tank (10) with a pressure in the through main channel (101), e.g. in the form a narrow equalizer channel and/or of an annular piston (121P) arranged between said swelling agent (5) in said tank and said through channel (101). This is so as for avoiding inadvertent release of the swelling agent (5) due to pressure differences across a valve or inlet rupture disc (129i) on said inlet (123) or said outlet rupture disc (129o) sealing off said outlet (120). Please see
In an embodiment of the invention said tank (10) comprises an annulus space (10ann) about an inner pipe (10inn) and within a concentric outer pipe (10out) of a so-called “dual pipe” (10D). This is illustrated in
In an embodiment of the invention there is arranged aid upper diverter sub (4) [with or without an inlet (123)], arranged on top of one or more said dual pipes (10D) further arranged on said lower diverter sub (6) with said outlet (120). A big advantage of this embodiment is that only the diverter subs (4, 6) have to be custom built.
In an embodiment the lower outlet (120) is provided with a lower valve (122). Please see
In an embodiment of the invention said lower valve (122) comprises a ball seat sliding sleeve (122S) for an obturator (122B) (ball or dart), please see
The tool is in an embodiment obturator-controlled. In an embodiment of the invention the tool (1) is alternatively, or supplementary, further comprising:
In a further embodiment the invention comprises:
The commands from surface are sent from an operator on the surface such as the driller as an response to indications of lost circulation.
Alternatively the commands from surface is sent from an surface control system with an algorithm for determining whether an undesired mud loss state is occurring. The downhole tool (1) may transmit to the surface simply that a loss of mud is detected, and wait for a confirmation to release the swelling agent (5), or act without confirmation.
In an embodiment of the invention a slow reacting pressure generating explosive charge in upper part of the tank (10)—release of the swellable sealing agent. is used. A slow combusting or slow reacting gas pressure generating charge (11) is arranged in an end portion of said tank (10) and arranged for breaking a rupture barrier (or move a piston) to said swellable matter (5) and force said swellable matter towards said outlet (120) which may comprise a rupture disc. There may be a narrow-channel and spacer buffered pressure equalizer mechanism behind the charge (11) so as for compensating for slow pressure variations relative to the tank (10) in the well. Please See
In an embodiment of the invention said charge (11) is ignited by a trigger mechanism (11Ct) comprising a ball seat and shear pin sleeve arranged in said central channel (101) and for being triggered by a ball landing and being pressurized in the ball seat.
Number | Date | Country | Kind |
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20191415 | Nov 2019 | NO | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/NO2020/050295 | 11/30/2020 | WO |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2021/107786 | 6/3/2021 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
3255833 | Kerr | Jun 1966 | A |
5343968 | Glowka | Sep 1994 | A |
5533570 | Streich | Jul 1996 | A |
6269878 | Wyatt et al. | Aug 2001 | B1 |
8047298 | Solhaug | Nov 2011 | B2 |
11578542 | Abdollahi | Feb 2023 | B2 |
20070246225 | Hailey, Jr. et al. | Oct 2007 | A1 |
20160201410 | Zhou | Jul 2016 | A1 |
20180340381 | Zhou | Nov 2018 | A1 |
20190249515 | Al-Shammari | Aug 2019 | A1 |
20200347686 | Carisella | Nov 2020 | A1 |
Number | Date | Country |
---|---|---|
104153738 | Nov 2014 | CN |
107429544 | Dec 2017 | CN |
1 653 042 | May 2006 | EP |
20180753 | Dec 2019 | NO |
WO 0066878 | Nov 2000 | WO |
Entry |
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International Preliminary Report on Patentability, issued in PCT/NO2020/050295, dated Feb. 11, 2022. |
International Search Report, issued in PCT/NO2020/050295, dated Mar. 22, 2021. |
Norwegian Search Report, issued in Priority Application No. 20191415, dated May 14, 2020. |
Written Opinion of the International Searching Authority, issued in PCT/NO2020/050295, dated Mar. 22, 2021. |
Number | Date | Country | |
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20230139705 A1 | May 2023 | US |