Patent Grant
11840899
The present invention relates to apparatus and methods for well abandonment and slot recovery and in particular, though not exclusively, to a method of tuning elements of the bottom hole assembly in a vibratory casing recovery system to improve casing recovery.
When a well has reached the end of its commercial life, the well is abandoned according to strict regulations in order to prevent fluids escaping from the well on a permanent basis. In meeting the regulations it has become good practise to create the cement plug over a predetermined length of the well and to remove the casing. This provides a need to provide tools which can pull long lengths of cut casing from the well to reduce the number of trips required to achieve casing recovery. However, the presence of drilling fluid sediments, partial cement, sand or other settled solids in the annulus between the outside of the casing and the inside of a surrounding downhole body e.g. outer casing or formation can act as a binding material limiting the ability to free the casing when pulled. Stuck casings are now a major issue in the industry.
Traditionally, cut casing is pulled by anchoring a casing spear to its upper end and using the elevator/top drive on a drilling rig. However, some drilling rigs have limited pulling capacity, and when the casing may be stuck, there may be insufficient power at the spear to recover the stuck casing section. Consequently, further trips must be made into the well to cut the casing into shorter lengths for multi-trip recovery. As each trip into the well takes significant time and costs, techniques have been developed to reduce the number of trips into the well.
Vibration has been successfully used to assist in the removal of stuck objects in well bores. U.S. Pat. No. 7,077,205, the disclosure of which is incorporated herein in its entirety by reference, describes a method of freeing stuck objects from a bore comprising running a string into the bore, the string including a flow modifier, such as a valve, for producing variations in the flow of fluid through the string, and a device for location in the string and adapted to axially extend or contract in response to variations in the flow of fluid through the string. A portion of the string engages the stuck object. Fluid is then passed through the string while applying tension to the string, whereby the tension applied to the stuck object varies in response to the operation of the flow modifier and the extending or retracting device. This arrangement is offered as the Agitator™ to National Oilwell Varco, USA to assist in freeing a cut casing section when located below the casing spear.
A disadvantage in this approach is that the device which is adapted to axially extend or contract in response to variations in the flow of fluid is typically a shock sub which includes a spring. Those of skill in that art will note that shock subs are normally used for reducing shock and vibration-induced drilling string damage and bit wear. In such systems the spring is selected to provide a system having a natural frequency orders of magnitude lower than that of the frequency of vibrations expected to be experienced on the drill string. In this way, the vibrations experienced are a forcing frequency (Ω) which induces vibration of the system at its natural frequency (ω). Vibration theory teaches that the magnification ratio is at a maximum when Ω=ω and the system resonates. In shock subs the frequency ratio is designed to be much greater than one so that the dynamic amplification factor of the system, DAF<<1 so that the vibration is significantly reduced as it travels up the string. Accordingly, while the Agitator™ creates a forcing frequency with an input amplitude, the shock sub will effectively reduce the output amplitude which determines the variation in tension applied to the stuck object, due to the low DAF, providing an inefficient transfer of energy from the flow modifier to the stuck object.
It is also known to use resonance to free stuck drill pipes and other objects in wellbores as all stuck tubulars exhibit resonant frequencies that are a function of the free length of the tubular. U.S. Pat. No. 6,009,948 describes a system for performing a suitable operation in a wellbore utilizing a resonator. The system includes a resonator for generating pulses of mechanical energy, an engaging device for securely engaging an object in the wellbore and a sensor for detecting the response of the object to pulses generated by the resonator. The resonator is placed at a suitable location in the wellbore and the engaging device is attached to the object. The resonator is operated at an effective frequency to induce pulses into the object. The sensor detects the response of the object to the induced pulses, which information is utilized to adjust the operating frequency. In such a system the resonator must be selected to have a sufficient frequency range and must be capable of switching frequencies in the wellbore. Further the system requires electrical connections so that the sensor can operate and feedback signals to the resonator to change frequency. Such a system is therefore expensive and requires trained technicians to operate at a well.
It is an object of the present invention is to provide a method for casing recovery in which one or more elements of the bottom hole assembly are tuned to maximise the tension variations on the cut section of casing by vibration of the bottom hole assembly to aid its release.
According to a first aspect of the present invention there is provided a method of casing recovery in a wellbore, comprising the steps;
In this way, elements of the bottom hole assembly are tuned to be at or near the frequency of the flow modifier so that the system operates near resonance. Preferably, such a system provides a DAF>1. Consequently there is a magnification of the amplitude of variation on the tension applied to the casing to be removed which aids casing recovery.
Preferably, the at least one element is configured to have a resonant frequency in the assembly when vibrated wherein:
0.9<first frequency/resonant frequency<1.1.
By making the natural or resonant frequency at or near the first frequency and thereby tuning the elements to the frequency of the flow modifier, the dynamic amplification factor of the bottom hole assembly is maximised thereby maximising the vibration experienced by the cut section of casing at the anchor point to the gripping mechanism.
The flow modifier may comprise an oscillating or rotating member, and is preferably in the form of a rotating valve, such as described in WO97/44565, the disclosure of which is incorporated herein by reference, although other valve forms may be utilised. The rotating valve may be driven by an appropriate downhole motor powered by any appropriate means, or a turbine, and most preferably by a fluid driven positive displacement motor (PDM).
The extension and retraction means preferably comprises a housing forming part of a string and containing a fluid flow or pressure actuated member and an oppositely acting biasing arrangement, fluid pressure or flow tending to actuate the member in one direction and the biasing arrangement acting in the opposite direction. Conveniently, the member is a piston and the biasing arrangement a spring; in the preferred arrangement an increase in pressure tends to move the piston in one direction, extending the housing, a decrease in fluid pressure allowing the spring to retract the housing. Those of skill in that art may recognise that these features may be found in downhole shock tools or shock absorbers, as normally used for reducing shock and vibration-induced drilling string damage and bit wear. They are also found in accelerators used for isolating the rig equipment from a downhole jarring force.
Preferably, the at least one element comprises the string and all tools suspended from the flow modifier wherein a length of the bottom hole assembly between the extraction and retraction means and an end of the string inside the casing to be recovered is selected to provide the natural frequency. More particularly, a weight of the bottom hole assembly between the extraction and retraction means and an end of the string inside the casing to be recovered is tuned to be near or at the first frequency. In this way, the mass of the bottom hole assembly below the extraction and retraction means will determine the amplitude variation in the vibration and thereby quantify the force of the cyclical loading on the casing to be removed at the anchor point.
Alternatively or additionally, the at least one element may be one or more pipe members arranged between the extension and retraction means and the casing spear wherein a length between the gripping mechanism and the extension and retraction means is selected to provide the natural frequency. In this way, the pipe members are tuned so as to transmit the maximum vibrational energy to the casing to be recovered at the anchor point.
Preferably, the pipe members may be drill collars. Alternatively, the pipe members may be drill pipe and more preferably a heavy-weight drill pipe.
The method may include providing a downhole pulling tool on the string above the vibratory casing recovery bottom hole assembly and using the downhole pulling tool to pull the vibratory casing recovery bottom hole assembly and casing to be recovered before pulling the string to recover the casing. In this way, a high static load can be applied to the casing to be recovered which in turn increases the dynamic amplification factor to further increase pulling capacity.
The method may include the additional steps of providing a casing cutter in the vibratory casing recovery bottom hole assembly and cutting casing to provide a cut section of casing to be removed on the same trip as recovering the casing.
Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as “including,” “comprising,” “having,” “containing,” or “involving,” and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term “comprising” is considered synonymous with the terms “including” or “containing” for applicable legal purposes.
All numerical values in this disclosure are understood as being modified by “about”. All singular forms of elements, or any other components described herein including (without limitations) components of the apparatus are understood to include plural forms thereof.
It is also realised that terms such as ‘above’ and below’ are relative and while the description assumes a perfectly vertical wellbore, the invention can be used on deviated wellbores.
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings of which:
Reference is initially made to
The tool string 16 is a drill string typically run from a rig (not shown) via a top drive/elevator system which can raise and lower the string 16 in the well 10. The well 10 has a second casing 14. Casing 14 has a greater diameter than casing 12. In an embodiment, length of casing 12 is 9⅝″ diameter while the outer casing is 13⅜″ diameter.
Casing 12 will have been cut to separate it from the remaining casing string. In an embodiment the vibratory casing recovery bottom hole assembly 11 includes a casing cutter 23 and the casing 12 is cut on the same trip into the well 10 as that to recover it. The cut section of casing 12 may be over 100 m in length. It may also be over 200 m or up to 300 m. Behind the casing 12 there may be drilling fluid sediments, partial cement, sand or other settled solids in the annulus between the outside of the casing 12 and the inside of a surrounding downhole body, in this case casing 14 but it may be the formation of the well 10. This material 26 can prevent the casing 12 from being free to be pulled from the well 10. It is assumed that this is the position for use of the present invention.
Casing spear 20 operates to grip the inner surface 62 of the length of casing 12. The casing spear anchors via a gripping mechanism being slips 66 designed to ride up a wedge and by virtue of wickers or teeth on its outer surface grips and anchors to the inner surface 62 of the casing 12. The casing spear 20 includes a switch which allows the casing spear to be inserted into the casing 12 and hold the slips in a disengaged position until such time as the grip is required. At this time, the casing spear 20 is withdrawn from the end 64 of the casing 12 and, as the switch exits the casing 12, it automatically operates the slips which are still within the casing 12 at the upper end 64 thereof. This provides the ideal setting position of the spear 20. In a preferred embodiment the casing spear 20 is the Typhoon® Spear as provided by Ardyne AS. The Typhoon® Spear is described in WO2017/059345, the disclosure of which is incorporated herein in its entirety by reference.
The flow modifier 24 is a circulation sub which creates fluid pulses in the flow passing through the device. This can be achieved by a rotating member or a rotating valve. In the embodiment shown the flow modifier 24 contains a positive displacement motor (PDM) and a rotating valve, such as described in WO97/44565, the disclosure of which is incorporated herein by reference. The valve includes a valve member which is rotated or oscillated about a longitudinal axis by the PDM and in doing so varies the flow area of the valve. This creates a cyclical or periodic variation in the fluid flow at a frequency. This frequency is determined by the size of plates or valve members and is typically 15 to 20 Hz.
Above the flow modifier 24 is a shock sub 22, as is illustrated in greater detail in
In a preferred embodiment the flow modifier 24 is the Agitator™ System available from National Oilwell Varco. It is described in U.S. Pat. No. 6,279,670, the disclosure of which is incorporated herein in its entirety by reference. The use of the flow modifier 24 with a shock sub 22 is described in U.S. Pat. No. 7,077,295, the disclosure of which is incorporated herein in its entirety by reference. In U.S. Pat. No. 7,077,295, the cyclic variation in the flow modifier is used to induce an axial variation in the shock sub at the same frequency. However, the spring 38 will have its own natural frequency or resonant frequency determined by its design (spring constant) and the mass it carries. In standard shock subs used to reduce the transmission of vibrations up a drill string, the spring is deliberately selected so that the natural or resonant frequency (ω) is far away, typically at least 20 times, different than that of the frequency of vibration, forced frequency (Ω) expected to be experienced. In the present invention, the reverse is the case.
In the present invention we can consider the shock sub 22 and the tools suspended from it as a spring-mass system. This system will have a natural frequency, ω. Standard vibration theory gives a relationship of:
ω=(½π)×(k/m)0.5
were k is the stiffness of the spring and m is the mass of the suspended tools. When the system is subjected to a forced frequency Ω, being the frequency of the cyclic variation in flow through the flow modifier 24, the amplitude of vibrations in the system will be determined from the magnification ratio M and the damping ratio ζ, according to the classic relationship:
M=1/{[1−(Ω/ω)2]2+4ζ2(Ω/ω)2}1/2
This is shown in
The flow modifier 24 will provide the forced frequency Ω in operation. This is typically 15 and 20 Hz for the Agitator™ supplied by NOV. The shock sub 22 and tools 24, 23 suspended from it on the string 16, are designed to provide a natural frequency ω, wherein the frequency ratio Ω/ω is close to 1. The frequency ratio may be between 0.6 and 1.2. It can be seen that for a damping ratio, ζ=0, the magnification ratio M=>1.6. Thus the amplitude of the vibration from the flow modifier 24, is magnified by at least 1.6 upon the system. In an embodiment, the frequency ratio is between 0.9 and 1.1. Therefore by tuning the system of the bottom hole assembly, to be close to or at the output frequency of the flow modifier, the system can be near or at resonance, causing a magnification of the amplitude of the vibration on the system.
As shown in
In the embodiment shown the string 16 also comprises a hydraulic jack 18. The hydraulic jack 18 is located above the casing spear 20 and a pressure drop sub may be located below the casing cutter 23 form part of the vibratory casing recovery bottom hole assembly 11.
The hydraulic jack 18 has an anchor 28 and an actuator system which pulls an inner mandrel 30 up into a housing of the jack 18. In a preferred embodiment the hydraulic jack is the DHPT available from Ardyne AS. It is described in U.S. Pat. No. 8,365,826, the disclosure of which is incorporated herein in its entirety by reference.
The anchor 28 of the jack 18, like the casing spear 20, has a number of slips 52 which are toothed to grip an inner surface 60 of the casing 14.
A pressure drop sub or valves can be used to create a build-up of fluid pressure in the throughbore 68 when fluid is pumped down the string 16. This is used to create pressure at the jack 18 for operating the hydraulic jack 18.
In a casing recovery operation, the string 16 is run into the well 10 with the flow modifier 24, shock sub 22, drill collars 21 and casing spear 20 being run-in the casing 12. The string 16 is raised to a position to operate the switch on the casing spear 20 and the slips 66 automatically engage the inner surface 62 of the casing 12 at the upper end 64 thereof. At this stage the string 16 can be pulled via the top drive/elevator to see if the casing 12 is stuck. Fluid pumped down the string 16 will operate the flow modifier 24 and create vibration of the bottom hole assembly 11. As the shock sub 22 is tuned to be at or near the frequency of the output of the flow modifier 24, an enhanced vibratory force will be experienced by the cut section of casing 12. Raising the string 16 can be done again to see if the material 26 has been dislodged sufficiently to allow the casing 12 to be recovered. If the casing 12 still does not move then the downhole pulling tool i.e. jack 18 is operated.
Referring now to
With fluid flowing down a throughbore 68 of the string 16, the pressure of the fluid will build up by virtue of restrictions at nozzles of the pressure drop sub. At the same time, the fluid flow through the flow modifier 24 will create pressure pulses seen as a cyclic variation of pressure and consequently applied load via the shock sub 22. The flow modifier 24 provides output at a frequency of less than 20 Hz and preferably between 15 and 20 Hz. The shock sub 22 is induced to oscillate at this frequency and as it closely matches the natural frequency of the sub 22 and tools suspended therefrom it will resonate the bottom hole assembly 11 causing periodic or cyclical loading on the casing 12 via the slips 66 of the casing spear 20. The amplitude of the cyclic variations can be selected via the spring load on the shock sub 22 due to the mass of elements in the string 16 below the shock sub 22 to determine the axial extent of the oscillatory movement on the assembly 11 and casing 12.
Build up of fluid pressure at the hydraulic jack 18 creates a fluid pressure which is sufficient to move inner pistons within the jack, so forcing the inner mandrel 30 upwards into the housing 32. As the inner mandrel 30 is connected to the casing spear 20 which is in turn anchored to the length of casing 12, the force on the length of casing will match the applied load of the pressure. This force is a large static load used to raise the assembly 11 and cut section of casing 12 and should be sufficient to release the casing 12 and allow it to move. At the same time, the casing 12 will vibrate or axially oscillate at the or near the resonant frequency by virtue of the shock sub 22 and tools suspended therefrom, being tuned to the output frequency of the flow modifier 24. Such vibration has been shown to assist in releasing stuck casing and thus this action can assist during the pulling of the casing 12 by the jack 18. Note that the high static load applied by the hydraulic jack 18 does not decrease the dynamic amplification factor DAF=((dynamic load+static load)/(static load). For the system with only a static load, DAF<<1. In the present invention, DAF>1.
It is hoped that the jack 18 can make a full stroke to give maximum lift to the casing 12. This is illustrated in
Raising the string 16 will now lift the housing 32 with respect to the inner mandrel 30, to re-set the jack 18 in the operating position as illustrated in
If the casing 12 remains stuck, the anchor 28 is re-engaged as illustrated in
As long as fluid is pumped down the throughbore 68, the flow modifier 24 and shock sub 22 will operate and resonant axial movement is induced in the assembly 11 to aid casing removal.
It will be appreciated by those skilled in the art that the use of the hydraulic jack 18 and pressure drop sub 24 is optionally and the casing 12 may be recovered using only the casing spear 20 with the flow modifier 24 and shock sub 22 in the bottom hole assembly 11. Additionally, any devices which cause periodic axial loading on the anchor point can be used as the flow modifier 24 and shock sub 22.
In a further embodiment, a length of connecting pipe is provided between the casing spear 20 and the shock sub 22. This connecting pipe may be formed as one or more drill collars 21 or lengths of drill pipe which may be heavy weight drill pipe. The distance between the anchor point of the slips 66 and the shock sub 22, can be adjusted by increasing and decreasing the length of drill collars 21. This length can be set to create resonance along the drill collars which is at a natural resonant frequency equal to the frequency of the output of the flow modifier 24. By tuning this element of the bottom hole assembly 11, the dynamic amplification factor can be maintained as the maximum vibrational energy is transmitted with the minimum losses to the casing 12.
The principle advantage of the present invention is that it provides a method of recovering longer lengths of casing by tuning the tuning elements of the bottom hole assembly to the frequency output of a fluid modifier.
A further advantage of the present invention is that it provides a method of vibratory enhanced casing recovery which increases cyclical loading on the casing to help dislodge material behind the casing.
The foregoing description of the invention has been presented for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. The described embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilise the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Therefore, further modifications or improvements may be incorporated without departing from the scope of the invention herein intended with the invention being defined within the scope of the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1902058 | Feb 2019 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2020/053796 | 2/13/2020 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2020/165364 | 8/20/2020 | WO | A |
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| Number | Date | Country | |
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| 20220145718 A1 | May 2022 | US |
