TREA

Wellhead acoustic insulation to monitor hydraulic fracturing

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Information

  • Patent Grant
  • 11619127
  • Patent Number
    11,619,127
  • Date Filed
    Monday, December 6, 2021
    3 years ago
  • Date Issued
    Tuesday, April 4, 2023
    2 years ago
Information
Abstract
To monitor hydraulic fracturing operations, an acoustic insulation tool acoustically insulates a wellhead installed at a surface of a wellbore. Multiple acoustic sensors attached to the wellhead sense acoustic signals generated responsive to operation of hydraulic fracturing components. The components perform hydraulic fracturing operations within the wellbore. The acoustic insulation tool acoustically insulates the wellhead from acoustic signals generated by sources other than the hydraulic fracturing components. The multiple acoustic sensors transmit the sensed acoustic signals to a computer system. Using the received acoustic signals, the computer system monitors the hydraulic fracturing operations performed within the wellbore.
Description
TECHNICAL FIELD

This disclosure relates to wellbore operations, for example, hydraulic fracturing within wellbores.


BACKGROUND

Hydraulic fracturing is a stimulation treatment routinely performed on oil and gas wells. Hydraulic fracturing fluids are pumped into a hydrocarbon-bearing formation causing fractures to open in the subsurface formation. Proppants, such as grains of sand of a particular size, may be mixed with the treatment fluid to keep the fracture open when the treatment is complete. Hydraulic fracturing operations involve activation of sleeves disposed within the wellbore to permit flow of the hydraulic fracturing fluids onto the formation. The operations, including the opening of the sleeves, can be monitored to ensure efficient hydraulic fracturing.


SUMMARY

This disclosure describes technologies relating to wellhead acoustic insulation to monitor hydraulic fracturing.


Certain aspects of the subject matter described in this disclosure can be implemented as a method. An acoustic insulation tool acoustically insulates a wellhead installed at a surface of a wellbore. Multiple acoustic sensors attached to the wellhead sense acoustic signals generated responsive to operation of hydraulic fracturing components. The components perform hydraulic fracturing operations within the wellbore. The acoustic insulation tool acoustically insulates the wellhead from acoustic signals generated by sources other than the hydraulic fracturing components. The multiple acoustic sensors transmit the sensed acoustic signals to a computer system. Using the received acoustic signals, the computer system monitors the hydraulic fracturing operations performed within the wellbore.


An aspect combinable with any other aspect includes the following features. To acoustically insulate the wellhead, a wellhead flange of the wellhead is acoustically insulated.


An aspect combinable with any other aspect includes the following features. To acoustically insulate the wellhead flange, an acoustic insulation tool that includes acoustic insulation material is wrapped around an entirety of the wellhead flange.


An aspect combinable with any other aspect includes the following features. To acoustically insulate the wellhead flange, an acoustic insulation box that includes acoustic insulation material is placed around the wellhead that has the acoustic insulation tool wrapped around the entirety of the wellhead flange.


An aspect combinable with any other aspect includes the following features. The hydraulic fracturing components include a hydraulic fracturing sleeve. The operation of the hydraulic fracturing components includes activation of the hydraulic fracturing sleeve. The activation of the hydraulic fracturing sleeve generates the acoustic signals.


An aspect combinable with any other aspect includes the following features. The sources other than the hydraulic fracturing components that perform the hydraulic fracturing operations within the wellbore include surface equipment. To acoustically insulate the wellhead installed at the surface of the wellbore, an interference of acoustic signals generated by the surface equipment on the acoustic signals generated by the activation of the hydraulic fracturing sleeve is minimized.


An aspect combinable with any other aspect includes the following features. The acoustic insulation tool is formed by layering a first insulation material over a second insulation material.


An aspect combinable with any other aspect includes the following features. A gap is left between the first insulation material and the second insulation material when forming the acoustic insulation tool.


Certain aspects of the subject matter described here can be implemented as a system. The system includes an acoustic insulation tool that can be attached to a wellhead installed at a surface of a wellbore. The acoustic insulation tool is configured to acoustically insulate the wellhead from acoustic signals generated by equipment on the surface of the wellbore. Multiple acoustic sensors are attached to the wellhead. Each acoustic signal can sense acoustic signals generated by operation of hydraulic fracturing components that perform hydraulic fracturing operations within the wellbore. The acoustic insulation tool is positioned relative to the multiple acoustic sensors to filter the acoustic signals generated by the equipment on the surface of the wellbore from being sensed by the multiple acoustic sensors. The system includes a computer system connected to the multiple acoustic sensors. The computer system includes one or more processors and a computer-readable medium storing instructions executable by the one or more processors to perform operations. The operations include receiving, from the multiple acoustic sensors, the acoustic signals generated by the operation of the hydraulic fracturing components that perform the hydraulic fracturing operations within the wellbore. The received acoustic signals are insulated from the acoustic signals generated by the equipment on the surface of the wellbore. The operations include monitoring the hydraulic fracturing operations performed within the wellbore based on the received acoustic signals.


An aspect combinable with any other aspect includes the following features. The acoustic insulation tool can be attached to a wellhead flange of the wellhead.


An aspect combinable with any other aspect includes the following features. The acoustic insulation tool includes an acoustic insulation belt that includes acoustic insulation material that can be wrapped around an entirety of the wellhead flange.


An aspect combinable with any other aspect includes the following features. The multiple acoustic sensors are attached to the wellhead flange. The acoustic insulation belt can be wrapped over the multiple acoustic sensors.


An aspect combinable with any other aspect includes the following features. The acoustic insulation tool is a first acoustic insulation tool. The system includes a second acoustic insulation tool that can acoustically insulate the first acoustic insulation tool and the wellhead flange.


An aspect combinable with any other aspect includes the following features. The second acoustic insulation tool includes an acoustic insulation box that includes acoustic insulation material. The acoustic insulation box is positioned over the wellhead to cover the wellhead flange and the first acoustic insulation tool.


An aspect combinable with any other aspect includes the following features. The acoustic insulation box includes a layer of a first insulation material positioned over a layer of a second insulation material.


An aspect combinable with any other aspect includes the following features. The acoustic insulation box includes a gap between the layer of the first insulation material and the layer of the second insulation material.


The details of one or more implementations of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.





BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1 is schematic diagram of an example of an acoustic insulation tool wrapped around a wellhead flange of a wellhead of a wellbore.



FIG. 2A is a schematic diagram of an example of an acoustic insulation tool covering a wellhead of a wellbore.



FIG. 2B is a schematic diagram of an example of a portion of the acoustic insulation tool of FIG. 2A.



FIG. 3 is a schematic diagram of an example of an acoustic insulation tool wrapped around a wellhead flange and an acoustic insulation tool covering a wellhead of a wellbore.



FIG. 4 is a flowchart of an example of a process of acoustically insulating a wellhead to monitor hydraulic fracturing operations.





Like reference numbers and designations in the various drawings indicate like elements.


DETAILED DESCRIPTION

Hydraulic fracturing operations are performed using equipment disposed both on a surface of the wellbore and within the wellbore. Fracturing operations within the wellbore can be monitored by recording and analyzing acoustic signals such as those generated by the propagation of hydraulic fractures during the fracturing operations. Ambient noise by equipment disposed on the surface of the wellbore, for example, fracturing pumps, and/or noise by other surroundings at the surface of the wellbore can interfere with the low-amplitude acoustic signals generated within the wellbore. This disclosure describes techniques to minimize or eliminate the effect of such ambient noise on the acoustic signals generated within the wellbore.


The techniques described in this disclosure can be implemented to monitor hydraulic fracturing operations, for example, monitor the activation of hydraulic sleeves disposed within the wellbore using acoustic signals generated by such activation. In some implementations, a wellhead disposed at a surface of the wellbore is acoustically insulated. Acoustic sensors are attached to the wellhead, and acoustic signals sensed by the sensors are collected by a processor. In particular, when a hydraulic sleeve within the wellbore is activated, the activation generates a high-amplitude signal that can be detected by the sensors on the wellhead. The acoustic insulation filters out the ambient noise such that the acoustic signal received by the processor represents the hydraulic sleeve activation, not the ambient noise.


In some implementations, a first acoustic insulation tool, namely an acoustic insulation belt can be wrapped around a wellhead flange to insulate the wellhead. In some implementations, a second acoustic insulation tool, namely an acoustic insulation box, can be placed around the wellhead. Implementations in which the first acoustic insulation tool and the second acoustic insulation tool are used together are also described below. A data acquisition unit/processor (for example, a computer system) can receive the signals sensed by the acoustic sensors (for example, pressure transducers) and can monitor hydraulic sleeve activation based on the acoustic signals.


By acoustically insulating the wellhead as described in this disclosure, ambient noise by frac pumps and other surroundings at the surface can be reduced. Consequently, the techniques described here can enable monitoring and recording low-amplitude acoustic signals such as those generated by the propagation of hydraulic fractures (close to the wellbore and deep in the formation) during hydraulic fracturing operations. The techniques described here are applicable to both openhole multi-stage fracturing (MSF) completions as well as plug-and-perf cemented completions. The techniques described here can also minimize computational post-processing and filtering of acoustic signals by implementing physical filters, namely, the acoustic insulation tools. The techniques described here can also be used to detect wellbore events in plug-and-perf completions such as confirmation of plug settings.



FIG. 1 is schematic diagram of an example of an acoustic insulation tool 100 wrapped around a wellhead flange 102 of a wellhead 104 of a wellbore 106. The wellbore 106 can be formed through a subterranean zone (not labeled). The subterranean zone can include a formation, a portion of a formation, or multiple formations. A portion of the subterranean zone through which the wellbore 106 is formed can be hydraulically fractured using hydraulic fracturing components, for example, a hydraulic fracturing sleeve 108 disposed within the wellbore 106. The hydraulic fracturing components disposed within the wellbore 106 can be operated by hydraulic fracturing equipment 110 disposed at a surface 112.


In some implementations, multiple acoustic sensors (for example, acoustic sensor 114a, acoustic sensor 114b or more or fewer acoustic sensors) are attached to the wellhead 104. Each acoustic sensor can be a high-frequency acoustic sensor or pressure transducer or both that can record surface acoustic signals and surface pressures at a high frequency, for example, one reading every 10,000th of a second. The number of acoustic sensors attached to the wellhead can depend on several factors. The factors include space available to attach the acoustic sensors, available computational processing power to process acoustic signals sensed by the acoustic sensors, amplitude of the acoustic signal generated during operation of the hydraulic fracturing components disposed within the wellbore 106, a depth at which such components are disposed within the wellbore 106, other factors, or any combination of them. For example, the wellhead 104 can include the wellhead flange 100 at a base of the wellhead 104 such that the wellhead flange 100 directly and immediately contacts the surface 112. The acoustic sensors can be attached to the wellhead flange 100 at multiple locations on a circumference of the flange 100. Alternatively or in addition, the sensors (or additional sensors) can be attached to any component of the wellhead including components above the flange 100. In some implementations, each acoustic sensor can be made of a material that is a good conductor of sound and can be constructed in a manner that allows the acoustic sensor to be easily attached, i.e., connected to, the flange 100. For example, each acoustic sensor can be constructed like a clip that can be clipped onto the flange 100.


In some implementations, the acoustic isolation tool 100 is attached to the wellhead 104 at the surface 112 of the wellbore 106. For example, the acoustic isolation tool 100 is a belt made of acoustic insulation material having a width at least equal to a width of the wellhead flange 100 and a length at least equal to a circumference of the wellhead flange 100. Examples of acoustic insulation material into acoustic mineral wool, acoustic plasterboard, mass-loaded vinyl, closed-cell phone or any material with soundproofing capabilities. A thickness of the acoustic isolation tool 100 can be selected based on an expected amount of ambient noise at the surface 112 or a required amount of acoustic insulation or a combination of the two.


In some implementations, the acoustic isolation tool 100 can be wrapped over the multiple acoustic sensors such that the sensors are sandwiched between the acoustic isolation tool 100 and the flange 100. In such an arrangement, the acoustic isolation tool 100 acoustically insulates the wellhead 102, specifically the portion of the wellhead 102 that is connected to the multiple acoustic sensors, from ambient noise or other acoustic signals generated by equipment (for example, the hydraulic fracturing equipment 110) on the surface 112 of the wellbore 106. By doing so, the acoustic insulation tool 100 filters the acoustic signal generated by the equipment on the surface 112 from being sensed by the multiple acoustic sensors. Consequently, the only (or a majority of) acoustic signals sensed by the acoustic sensors originate from within the wellbore 106 and are due to operation of the hydraulic fracturing components within the wellbore 106. In some implementations, a longer length or width of the acoustic insulation tool 100 can be implemented to wrap an entirety of the wellhead 104 to further acoustically insulate the wellhead 104. In some implementations, acoustic sensors can be attached to portions of the wellhead 104 other than or in addition to the flange 102. In such implementations, the acoustic insulation tool 100 can be wrapped around any portion of the wellhead 104 to which acoustic sensors are attached.


In some implementations, each acoustic sensor is a pressure transducer that can sense pressure-induced sound and convert the sound into a digital signal. Each acoustic sensor is connected to a computer system 116 through wired or wireless connections or a combination of them to transfer the digital signal from each sensor to the computer system 116. The computer system 116 includes one or more processors (for example, a processor 118) and a computer-readable medium 120 (for example, a non-transitory computer-readable medium) storing computer instructions executable by the one or more processors to perform operations described in this disclosure.


In some implementations, the computer system 116 receives, from the multiple acoustic sensors, the acoustic signals generated by the operation of the hydraulic fracturing components (for example, the hydraulic sleeve 108) that perform the hydraulic fracturing operations within the wellbore 106. As described above, the received acoustic signals are insulated from the acoustic signal generated by the equipment on the surface of the wellbore 106. The computer system 116 monitors the hydraulic fracturing operations performed within the wellbore 106 based on the received acoustic signals.


In some implementations, the computer system 116 can deploy real-time visualization to monitor the hydraulic fracturing operations. To do so, the computer system 116 can receive, as input, data from two sources—the data from the acoustic/pressure sensors and real-time hydraulic fracturing data received from the hydraulic fracturing equipment 110, specifically from a fracking computer included in the hydraulic fracturing equipment 110. The computer system 116 can digitally integrate the data from the two sources and, in real time, generate a visualization, which the computer system 116 can display on a monitor (not shown). Such a visualization allows an operator of the hydraulic fracturing equipment 110 to identify characteristics sounds that are related to certain hydraulic fracturing operations such as an actuation ball being dropped into the wellbore 106 from the surface 112, landing on a ball seat disposed within the wellbore 106, functioning a downhole port and subsequently activating the hydraulic sleeve 108. By implementing the acoustic insulation tool 100, an effect of ambient noise on the data sensed by the acoustic sensors is minimized or eliminated. Consequently, the monitoring operations in prevented by the computer system 116 are improved.



FIG. 2A is a schematic diagram of an example of an acoustic insulation tool 200 covering the wellhead 104 of the wellbore 106. In some implementations, instead of the acoustic insulation tool 100 (i.e., the acoustic belt), another acoustic insulation tool 200 can be used to perform the same function as the acoustic insulation tool 100. For example, the acoustic insulation tool 200 can be an acoustic insulation box. The acoustic insulation box can be dimensioned to be positioned over the wellhead 104 to cover the wellhead 104 and the multiple acoustic sensors attached to the wellhead 104. The acoustic insulation box can be made of acoustic insulation material similar to those used to make the acoustic insulation tool 100. FIG. 2B is a schematic diagram of an example of a portion of the acoustic insulation tool 200. In some implementations, the acoustic insulation box is a cuboid with one open side to cover the wellhead 104. Each wall of the cuboid can be made with multiple layers of different insulation material positioned over each other. In some constructions, one or more or all of the walls of the cuboid can include a layer of the first insulation material 202 positioned over a layer of the second insulation material 204. In some constructions, a gap 206 can be left between the two layers 202 and 204 to create a room-within-a-room effect for improved acoustic insulation.



FIG. 3 is a schematic diagram of an example of the acoustic insulation tool 100 wrapped around the wellhead flange 102 and the acoustic insulation tool 200 covering the wellhead 104 of the wellbore 106. By implementing both acoustic insulation tools 100, interference of ambient signals on the acoustic signals sensed by the acoustic sensors can be further decreased.



FIG. 4 is a flowchart of an example of a process 400 of acoustically insulating a wellhead to monitor hydraulic fracturing operations. One or more steps of the process 400 can be performed by the acoustic insulation tools described above. One or more steps of the process 400 can be performed by the computer system 116 described above. At 402, an acoustic insulation tool (for example, the acoustic insulation tool 100 or the acoustic insulation tool 200 or both) acoustically insulates a wellhead (for example, the wellhead 102) installed at a surface (for example, the surface 112) of a wellbore (for example, the wellbore 106). At 402, multiple acoustic sensors sense acoustic signals generated responsive to operation of hydraulic fracturing components (for example, the hydraulic sleeve 108) that perform hydraulic fracturing operations within the wellbore. The acoustic insulation tool acoustically insulates the wellhead from acoustic signals generated by sources other than the hydraulic fracturing components that perform the hydraulic fracturing operations within the wellbore. For example, such sources can include the hydraulic fracturing equipment 110 disposed at the surface 112 of the wellbore 106. In the context of this disclosure, “a component disposed at the surface of the wellbore” means that the component is positioned at the surface of the wellbore at a distance from the wellhead such that noise generated by the component can affect acoustic signals sensed by the acoustic sensors described above. Thus, such components need not be directly connected to the surface, but instead can be positioned on other components, for example, platforms, that are directly connected to the surface. At 406, the multiple acoustic sensors transmit the sense acoustic signals to a computer system, for example, the computer system 116. At 408, the computer system, using the received acoustic signals, monitors the hydraulic fracturing operations performed within the wellbore. For example, the computer system 116 monitors the activation of the hydraulic sleeve 108 disposed within the wellbore 106. In some implementations, the computer system 116 deploys the real-time visualization described earlier to display an output of the monitoring to a hydraulic fracturing operator. Using the output of the computer system 116, the operator can control hydraulic fracturing operations.


In some implementations, the computer system 116 can use the acoustic signals filtered from the ambient noise using the acoustic insulation tools described above to monitor the propagation of hydraulic fracture in the subterranean zone. Because the input acoustic signals to the computer system 116 exclude (or include very minimal) ambient acoustic signals at the surface, the computer system 116 can detect fracture propagating within the wellbore 106. For example, the computer system 116 can detect a baseline acoustic signal level with an acoustic frequency within the wellbore 106 prior to commencing hydraulic fracturing operations. When the fracturing operations commence, higher frequency acoustic signals or increased overall noise within the wellbore 106 with hydraulic fracture. The computer system 116 can associate higher noise levels with larger fractures, larger generated overall fracture surface area or larger stimulated reservoir volume (SRV).


Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims.

Claims
  • 1. A method comprising: acoustically insulating, by an acoustic insulation tool, a wellhead installed at a surface of a wellbore;sensing, by a plurality of acoustic sensors attached to the wellhead, acoustic signals generated responsive to operation of hydraulic fracturing components that perform hydraulic fracturing operations within the wellbore, wherein the acoustic insulation tool acoustically insulates the wellhead from acoustic signals generated by sources other than the hydraulic fracturing components that perform the hydraulic fracturing operations within the wellbore; andtransmitting, by the plurality of acoustic sensors, the sensed acoustic signals to a computer system; andmonitoring, by the computer system and using the received acoustic signals, the hydraulic fracturing operations performed within the wellbore.
  • 2. The method of claim 1, wherein acoustically insulating the wellhead comprises acoustically insulating a wellhead flange of the wellhead.
  • 3. The method of claim 2, wherein acoustically insulating the wellhead flange comprises wrapping an acoustic insulation tool comprising acoustic insulation material around an entirety of the wellhead flange.
  • 4. The method of claim 3, wherein acoustically insulating the wellhead flange comprises placing an acoustic insulation box comprising acoustic insulation material around the wellhead having the acoustic insulation tool wrapped around the entirety of the wellhead flange.
  • 5. The method of claim 1, wherein the hydraulic fracturing components comprise a hydraulic fracturing sleeve, wherein the operation of the hydraulic fracturing components comprises activation of the hydraulic fracturing sleeve, wherein the activation of the hydraulic fracturing sleeve generates the acoustic signals.
  • 6. The method of claim 5, wherein the sources other than the hydraulic fracturing components that perform the hydraulic fracturing operations within the wellbore comprise surface equipment, wherein acoustically insulating the wellhead installed at the surface of the wellbore comprises minimizing an interference of acoustic signals generated by the surface equipment on the acoustic signals generated by the activation of the hydraulic fracturing sleeve.
  • 7. The method of claim 1, further comprising forming the acoustic insulation tool by layering a first insulation material over a second insulation material.
  • 8. The method of claim 7, further comprising leaving a gap between the first insulation material and the second insulation material when forming the acoustic insulation tool.
  • 9. A system comprising: an acoustic insulation tool configured to be attached to a wellhead installed at a surface of a wellbore, the acoustic insulation tool configured to acoustically insulate the wellhead from acoustic signals generated by equipment on the surface of the wellbore;a plurality of acoustic sensors attached to the wellhead, each acoustic signal configured to sense acoustic signals generated by operation of hydraulic fracturing components that perform hydraulic fracturing operations within the wellbore, wherein the acoustic insulation tool is positioned relative to the plurality of acoustic sensors to filter the acoustic signals generated by the equipment on the surface of the wellbore from being sensed by the plurality of acoustic sensors; anda computer system connected to the plurality of acoustic sensors, the computer system comprising: one or more processors, anda computer-readable medium storing instructions executable by the one or more processors to perform operations comprising: receiving, from the plurality of acoustic sensors, the acoustic signals generated by the operation of the hydraulic fracturing components that perform the hydraulic fracturing operations within the wellbore, wherein the received acoustic signals are insulated from the acoustic signals generated by the equipment on the surface of the wellbore; andmonitoring the hydraulic fracturing operations performed within the wellbore based on the received acoustic signals.
  • 10. The system of claim 9, wherein the acoustic insulation tool is configured to be attached to a wellhead flange of the wellhead.
  • 11. The system of claim 10, wherein the acoustic insulation tool comprises an acoustic insulation belt comprising acoustic insulation material and that is configured to be wrapped around an entirety of the wellhead flange.
  • 12. The system of claim 11, wherein the plurality of acoustic sensors are attached to the wellhead flange, and wherein the acoustic insulation belt is configured to be wrapped over the plurality of acoustic sensors.
  • 13. The system of claim 10, wherein the acoustic insulation tool is a first acoustic insulation tool, wherein the system further comprises a second acoustic insulation tool configured to acoustically insulate the first acoustic insulation tool and the wellhead flange.
  • 14. The system of claim 13, wherein the second acoustic insulation tool comprises an acoustic insulation box comprising acoustic insulation material, wherein the acoustic insulation box is positioned over the wellhead to cover the wellhead flange and the first acoustic insulation tool.
  • 15. The system of claim 14, wherein the acoustic insulation box comprises a layer of a first insulation material positioned over a layer of a second insulation material.
  • 16. The system of claim 15, wherein the acoustic insulation box comprises a gap between the layer of the first insulation material and the layer of the second insulation material.
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