US20120073814A1 - Expansion against cement for zonal isolation - Google Patents

Expansion against cement for zonal isolation Download PDF

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Publication number
US20120073814A1
US20120073814A1 US13/260,958 US201013260958A US2012073814A1 US 20120073814 A1 US20120073814 A1 US 20120073814A1 US 201013260958 A US201013260958 A US 201013260958A US 2012073814 A1 US2012073814 A1 US 2012073814A1
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Prior art keywords
cement
expansion
tubular
annulus
pipe
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US13/260,958
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Devendra R. Algu
James Frank Heathman
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Enventure Global Technology Inc
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Assigned to SHELL OIL COMPANY reassignment SHELL OIL COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HEATHMAN, JAMES FRANK, ALGU, DEVENDRA R.
Publication of US20120073814A1 publication Critical patent/US20120073814A1/en
Assigned to ENVENTURE GLOBAL TECHNOLOGY, LLC reassignment ENVENTURE GLOBAL TECHNOLOGY, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SHELL OIL COMPANY
Assigned to ENVENTURE GLOBAL TECHNOLOGY, L.L.C. reassignment ENVENTURE GLOBAL TECHNOLOGY, L.L.C. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
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    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00—Sealing or packing boreholes or wells
    • E21B33/10—Sealing or packing boreholes or wells in the borehole
    • E21B33/13—Methods or devices for cementing, for plugging holes, crevices or the like
    • E21B33/14—Methods or devices for cementing, for plugging holes, crevices or the like for cementing casings into boreholes

Definitions

  • the invention relates to the use of cementitious materials outside of a downhole tubular as a means for providing zonal isolation after expansion of a tubular.
  • cementitious materials including but not limited to Portland cements, resins, blast-furnace slag, and blends of those materials, are typically placed in the annulus between the casing and the wellbore so as to isolate and protect the casing during drilling, completion, and operation of the well. Once pumped in place and allowed to harden, these materials provide isolation between the various formations and between the formations and surface such that the hydrocarbons can be safely produced, or alternatively the wellbore can be used for injection operations.
  • the hardened cement may not fill the annuls as completely as desired.
  • the hardened cement may be subjected to mechanical damage—stress fractures and/or separation from the casing wall (debonding)—such that hydraulic isolation may be jeopardized.
  • mechanical damage stress fractures and/or separation from the casing wall (debonding)—such that hydraulic isolation may be jeopardized.
  • mechanical failure of the cement may cause zonal isolation is lost.
  • Expansion can be carried out using a top-down technique, in which an expansion tool starts at the upper end of the expandable tubular and is pushed through the tubular until it has expanded the full length of the tubular, or using a bottom-up technique, in which an expansion tool starts at the bottom of the tubular and is pulled upward through the tubular. Regardless of which technique is used, if the tubular is not anchored, it will move with the expansion tool. Without movement of the expansion tool relative to the tubular, expansion will not occur.
  • top-down expansion techniques the downward force of the expansion tool on the tubular can be resisted by anchoring the tubular to an adjacent tubing string or applying an upwards force by some other means.
  • bottom-up expansion it is typically desirable to leave the top end of the tubular free to move within the borehole, so as to allow for the axial shrinkage of the tubular will occur during expansion. Therefore, it may not be practical to use top-anchoring techniques and it may be desirable to anchor the lower end of the tubing instead.
  • One way to perform a bottom-up expansion is to use a mechanical jack.
  • the mechanical jack works within the tubular and expands a section of the tubular without requiring additional outside forces to be applied to the tubular.
  • the localized expansion serves to anchor the tubular string in the wellbore sufficiently that the expansion tool can then be pulled through the tubular.
  • a jack can be used to expand and anchor the lower end of a tubular for a bottom-up expansion.
  • Another well-established method for expanding tubulars in a wellbore uses only hydraulic pressure.
  • means are provided for means for achieving or improving zonal isolation in situations where it is not practical to access the annulus, such as when cement has already hardened in the annulus.
  • zonal isolation between formations along a borehole is improved by a) providing a pipe in the borehole, wherein at least a portion of the pipe lies between the formations, b) providing a body of cement in the annulus between the borehole wall and said pipe portion, c) allowing the body of cement to cure until it has reached at least 70 Bearden units consistency, and d) expanding said pipe portion so as to decrease the cross-sectional area of the annulus between the borehole wall and said pipe portion.
  • Step d) may eliminate fluid channels in the cement body and/or increase the density of the cement body.
  • Step c) may or may not cause the second cement body to fracture.
  • the method may further include providing a second cement body in the annulus, wherein the second cement body has a longer cure time than the first cement portion. The second cement body is not necessarily cured when step d) is carried out.
  • At least one of the cement bodies may contain ringing gels and/or other polymers.
  • the method may further include the step of providing an exit path for water expelled from the cement during expansion.
  • the hardened cement material is designed to have specific mechanical properties such that it can withstand sufficient forces to allow the tubular to be radially expanded to a larger diameter.
  • Some embodiments of the invention include a two-slurry approach in which a relatively rapid-hardening cement slurry is placed in the annulus around the lower portion of the tubular to be expanded, and a second, slower-setting slurry is placed around a second portion of the tubular and does not harden until after the expansion process is complete.
  • cement slurries are designed to have mechanical properties such that the slurry placed around the bottom of the tubular provides the means to anchor the tubular during initiation of expansion, but without resulting in mechanical failure of one or both cement sheaths.
  • either cement slurry may contain elastomeric materials that swell if contacted by wellbore or subterranean fluids such as water, hydrocarbon, gas, and/or drilling fluids, etc., and re-establish annular hydraulic isolation, even if the presence of mechanical damage to the hardened cement.
  • anchor refers to a system or device that provides sufficient engagement between the tubular and the borehole wall to allow an expansion tool to move relative to the tubular and thus to expand the tubular.
  • liner and “casing” are used interchangeably, inasmuch as aspects of the invention that relate to casings also relate to liners, and vice versa.
  • bottom refers to locations that are farther from the surface, even if the borehole is not vertical.
  • cement formulations may contain any additives that are known in the art to achieve specific slurry properties necessary for pumping and placement, including additives and gases for foamed cements.
  • FIG. 1 is a schematic illustration of the bottom of a borehole in which an expandable liner and a tubing string are present.
  • FIG. 2 is a schematic cross-section along lines 2 - 2 of FIG. 1 .
  • FIG. 3 is a schematic cross-section showing the system of FIG. 2 post-expansion.
  • a borehole 10 may contain an expandable liner 12 and a tubing string 14 .
  • An expansion device 16 is affixed to the lower end of the tubing 14 .
  • Expansion device 16 is illustrated as an expansion cone, but may be any suitable device that is capable of incrementally radially expanding the expandable liner as the device moves through the casing.
  • This assembly may further include an eccentric guide nose, stabilizer above the cone, autofill float collar, a dart catcher, two darts, safety joint, debris catcher and drill pipe to surface (all not shown), such as are known in the art. The equipment is made up and lowered into the hole with the drill pipe.
  • the anchoring may be provided by the cement.
  • cement refers to cement in the annulus between liner 12 and borehole 10 as shown at reference numeral 18 .
  • the cement may provide a mechanical engagement between the outside of the tubular and the inside of the borehole wall. If the cement is the sole anchoring means, the mechanical engagement must be sufficient to restrain the tubular against the strong upward force that is applied at the initiation of expansion.
  • cement is also typically used to seal the annulus.
  • the cement is mixed and pumped downhole. It is preferably separated from the other fluids by the two darts as it is pumped.
  • the first dart lands in the dart catcher, indicating that the cement is about to enter the annulus. Extra fluid is pumped until the second dart lands, indicating that all the cement is in the annulus.
  • Pumping is preferably stopped after a few barrels are pumped to clear the drill string of any cement. Once the pumping stops, the float collar acts as a back pressure valve to prevent the cement from flowing back up the drill string. After a predetermined amount of time to allow the cement to at least partially cure, casing expansion is initiated by pulling on the drill string to start movement at the cone.
  • the safety joint is preferably included in the assembly to enable easy release from the drill string if there are any problems with the tools or operations.
  • cement that has been allowed to at least partially cure before expansion may provide a superior annular seal after expansion.
  • the cement is allowed to hydrate to a point at which its pumpability is at least 70 Bearden units of consistency (Bc).
  • Bc Bearden units of consistency
  • the present invention can be used to cure defective cement seals, which may be located by logging or indicated by the presence of fluid flow in the annulus.
  • Some embodiments of the invention include a two-slurry approach in which a more-rapidly-setting cement slurry is placed in the annulus around a first portion of the tubular to be expanded, thereby providing an optional anchor, and a second, slower-setting slurry is placed around a second portion of the tubular and does not harden until after the expansion process is complete, so that formation isolation is enhanced.
  • the second slurry may be provided above the first in the annulus, as shown at 22 in the Figure, or below it.
  • the faster-setting cement portion may be fractured during the expansion process but may nonetheless retain its ability to anchor the tubular.
  • the cure time for each cement portion will depend on various factors, including downhole temperature, cement water content, and the presence of additives. It is preferred that these factors be controlled, to the extent possible, such that the fast-setting cement portion sets within a first pre-determined time window and the slow-setting cement portion sets within a second pre-determined time window that is longer than the first pre-determined time window.
  • the first cement may cure in less than 12 hours, while the slow cement may cure in no less than 50 hours.
  • one of the cement slurries may be designed to have mechanical properties such that the slurry placed around the bottom of the tubular provides the means to anchor the tubular during initiation of expansion, but can be radially expanded without resulting in mechanical failure of one or both cement sheaths.
  • the formation of a cement layer that can be radially expanded without fracturing can be accomplished by use of various blends of latexes, rubber particles, fibers, and binders that cure in place, such as hydraulic cements, cross-linked polymers, resins, rubber, and the like.
  • the parameters that preferably controlled in this embodiment include the shear bond between the pipe and the cement, and the mechanical properties of the cement itself, including its Young's Modulus, Poisson ratio, cohesion, and friction angle. Methods for determining desired ranges for these properties and for controlling them in the cement are known to those of skill in the art.
  • the cement portion that is used to anchor the expandable liner can include a crosslinked polymer gel, including those known in the art as ringing gels. Examples of suitable polymers include those disclosed in U.S. Pat. No. 7,267,174.
  • the cement portion that anchors the expandable liner comprises a cross-linked polymer and a suitable cementitious material, including but not limited to Portland cement, pozzolan, and/or slag.
  • the cement does not fully cure before expansion occurs, so the cement portion that functions as an anchor is only partially cured.
  • a cement that provides a high shear bond to the pipe may require only a relatively short length of cemented pipe for to provide the anchoring force, while a cement that does not achieve as much shear bond at the time of expansion will require contact with more of the surface area of the tubular and thus a greater axial portion of the annulus.
  • a 95 ⁇ 8-inch, 43.5 lb/ft casing section 24-inches long was placed inside an outer jacket of 133 ⁇ 8-inch casing.
  • the outside of the 95 ⁇ 8-inch pipe was blasted with medium grit aluminum oxide to increase the roughness of the pipe, thus improved shear bond between the pipe and the cement.
  • the annular gap was filled with a cement slurry composed of API Class H Portland cement+73% fresh water+0.6% Hydroxyethyl cellulose (viscosifier)+0.2% fluid loss agent, mixed at 13.8 lb/gal.
  • the cement was cured at 170° F. and atmospheric pressure for approximately 8 hrs, at which time samples indicated a compressive strength of 579 psi.
  • anchor slurries in accordance with the present invention can be composed of any Portland or non-Portland cementitious material, and likewise make use of any mixing fluids and additives that are known in the art to provide a pumpable slurry that can be placed in the wellbore as desired.
  • the composition may contain any additive or combination thereof as is known in the art to achieve specific mechanical properties such as but not limited to elastomers, polymers, copolymers, latexes, binding agents, fibers, salts, and aggregates. Examples of suitable polymers include the PermSeal® and H 2 Zero® products available from Halliburton, Houston, Tex.
  • either cement slurry may contain elastomeric materials that swell if contacted by wellbore or subterranean fluids (water, hydrocarbon, gas, and/or drilling fluids, etc.) and re-establish annular hydraulic isolation, even in the presence of mechanical damage to the hardened cement.
  • wellbore or subterranean fluids water, hydrocarbon, gas, and/or drilling fluids, etc.
  • Such swellable elastomers are known to those skilled in the art.
  • cement properties are selected for implementation of the present invention
  • Techniques for achieving this are well known in the art and include but are not limited to the addition of post-set expanding agents (manganese oxide, tricalcium aluminate, salts) to the cement slurry, plastic set expanders (foam, reactive gas generators), and surfactants.
  • this unreacted water may escape to the formation via either natural permeability, or natural or induced fractures.
  • this outlet may not always exist or be present in such a volumetric flow rate to accommodate the desired expansion rate. It is believed that significant advantages may be realized by providing a pathway by which such expelled water can escape from the compression zone.
  • One way to provide a pathway for the expelled water is to provide an in-place sacrificial collapse volume in the cement sheath.
  • the sacrificial collapse volume provides an in situ compressible volume, thus a means to prevent trapped pressure build up during the expansion process.
  • One method to provide this collapsible volume to the cement sheath are foamed cement, in which the cement is foamed with a gas such as air or nitrogen during pumping so that after it hardens the cement sheath includes a volume fraction of compressible gas.
  • collapsible cement sheath may also include other mechanical modifiers such as but not limited to the previously-mentioned rubber particles, copolymers, latex, insitu gas generating compounds, and other means.
  • the formation may be affected by creating stress risers via hydrojetting the formation prior to running the expandable tubular in the wellbore. This would create a weakness in the formation and allow it to more easily fail due to pressure buildup during the expansion process, but not necessarily fail prior to that point and thus allowing the wellbore to be more easily controlled, circulated, and cemented.
  • the cement in the annulus is overdisplaced, so that the lower end of the expandable tubular is surrounded by drilling fluid, cement spacer, or other noncementitious fluid at the bottom of the hole.
  • this fluid may also consist of a hydraulic cement that has a longer set time that the anchoring cement above it. This process is preferred so as to allow the initiation of the expansion process to occur with less force.
  • This fluid would be to ensure that the rubblized cement in the annulus of the expanded tubular does not leak or otherwise allow communication of fluids behind the expanded tubular from deeper formations. This practice is commonly referred to by those skilled in the art as a shoe squeeze.
  • cement anchoring techniques disclosed herein can be used alone, or in combination with other anchoring techniques, such as jacks or hangers. Likewise, the techniques disclosed herein can be repeated for successive lengths of expandable liner, and each length may be expanded to the same inside diameter, so that a monodiameter borehole is formed.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Piles And Underground Anchors (AREA)
US13/260,958 2009-03-31 2010-03-31 Expansion against cement for zonal isolation Abandoned US20120073814A1 (en)

Priority Applications (1)

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US13/260,958 US20120073814A1 (en) 2009-03-31 2010-03-31 Expansion against cement for zonal isolation

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US16512809P 2009-03-31 2009-03-31
PCT/US2010/029407 WO2010120523A2 (en) 2009-03-31 2010-03-31 Expansion against cement for zonal isolation
US13/260,958 US20120073814A1 (en) 2009-03-31 2010-03-31 Expansion against cement for zonal isolation

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US13/260,974 Abandoned US20120061078A1 (en) 2009-03-31 2010-03-31 Cement as anchor for expandable tubing

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US (2) US20120073814A1 (pt)
CN (2) CN102365420A (pt)
AU (2) AU2010236839A1 (pt)
BR (2) BRPI1013587A2 (pt)
CA (2) CA2757242C (pt)
GB (2) GB2480963B (pt)
WO (2) WO2010120523A2 (pt)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014085055A1 (en) * 2012-11-28 2014-06-05 Halliburton Energy Services, Inc. Methods of enhancing the fracture conductivity of multiple interval fractures in subterranean formations propped with cement packs
WO2015153286A1 (en) * 2014-03-31 2015-10-08 Schlumberger Canada Limited Methods for maintaining zonal isolation in a subterranean well
US10472554B2 (en) 2013-05-24 2019-11-12 Schlumberger Technology Corporation Methods for maintaining zonal isolation in a subterranean well

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WO2016023864A1 (en) 2014-08-13 2016-02-18 Shell Internationale Research Maatschappij B.V. Assembly and method for creating an expanded tubular element in a borehole
US10563475B2 (en) * 2015-06-11 2020-02-18 Saudi Arabian Oil Company Sealing a portion of a wellbore
AU2015413609B2 (en) * 2015-11-02 2021-05-20 Halliburton Energy Services, Inc. Settable compositions with variable set times
WO2018083069A1 (en) * 2016-11-01 2018-05-11 Shell Internationale Research Maatschappij B.V. Method for sealing cavities in or adjacent to a cured cement sheath surrounding a well casing
EP3824157B1 (en) 2018-07-20 2022-11-16 Shell Internationale Research Maatschappij B.V. Method of remediating leaks in a cement sheath surrounding a wellbore tubular
CN112610177B (zh) * 2021-01-14 2021-09-28 长江大学 一种用于弃井套管回收作业的挤压装置及挤压作业方法

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US10472554B2 (en) 2013-05-24 2019-11-12 Schlumberger Technology Corporation Methods for maintaining zonal isolation in a subterranean well
WO2015153286A1 (en) * 2014-03-31 2015-10-08 Schlumberger Canada Limited Methods for maintaining zonal isolation in a subterranean well

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WO2010120523A3 (en) 2011-01-20
GB201116395D0 (en) 2011-11-02
GB2480788A (en) 2011-11-30
BRPI1013589A2 (pt) 2016-04-19
CA2756983A1 (en) 2010-10-14
CA2757242A1 (en) 2010-10-21
WO2010117851A3 (en) 2011-02-10
WO2010120523A2 (en) 2010-10-21
AU2010234746A1 (en) 2011-09-29
GB2480963A (en) 2011-12-07
BRPI1013587A2 (pt) 2016-04-19
AU2010236839A1 (en) 2011-09-22
US20120061078A1 (en) 2012-03-15
WO2010117851A2 (en) 2010-10-14
CN102365420A (zh) 2012-02-29
GB201116246D0 (en) 2011-11-02
GB2480963B (en) 2013-01-30
CN102365419A (zh) 2012-02-29
CA2757242C (en) 2016-11-01

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Effective date: 20140808

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION