WO2019152036A1

WO2019152036A1 - Drillable hydraulic setting tool

Info

Publication number: WO2019152036A1
Application number: PCT/US2018/016380
Authority: WO
Inventors: Garry Martin HOWITT
Original assignee: Halliburton Energy Services, Inc.
Priority date: 2018-02-01
Filing date: 2018-02-01
Publication date: 2019-08-08

Abstract

An apparatus for setting or removing one or more devices downhole in a well includes a setting tool comprising a glass fiber composite or a soft metal, wherein a majority of the metal by volume comprises aluminum, brass, a dissolvable alloy or combinations therof, the setting tool adapted to set a device downhole, such as a plug, bridge plug, frac plug, or a packer. The soft metal or glass fiber composite may have a hardness in the range of about 55 to about 80 HrB. The setting tool may be a part of a dual plug run bottom hole assembly. The setting tool can be removed to reenter a well by drilling out the setting tool or dissolving the setting tool.

Description

DRILLABLE HYDRAULIC SETTING TOOL

TECHNICAL FIELD

[0001] This disclosure relates, in general, to equipment utilized in conjunction with operations performed in subterranean production and injection wells and, in particular, to drillable or dissolvable setting tools.

BACKGROUND

[0002] Without limiting the scope of the present disclosure, its background will be described with reference to setting tool equipment that is used for producing fluid from a hydrocarbon bearing subterranean formation, as an example.

[0003] During the completion of a well that traverses a hydrocarbon bearing subterranean formation, various downhole components may be required to be placed using a setting tool within the wellbore or working tubing string such as, for example, plugs, bridge plugs, frac plugs and packers.

[0004] The downhole setting tool commonly employed today typically comprises metals such a steel or iron that remain in a wellbore permanently, or may be temporarily placed in the well bore but is removable with considerable effort, cost and time.

[0005] Accordingly, a need has arisen for reducing time, cost, and including easier removal of downhole setting tools.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] For a more complete understanding of the features and advantage of the present disclosure, reference is now made to the detailed description along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:

[0007] Figure 1 is a cross-sectional elevation view of an example of a setting tool, according to principles of the present disclosure; [0008] Figure 2A is a cross-sectional elevation view of a hydraulic setting tool as run into a well, and showing that the plug has not been set into position, according to principles of the present disclosure;

[0009] Figure 2B is a cross-sectional elevation view of the hydraulic setting tool of Fig. 2A, showing that the plug has been set into positon within the well casing, according to principles of the present disclosure;

[00010] Figure 3A is an elevation view of a dual plug bottom hole assembly run into a well, according to principles of the present disclosure;

[00011] Figure 3B is an elevation view of the dual plug bottom hole assembly of Fig. 3A, showing setting of a lower plug, according to principles of the present disclosure;

[00012] Figure 3C is an elevation view of the dual plug bottom hole assembly of Figs. 3A and 3B, showing placement of cement proximate the lower plug, according to principles of the present disclosure;

[00013] Figure 3D is an elevation view of the dual plug bottom hole assembly of Figs. 3A-3C, showing placement of cement proximate the upper plug, according to principles of the present disclosure; and

[00014] Figure 3E is a cross-sectional elevation view showing removal of the upper plug of Fig. 3D and associated setting tool, according to principles of the present disclosure.

DETAILED DESCRIPTION

[00015] While apparatuses, methods and embodiments are discussed in detail below, it should be appreciated that the present disclosure provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are illustrative and do not delimit the scope of the present disclosure.

[00016] In the following detailed description of the illustrative embodiments, reference is made to the accompanying drawings that form a part hereof. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosed subject matter, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosure. To avoid detail not necessary to enable those skilled in the art to practice the embodiments described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative embodiments is defined only by the appended claims.

[00017] As used herein, the singular forms“a”,“an,” and“the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms“comprise” and/or“comprising,” when used in this specification and/or the claims, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. In addition, the steps and components described in the embodiments and figures are merely illustrative and do not imply that any particular step or component is a requirement of a claimed embodiment. The term“about” herein refers to +/- 10% of the value indicated, unless context specifies otherwise

[00018] Unless otherwise specified, any use of any form of the terms "connect," "engage," "couple," "attach," or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to". Unless otherwise indicated, as used throughout this document, "or" does not require mutual exclusivity.

[00019] Setting tools are often used during well completion to place plugs within wellbores. A plug such as, for example, plugs, bridge plugs, frac plugs and packers, is attached to a setting tool and this bottom hole assembly (BHA) is run downhole on a tubing string in a wellbore. The setting tool sets the plug into position in the wellbore, and may be left in place or removed. Bottom hole assembly (BHA) herein refers to the combination of tool members connectable to an end tubing or tubing string, or other well conduit, for performing one or more operations downhole, which may comprise a setting tool and a releasably attachable plug. [00020] A setting tool constructed according to principles of the present disclosure comprises a soft metallic and/or composite components such as aluminum, brass, glass fiber composites, dissolvable metallic, or combinations thereof, along with elastomer seals. The setting tool according to principles of the present disclosure does not require hard compositions like steel or iron, and the like. The setting tool according to principles of the present disclosure may comprise only soft metallic and/or composite components such as aluminum, brass, glass fiber composites, dissolvable metallic, or combinations thereof, along with elastomer seals. The setting tool can be left in a well as a sold item which can be drilled out of the well if subsequent re-entry into the well is required at a later time. The soft metallic or composite components require much less effort when removing the setting tool from a well, as compared with traditional setting tools. Drilling out soft metallic or composite components of a setting tool requires much less time and cost. In contrast, traditional setting tools that are made from steel, iron or hard components make removal much more difficult and time consuming.

[00021] The setting tool constructed according to principles of the present disclosure would provide a capability of an inexpensive method for deploying one or more devices such as plugs into a well and also provides for a simple removal by milling, drilling or dissolution at a later time if reentry to the well bore is required. This permits drillable barriers to be set in a single run with minimal additional components. The setting tool herein does not require redress or backload, and a number of setting tool assemblies could be kept on a location for contingency plug running if required. In some applications, a plug may create an

impermeable barrier between two zones in the well. Moreover, well plugs may be used for several different operations in the oil and gas industry, such as lost circulation control, formation testing, directi onal/sidetrack drilling, zonal isolation and well abandonment.

[00022] Figure 1 is an elevation view of an example of a setting tool 100, according to principles of the present disclosure. The example setting tool 100 of Fig. 1 comprises a hydraulic setting tool. Fig. 1 shows various basic features for explanation, but other features or configurations, not shown, may be included in a setting tool as one of ordinary skill in the art would know. Setting tool includes a tool setting casing 105, a top adapter 110 with a threaded connection 115 for attaching to other well drilling components such as a working string 145 (Fig. 2A). A piston 120 is configured within the hydraulic setting tool that is responsive to hydraulic fluid pressure applied to the setting tool 100 to cause setting of a plug at a desired location downhole. At least one shear pin 135 is configured to hold or maintain the setting tool in a first position to prevent premature or inadvertent activation of the setting tool. Once the setting tool 100 and plug is located at a desired location in a well bore, a sufficient hydraulic pressure is applied to the setting tool 100 to cause shearing of the at least one pin 135 to cause setting of a plug downhole, as described in more detail below.

[00023] As part of setting tool 100, a mandrel 130 is configured to releaseably connect to a plug (e.g., 140, Fig. 2A) via a connection means such as threads 132. Upper mandrel 125 operatively connects the mandrel 130 with the piston 120. One or more seals 137 maintain an internal hydraulic fluid seal while also permitting the piston 120 to slide along the upper mandrel 125 during plug setting.

[00024] Figure 2A is a cross-sectional elevation view of a hydraulic setting tool as run into a well, and showing that a plug connected to the setting tool has not yet been set into position, according to principles of the present disclosure. The hydraulic setting tool 100 and plug 140 comprise a single plug BHA. The well casing 150 was previously run from the surface into a geological formation 160. The setting tool 100 is shown connected to a drill string or working string 145 that has been run during well completion from the surface and positioning the setting tool 100 within a well casing 150. Plug 140, which may be a bridge plug, frac plug or a packer plug, is shown in Figure 2A in a non-expanded state. That is, the plug 140 has not yet been set into positon downhole. The at least one shearing pin 135 has not yet been sheared maintaining the piston 120 in a first position.

[00025] Figure 2B is a cross-sectional elevation view of the hydraulic setting tool 100 of Fig. 2A, showing that the plug 140 has been set into positon within the well casing 150, according to principles of the present disclosure. Shearing pins 135’ and l35”are shown sheared due to hydraulic fluid 155 entering the setting tool 100 from the drill string 145 at a sufficient pressure to cause shearing of the at least one shearing pin 135, and forcing the piston 120 to move thereby setting the plug 140 into place by expanding the plug 140 within casing 150. The setting tool 100 may be left in the well casing 150. If at a later date the setting tool 150 requires to be removed for the well, it may be drilled out as discussed more below in relation to Fig. 3E.

[00026] Figure 3A is an elevation view of a dual plug bottom hole assembly 200 run into a well, according to principles of the present disclosure. The dual plug bottom hole assembly 200 is connected to a work string 145. The dual plug bottom hole assembly 200 is showed positioned downhole within geological formation 260 and within well casing 150. The dual plug bottom hole assembly 200 comprises a lower hydraulic setting tool 100 attached to a lower plug 205, a spacer pipe 215 connecting the lower setting tool 100 to the upper plug 210, which is attached to an upper mechanical setting tool 100’. Lower plug 205 and upper plug 210 may comprise drillable plug, for example, a bridge plug, frac plug or a packer plug. The lower hydraulic setting tool 100 may be attached to the bottom of an existing drillable tool by using a drill gun adaptor 220, which is readily available. The upper setting tool 100’ may be a traditional mechanical setting tool. Lower hydraulic setting tool 100 is shown further downhole than the upper mechanical setting tool 100’.

[00027] Figure 3B is an elevation view of the dual plug bottom hole assembly of Fig. 3 A, showing setting of a lower plug 205, according to principles of the present disclosure. Hydraulic setting tool 100 is operated by an increase in fluid pressure applied from the surface of sufficient pressure to cause operation of the hydraulic setting tool, as was described previously in relation to Figures 2A and 2B. An extended tension sleeve 225 is run to ensure that the sliding sleeve on the upper setting tool 100’ is closed and that pressure is transmitted through the inner diameter of the setting tool 100’ to activate the lower hydraulic setting tool 100. Hydraulic setting tool 100 is shown being retracted from plug 205 which has been set into place. The plug 205 is shown expanded conforming to the inner surface of the well casing 150 thereby creating a barrier within the casing, such as for zonal isolation.

[00028] Figure 3C is an elevation view of the dual plug bottom hole assembly of Fig. 3 A, showing placement of cement 240 proximate the lower plug 105, according to principles of the present disclosure. Cement 240 may be pumped downhole through the dual plug bottom hole assembly 200 to fix the plug 205 in place.

[00029] Figure 3D is an elevation view of the dual plug bottom hole assembly of Fig. 3A, showing setting of the upper plug 210, according to principles of the present disclosure. Mechanical setting tool 100’ is shown being retracted from plug 210 which has been set into place at a desired location within the well. The plug 210 is shown set and expanded conforming to the inner surface of the well casing 150 thereby creating a barrier within the casing 150, such as for zonal isolation. Mechanical setting tool 100’ is operated by rotation of the working string 145 from the surface, which causes setting of the plug 210. Cement 240 may be pumped downhole to fix plug 210 in place. One or both of the setting tools 100, 100’ may be left downhole.

[00030] Figure 3E is a cross-sectional elevation view showing removal of the dual plug bottom hole assembly 200, according to principles of the present disclosure. Reentry to a well can be accomplished by milling or drilling out the BHA. As shown in Fig. 3E, working string 145 is shown rotating a mill or drill bit 250 to remove the bottom home assembly 200, which may include plug 210, 205 and hydraulic setting tool 100. Drill bit 250 is shown milling the setting tool 100 and also can continue the removal process by milling cement 240 and plug 205. In a like manner, hydraulic setting tool 100 and plug 140 of Fig. 2B may be drilled or milled for removal.

[00031] Because the setting tools 100 comprise a soft metallic and/or composite components such as aluminum, brass, glass fiber composites, dissolvable metallic, or combinations thereof, along with any elastomer seals, the setting tool scan be easily milled and the resulting particulate 255 removed, if needed, by fluid flow. Plugs 205 and 210 may be drilled out in a similar manner.

[00032] The setting tools 100 are primarily aluminum, brass, glass fiber composites, dissolvable metallic, or combinations thereof which are of much less hardness as compared with traditional setting tools. A setting tool 100 comprising aluminum, brass, a glass fiber composite, a magnesium alloy, or a combinations thereof, has a hardness in the range of 55-

80 HrB (Rockwell hardness scale), excluding non-metallic components such as any elastomer seals. The hardness may be less than 55 HrB. The hardness can be in the range of 60-80 HrB.

The hardness can be in the range of 60-70 HrB. The hardness may be less than 80 HrB. The setting tool 100 comprising aluminum, brass, a glass fiber composite, a magnesium alloy, or a combinations thereof does not require steel or iron components. The setting tool 100 may comprise a metal wherein the majority of the metal by volume comprises aluminum, brass, a combination of aluminum and brass, or a dissolvable alloy. The setting tool 100 does not require steel or iron components. The setting tool 100 comprising aluminum, brass, a glass fiber composites, a magnesium alloy, or a combinations thereof, has a hardness less than the hardness of a setting tool comprising a majority of steel or iron, making drilling or milling much more efficient for removal. In embodiments, the setting tool 100 may comprise only aluminum, brass, magnesium, a glass fiber composite or a combination thereof, except for other non-metallic components such as any elastomer seals. When made of dissolvable material such as a magnesium alloy, the setting tool 100 may be dissolved in the well bore for removal.

[00033] In one embodiment, the setting tool 100 comprises a dissolvable material such as a magnesium alloy. The magnesium alloy may be dissolved by introducing a fluid downhole for dissolving the setting tool 100. The solvent may comprise many different fluids from water to chloride containing fluids, such as e.g., potassium chloride. Dissolution rate typically increases as the chloride content of the fluid increases. Once the setting tool 100 dissolves, access to the plug for removal can be achieved.

[00034] The setting tool 100 can set bridge plugs, frac plus and packers in sizes of about 2 7/8” to about 20”. A common BHA deployment may include a jointed pipe onto a mechanical setting tool 100’ and upper plug 210, an E-Z Drill^® or a FAS Drill^® with threaded lower slip support adaptor, and either the setting tool 100 or spacer pipe and then the setting tool 100, and the lower drillable plug 205. The BHA assembly can be run to depth while top filling the working string 145 to apply pressure down the working string 145 to set the lower plug 100. The working string 145 may be repositioned to and the upper plug 210 set at a desired location.

[00035] The setting tool 100 provides for an inexpensive method for deploying plugs which also provides for an ability to remove the setting tool 100 by drilling, milling, dissolution, or combinations thereof, if re-entry to the wellbore is required. Single or dual drillable devices for creating one or more barriers downhole, such as drillable plugs, can be set in a single run with minimal additional components.

[00036] The above-disclosed embodiments have been presented for purposes of illustration and to enable one of ordinary skill in the art to practice the disclosure, but the disclosure is not intended to be exhaustive or limited to the forms disclosed. Many insubstantial modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The scope of the claims is intended to broadly cover the disclosed embodiments and any such modification. Further, the following clauses represent additional embodiments of the disclosure and should be considered within the scope of the disclosure: [00037] Clause 1, in aspects, an apparatus for setting one or more devices downhole in a well, comprising a setting tool comprising a glass fiber composite or a metal, wherein a majority of the metal by volume comprises aluminum, brass, a dissolvable alloy or a combination thereof, the seting tool adapted to set one or more devices downhole.

[00038] Clause 2, the apparatus of clause 1, wherein all of the metal in the seting tool comprises aluminum, brass, a magnesium alloy, or combinations thereof.

[00039] Clause 3, the apparatus of clauses 1 or 2, wherein the seting tool does not include steel or iron.

[00040] Clause 4, the apparatus of any one of clauses 1-3, wherein the metal or glass fiber composite has a hardness in the range of about 55 to about 80 HrB.

[00041] Clause 5, the apparatus of any one of clauses 1-4, wherein the metal or glass fiber composite has a hardness in the range of about 60 to about 80 HrB.

[00042] Clause 6, the apparatus of any one of clauses 1-5, wherein the metal or glass fiber composite has a hardness in the range of about 60 to about 70 HrB.

[00043] Clause 7, the apparatus of any one of clauses 1-6, wherein the metal or glass fiber composite has a hardness less than 55 HrB.

[00044] Clause 8, the apparatus of any one of clauses 1-7, further comprising at least one non-metal seal.

[00045] Clause 9, the apparatus of any one of clauses 1-8, wherein the seting tool comprises a hydraulic seting tool.

[00046] Clause 10, the apparatus of any one of clauses 1-9, further comprising a sliding sleeve or a tension sleeve, the sliding sleeve or tension sleeve comprising aluminum, brass, a combination of aluminum and brass, or a dissolvable alloy.

[00047] Clause 11, the apparatus of any one of clauses 1-10, wherein the one or more devices comprise a plug, a bridge plug, a frac plug or a packer.

[00048] Clause 12, the apparatus of any one of clauses 1-11, wherein the seting tool is part of a dual plug run botom hole assembly. [00049] Clause 13, in aspects, a method of setting one or more devices downhole in a well, comprising: running a setting tool downhole, the setting tool comprising a glass fiber composite, a dissolvable alloy or a metal wherein a majority of the metal by volume comprises aluminum, brass, a magnesium alloy, or a combination thereof, the setting tool adapted to set one or more devices downhole; and removing the setting tool by drilling, milling or dissolving the setting tool.

[00050] Clause 14, the method of clause 13, further comprising pumping cement downhole proximate the one or more devices.

[00051] Clause 15, the method of clause 14, further comprising drilling or milling the cement proximate the one or more devices, or milling or drilling out the one or more devices.

[00052] Clause 16, the method of any one of clauses 13-15, wherein the one or more devices comprise a plug, a bridge plug, a frac plugs or a packer.

[00053] Clause 17, the method of any one of clauses 13-16, wherein the majority of the metal or glass fiber composite has a hardness in the range of about 55 to about 80 HrB.

[00054] Clause 18, the method of any one of clause 13-17, wherein the majority of the metal or glass fiber composite has a hardness in the range of about 60 to about 70 HrB.

[00055] Clause 19, the method of any one of clauses 13-18, wherein the majority of the metal or glass fiber composite has a hardness less than about 80 HrB.

[00056] Clause 20, the method of clauses 13-19, wherein all of the metal in the setting tool comprises aluminum, brass, a magnesium alloy, or combinations thereof.

[00057] It should be apparent from the foregoing disclosure of illustrative embodiments that significant advantages have been provided. The illustrative embodiments are not limited solely to the descriptions and illustrations included herein and are instead capable of various changes and modifications without departing from the spirit of the disclosure.

Claims

I claim:

1. An apparatus for setting one or more devices downhole in a well, comprising: a setting tool comprising a glass fiber composite or metal, wherein a majority of the metal by volume comprises aluminum, brass, a dissolvable alloy, or a combination thereof, the setting tool adapted to set one or more devices downhole.

2. The apparatus of claim 1, wherein all of the metal in the setting tool comprises

aluminum, brass, a magnesium alloy, or combinations thereof.

3. The apparatus of claims 1 or 2, wherein the setting tool does not include steel or iron.

4. The apparatus of any one of claims 1-3, wherein the metal or glass fiber composite has a hardness in the range of about 55 to about 80 HrB.

5. The apparatus of any one of claims 1-4, wherein the metal or glass fiber composite has a hardness in the range of about 60 to about 80 HrB.

6. The apparatus of any one of claims 1-5, wherein the metal or glass fiber composite has a hardness in the range of about 60 to about 70 HrB.

7. The apparatus of any one of claims 1-6, wherein the metal or glass fiber composite has a hardness less than about 55 HrB.

8. The apparatus of any one of claims 1-7, further comprising at least one non-metal seal.

9. The apparatus of any one of claims 1-8, wherein the setting tool comprises a hydraulic setting tool.

10. The apparatus of any one of claims 1-9, further comprising a sliding sleeve or a tension sleeve, the sliding sleeve or tension sleeve comprising aluminum, brass, a combination of aluminum and brass, or a dissolvable alloy.

11. The apparatus of any one of claims 1-10, wherein the one or more devices comprise a plug, a bridge plug, a frac plug or a packer.

12. The apparatus of any one of claims 1-11, wherein the setting tool is part of a dual plug run bottom hole assembly.

13. A method of setting one or more devices downhole in a well, comprising: running a setting tool downhole, the setting tool comprising a glass fiber composite or metal wherein a majority of the metal by volume comprises aluminum, brass, a dissolvable alloy, or a combination thereof, the setting tool adapted to set one or more devices downhole; and removing the setting tool by drilling, milling or dissolving the setting tool.

14. The method of claim 13, further comprising pumping cement downhole proximate the one or more devices.

15. The method of claim 14, further comprising drilling or milling the cement proximate the one or more devices, or milling or drilling out the one or more devices.

16. The method of any one of claims 13-15, wherein the one or more devices comprise a plug, a bridge plug, a frac plugs or a packer.

17. The method of any one of claims 13-16, wherein the majority of the metal or glass fiber composite has a hardness in the range of about 55 to about 80 HrB.

18. The method of any one of claims 13-17, wherein the majority of the metal or glass fiber composite has a hardness in the range of about 60 to about 70 HrB.

19. The method of any one of claims 13-18, wherein the majority of the metal or glass fiber composite has a hardness less than about 80 HrB.

20. The method of any one of claims 13-19, wherein all of the metal in the setting tool comprises aluminum, brass, a magnesium alloy, or combinations thereof.