U.S. patent application number 10/196635 was filed with the patent office on 2004-01-22 for apparatus and method for completing an interval of a wellbore while drilling.
Invention is credited to Cox, Morris Wayne, Dailey, Terry Michael, Freeman, Tommie Austin, Simonds, Floyd Randolph.
Application Number | 20040011534 10/196635 |
Document ID | / |
Family ID | 30442827 |
Filed Date | 2004-01-22 |
United States Patent
Application |
20040011534 |
Kind Code |
A1 |
Simonds, Floyd Randolph ; et
al. |
January 22, 2004 |
Apparatus and method for completing an interval of a wellbore while
drilling
Abstract
An apparatus and method for completing an interval of a wellbore
while drilling comprises a drill string (52) having a drill bit
(30) mounted on the lower end thereof. A completion assembly (50)
is positioned around a section of the drill string (52) such that
when the wellbore (32) is extended by rotating the drill bit (30)
and advancing the drill string (52), the completion assembly (50)
does not rotate. The advancement of the drill string (52) and
rotation of the drill bit (30) is ceased when the completion
assembly (50) has reached the desired interval of the wellbore
(32). Thereafter, the drill string (52) is disconnected from the
drill bit (30) for retrieval to the surface leaving the completion
assembly (50) and the drill bit (30) downhole.
Inventors: |
Simonds, Floyd Randolph;
(Richardson, TX) ; Cox, Morris Wayne; (Conroe,
TX) ; Dailey, Terry Michael; (Humble, TX) ;
Freeman, Tommie Austin; (Flower Mound, TX) |
Correspondence
Address: |
LAWRENCE R. YOUST
Danamraj & Youst, P.C.
Suite 1200, LB 15
12900 Preston Road
Dallas
TX
75230-1328
US
|
Family ID: |
30442827 |
Appl. No.: |
10/196635 |
Filed: |
July 16, 2002 |
Current U.S.
Class: |
166/384 ;
166/207 |
Current CPC
Class: |
E21B 43/08 20130101;
E21B 43/045 20130101; E21B 43/108 20130101; E21B 7/20 20130101;
E21B 43/105 20130101; E21B 43/103 20130101 |
Class at
Publication: |
166/384 ;
166/207 |
International
Class: |
E21B 023/02 |
Claims
What is claimed is:
1. A method of completing a wellbore while drilling comprising the
steps of: disposing a drill bit on an end of a drill string;
positioning a completion assembly around a section of the drill
string; extending the wellbore by rotating the drill bit and
advancing the drill string without rotating the completion
assembly; and ceasing the advancement of the drill string when the
completion assembly has reached a desired depth.
2. The method as recited in claim 1 further comprising the steps of
disconnecting the drill string from the drill bit and retrieving
the drill string to the surface leaving the completion assembly and
the drill bit downhole.
3. The method as recited in claim 1 wherein the step of positioning
a completion assembly around a section of the drill string further
comprises positioning an expandable screen around the section of
the drill string.
4. The method as recited in claim 3 further comprising the step of
expanding the expandable screen after the completion assembly has
reached the desired depth.
5. The method as recited in claim 1 wherein the step of positioning
a completion assembly around a section of the drill string further
comprises positioning a sand control screen and a gravel packing
assembly around the section of the drill string.
6. The method as recited in claim 5 further comprising the step of
gravel packing the wellbore around the sand control screen and the
gravel packing apparatus.
7. The method as recited in claim 1 wherein the step of positioning
a completion assembly around a section of the drill string further
comprises establishing a fluid seal between the completion assembly
and the drill string to prevent fluid migration therebetween.
8. The method as recited in claim 1 wherein the step of positioning
a completion assembly around a section of the drill string further
comprises rotatably coupling the completion assembly to the drill
string to prevent torque transfer therebetween.
9. The method as recited in claim 1 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
rotating the drill bit by operating a downhole motor.
10. The method as recited in claim 1 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
rotating the drill bit by rotating the drill string.
11. The method as recited in claim 1 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
extending the wellbore beyond the end of a casing in the
wellbore.
12. The method as recited in claim 11 further comprising the step
of supportably coupling the completion assembly to the casing with
a suspension tool.
13. The method as recited in claim 1 further comprising the step of
installing a production tubing relative to the completion assembly
providing for fluid communication therebetween.
14. A method of completing a wellbore while drilling comprising the
steps of: disposing a drill bit on an end of a drill string;
positioning a completion assembly including an expandable screen
around a section of the drill string; extending the wellbore by
rotating the drill bit and advancing the drill string without
rotating the completion assembly; ceasing the advancement of the
drill string when the completion assembly has reached a desired
depth; and expanding the expandable screen.
15. The method as recited in claim 14 further comprising the steps
of disconnecting the drill string from the drill bit and retrieving
the drill string to the surface leaving the completion assembly and
the drill bit downhole.
16. The method as recited in claim 14 wherein the step of
positioning a completion assembly around a section of the drill
string further comprises establishing a fluid seal between the
completion assembly and the drill string to prevent fluid migration
therebetween.
17. The method as recited in claim 14 wherein the step of
positioning a completion assembly around a section of the drill
string further comprises rotatably coupling the completion assembly
to the drill string to prevent torque transfer therebetween.
18. The method as recited in claim 14 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
rotating the drill bit by operating a downhole motor.
19. The method as recited in claim 14 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
rotating the drill bit by rotating the drill string.
20. The method as recited in claim 14 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
extending the wellbore beyond the end of a casing in the
wellbore.
21. The method as recited in claim 20 further comprising the step
of supportably coupling the completion assembly to the casing with
a suspension tool.
22. The method as recited in claim 14 further comprising the step
of installing a production tubing relative to the completion
assembly providing for fluid communication therebetween.
23. A method of completing a wellbore while drilling comprising the
steps of: disposing a drill bit on an end of a drill string;
positioning a completion assembly including a sand control screen
and a gravel packing assembly around a section of the drill string;
extending the wellbore by rotating the drill bit and advancing the
drill string without rotating the completion assembly; ceasing the
advancement of the drill string when the completion assembly has
reached a desired depth; and gravel packing the wellbore around the
sand control screen and the gravel packing apparatus.
24. The method as recited in claim 23 further comprising the steps
of disconnecting the drill string from the drill bit and retrieving
the drill string to the surface leaving the completion assembly and
the drill bit downhole.
25. The method as recited in claim 23 wherein the step of
positioning a completion assembly around a section of the drill
string further comprises establishing a fluid seal between the
completion assembly and the drill string to prevent fluid migration
therebetween.
26. The method as recited in claim 23 wherein the step of
positioning a completion assembly around a section of the drill
string further comprises rotatably coupling the completion assembly
to the drill string to prevent torque transfer therebetween.
27. The method as recited in claim 23 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
rotating the drill bit by operating a downhole motor.
28. The method as recited in claim 23 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
rotating the drill bit by rotating the drill string.
29. The method as recited in claim 23 wherein the step of extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly further comprises
extending the wellbore beyond the end of a casing in the
wellbore.
30. The method as recited in claim 29 further comprising the step
of supportably coupling the completion assembly to the casing with
a suspension tool.
31. The method as recited in claim 23 further comprising the step
of installing a production tubing relative to the completion
assembly providing for fluid communication therebetween.
32. A method of completing a wellbore while drilling comprising the
steps of: disposing a drill bit on an end of a drill string;
positioning a completion assembly including an expandable screen
around a section of the drill string; establishing a fluid seal and
a rotatable coupling between the completion assembly and the drill
string to prevent fluid migration and torque transfer therebetween;
extending the wellbore by rotating the drill bit and advancing the
drill string beyond the end of a casing in the wellbore without
rotating the completion assembly; ceasing the advancement of the
drill string when the completion assembly has reached a desired
depth; supportably coupling the completion assembly to the casing
with a suspension tool; disconnecting the drill string from the
drill bit; retrieving the drill string to the surface leaving the
completion assembly and the drill bit downhole; and expanding the
expandable screen.
33. A method of completing a wellbore while drilling comprising the
steps of: disposing a drill bit on an end of a drill string;
positioning a completion assembly including a sand control screen
and a gravel packing apparatus around a section of the drill
string; establishing a fluid seal and a rotatable coupling between
the completion assembly and the drill string to prevent fluid
migration and torque transfer therebetween; extending the wellbore
by rotating the drill bit and advancing the drill string beyond the
end of a casing in the wellbore without rotating the completion
assembly; ceasing the advancement of the drill string when the
completion assembly has reached a desired depth; supportably
coupling the completion assembly to the casing with a suspension
tool; disconnecting the drill string from the drill bit; retrieving
the drill string to the surface leaving the completion assembly and
the drill bit downhole; and gravel packing the wellbore around the
sand control screen and the gravel packing apparatus.
34. An apparatus for completing a wellbore while drilling
comprising: a drill string; a drill bit mounted on an end of the
drill string; and a completion assembly positioned around a section
of the drill string, whereby the wellbore is extended by rotating
the drill bit and advancing the drill string without rotating the
completion assembly and the advancement of the drill string is
ceased when the completion assembly has reached a desired
depth.
35. The apparatus as recited in claim 34 wherein the drill string
is removable from the completion assembly and the drill bit such
that the drill string is retrievable to the surface leaving the
completion assembly and the drill bit downhole.
36. The apparatus as recited in claim 34 wherein the completion
assembly further comprises an expandable screen and wherein the
expandable screen is expanded after the completion assembly has
reached the desired depth.
37. The apparatus as recited in claim 34 wherein the completion
assembly further comprises a sand control screen and a gravel
packing assembly and wherein the wellbore around the sand control
screen and the gravel packing apparatus is gravel packed after the
completion assembly has reached the desired depth.
38. The apparatus as recited in claim 34 wherein the completion
assembly further comprises a seal member that is coupled to the
drill string to prevent fluid migration therebetween.
39. The apparatus as recited in claim 34 wherein the completion
assembly further comprises a rotatable coupling that is coupled to
the drill string to prevent torque transfer therebetween.
40. The apparatus as recited in claim 34 further comprising a
downhole motor that drives the rotation of the drill bit.
41. The apparatus as recited in claim 34 further comprising a
suspension tool that supportably couples the completion assembly to
a casing within the wellbore.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates, in general, to drilling and
completing a well that traverses a hydrocarbon bearing subterranean
formation and, in particular, to an apparatus and method for
completing an interval of a wellbore while drilling.
BACKGROUND OF THE INVENTION
[0002] Without limiting the scope of the present invention, its
background will be described with reference to producing fluid from
a subterranean formation, as an example.
[0003] After drilling each of the sections of a subterranean
wellbore and retrieving the drill bit and drilling string to the
surface, individual lengths of relatively large diameter metal
tubulars are typically secured together to form a casing string
that is positioned within each section of the wellbore. This casing
string is used to increase the integrity of the wellbore by
preventing the wall of the hole from caving in. In addition, the
casing string prevents movement of fluids from one formation to
another formation. Conventionally, each section of the casing
string may be cemented within the wellbore before the next section
of the wellbore is drilled. Accordingly, each subsequent section of
the wellbore must have a diameter that is less than the previous
section.
[0004] For example, a first section of the wellbore may receive a
conductor casing string having a 20-inch diameter. The next several
sections of the wellbore may receive intermediate casing strings
having 16-inch, 133/8 inch and 95/8-inch diameters, respectively.
The final sections of the wellbore may receive production casing
strings having 7-inch and 41/2-inch diameters, respectively. Each
of the casing strings may be hung from a casing head near the
surface. Alternatively, some of the casing strings may be in the
form of liner strings that extend from near the setting depth of
previous section of casing. In this case, the liner string will be
suspended from the previous section of casing on a liner
hanger.
[0005] It has been found, however, that rig time can be reduced by
utilizing the casing string as the drill string for rotating a
drill bit. As this procedure, referred to as casing while drilling,
does not require the use of a separate liner or casing string to be
run downhole after the retrieval of the drill bit and drill string,
the time needed to drill, case and cement a section of wellbore can
be reduced. Typically, when the casing string operates as the drill
string to rotate the drill bit, particularly robust casing must be
utilized.
[0006] Whether conventionally drilled or after performing as casing
while drilling operation, once the well construction process is
finished, the various steps of the completion process may begin.
For example, hydraulic openings or perforations are typically made
through the production casing string, the cement, if any, and a
short distance into the desired formation or formations so that
production fluids may enter the interior of the wellbore. In
addition, the completion process may involve formation stimulation
to enhance production, gravel packing to prevent sand production
and the like. The completion process also includes installing a
production tubing string within the well that extends from the
surface to the production interval or intervals. The tubing may
include sand control screen sections that are positioned adjacent
to the perforated intervals.
[0007] It would be desirable to further reduce rig time by
minimizing the number of trips downhole required to drill and
complete a well. Accordingly, it would be desirable to combine
certain aspects of the drilling operation and the completion
operation into the same trip downhole. Therefore, a need has arisen
for an apparatus and a method for completing an interval of a
wellbore while drilling.
SUMMARY OF THE INVENTION
[0008] The present invention disclosed herein comprises an
apparatus and a method that allow for a reduction in rig time by
minimizing the number of trips downhole required to drill and
complete a well. The apparatus and the method of the present
invention achieve this result by combining certain aspects of the
drilling operation and the completion operation into the same trip
downhole, thereby providing for the completion of an interval of a
wellbore while drilling.
[0009] The apparatus of the present invention comprises a drill
string having a drill bit mounted on the lower end thereof. A
completion assembly is positioned around a section of the drill
string such that when the wellbore is extended by rotating the
drill bit and advancing the drill string, the completion assembly
is not rotated. Once the completion assembly has reached the
desired position adjacent to a production interval traversed by the
wellbore, the advancement of the drill string is ceased.
Thereafter, the drill string is disconnected from the completion
assembly and the drill bit such that the drill string may be
retrievable to the surface leaving only the completion assembly and
the drill bit downhole. Accordingly, using the completion assembly
of the present invention assures that the completion equipment is
placed within the wellbore before the wellbore has an opportunity
to cave in.
[0010] In one embodiment of the present invention, the completion
assembly may include an expandable screen. In this embodiment, the
expandable screen is expanded after the completion assembly has
reached the desired depth on the same trip or a subsequent trip
into the wellbore. In another embodiment, the completion assembly
may include a sand control screen with a gravel packing assembly
positioned therearound. In this embodiment, after the completion
assembly has reached the desired depth, a gravel packing operation
may be performed wherein the wellbore around the sand control
screen and the gravel packing apparatus is filled with gravel.
[0011] In one embodiment of the present invention, the completion
assembly includes a seal member that is coupled to the drill string
to prevent fluid migration therebetween. Additionally or
alternatively, the completion assembly may include a rotatable
coupling that is coupled to the drill string to prevent torque
transfer therebetween.
[0012] In one embodiment of the present invention, the rotation of
the drill bit may be generated with a downhole motor that is driven
by drilling fluid. In another embodiment, the rotation of the drill
bit may be generated by rotating the drill string from the
surface.
[0013] In another aspect, the present invention comprises a method
of completing a wellbore while drilling. The method involves
disposing a drill bit on an end of a drill string, positioning a
completion assembly around a section of the drill string, extending
the wellbore by rotating the drill bit and advancing the drill
string without rotating the completion assembly, ceasing the
advancement of the drill string when the completion assembly has
reached a desired depth, disconnecting the drill string from the
drill bit and retrieving the drill string to the surface leaving
only the completion assembly and the drill bit downhole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a more complete understanding of the features and
advantages of the present invention, reference is now made to the
detailed description of the invention along with the accompanying
figures in which corresponding numerals in the different figures
refer to corresponding parts and in which:
[0015] FIG. 1 is a schematic illustration of an offshore oil and
gas platform performing a completion while drilling operation
according to the present invention;
[0016] FIG. 2 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned within a wellbore during a drilling operation;
[0017] FIG. 3 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned within a wellbore after the drill string has been
retrieved to the surface;
[0018] FIG. 4 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned within a wellbore before an expansion operation;
[0019] FIG. 5 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned within a wellbore after the expansion operation;
[0020] FIG. 6 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned within a wellbore and ready for production;
[0021] FIG. 7 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned within a wellbore during a drilling operation;
[0022] FIG. 8 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned with a wellbore during a suspension tool actuation
operation;
[0023] FIG. 9 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned within a wellbore during a gravel packing operation;
and
[0024] FIG. 10 is a half sectional view of a completing while
drilling apparatus according to the present invention that is
positioned within a wellbore and ready for production.
DETAILED DESCRIPTION OF THE INVENTION
[0025] While the making and using of various embodiments of the
present invention are discussed in detail below, it should be
appreciated that the present invention provides many applicable
inventive concepts which can be embodied in a wide variety of
specific contexts. The specific embodiments discussed herein are
merely illustrative of specific ways to make and use the invention,
and do not delimit the scope of the present invention.
[0026] Referring initially to FIG. 1, an apparatus for completing
an interval of a wellbore while drilling of the present invention
is being installed from an offshore oil and gas platform that is
schematically illustrated and generally designated 10. A
semi-submersible platform 12 is centered over a submerged oil and
gas formation 14 located below sea floor 16. A subsea conduit 18
extends from deck 20 of platform 12 to wellhead installation 22
including subsea blow-out preventers 24. Platform 12 has a hoisting
apparatus 26 and a derrick 28 for raising and lowering pipe strings
such as a drill string (not pictured) used to rotate drill bit 30
during the drilling operation used to lengthen wellbore 32 through
formation 14.
[0027] As illustrated, an upper portion of wellbore 32 includes a
casing 34 that is cemented therein by cement 36. A lower portion of
wellbore 32 that traverses formation 14 is not cased but rather
includes a completing while drilling apparatus 38 suspended from
casing 34 via suspension tool 40. As explained in greater detail
below, completing while drilling apparatus 38 is initially
positioned around a section of the drill string such that when
wellbore 32 is being extended through formation 14 by rotating
drill bit 30 and advancing the drill string, completing while
drilling apparatus 38 is not rotated. Once the desired depth is
reached and the extension of wellbore 32 ceases, the drill string
is disconnected from drill bit 30 and completion assembly 38 then
retrieved to the surface. Thereafter, as illustrated, an expansion
tool 42 is run in the hole, for example, carried on the lower end
of a coiled tubing 44 or other suitable conveyance including, but
not limited to, jointed pipe or composite tubing, to expand
portions of completing while drilling apparatus 38 such as an
expandable sand control screen assembly 46.
[0028] Even though FIG. 1 depicts a vertical well, it should be
noted by one skilled in the art that the completing while drilling
apparatus of the present invention is equally well-suited for use
in deviated wells, inclined wells or horizontal wells. Also, even
though FIG. 1 depicts an offshore operation, it should be noted by
one skilled in the art that the apparatus for gravel packing an
interval of a wellbore of the present invention is equally
well-suited for use in onshore operations.
[0029] Referring now to FIG. 2, therein is depicted one embodiment
of an apparatus for completing an interval of a wellbore while
drilling that is generally designated 50. As illustrated,
completing while drilling apparatus 50 is being used to lengthen
wellbore 32 beyond an upper section of wellbore 32 that includes
casing 34 that is cemented therein by cement 36. Completing while
drilling apparatus 50 includes a conventional drill string 52 that
is used to apply weight on drill bit 30 as drill bit 30 rotates
such that wellbore 32 may be extended. Drill bit 30 may be
conventionally rotated by drill string 52 but is preferably rotated
using a downhole mud motor 54 which utilizes drilling fluid,
indicated as arrows 56, to impart rotation to drill bit 30. The
drilling fluid including the cuttings created by drill bit 30 are
then returned to the surface around the exterior of completing
while drilling apparatus 50 as indicated by arrows 58.
[0030] Between drill string 52 and mud motor 54, completing while
drilling apparatus 50 may include a variety of other tools 60 such
as measurement while drilling tools, logging while drilling tools
or the like. Completing while drilling apparatus 50 also includes a
lug 62, the operation of which is explained below.
[0031] Mud motor 54 is coupled to drill bit 30 via a splined
subassembly 64. Splined subassembly 64 includes mating members that
transfer rotation from mud motor 54 to drill bit 30 and allow the
flow of drilling mud therethrough. The mating members of splined
subassembly 64 are initially coupled together using shear pins or
other suitable means. The shear pins allow for the transfer of
rotation between the mating members and initially prevent relative
translational movement therebetween. As explained below, shearing
of the shear pins in splined subassembly 64 allows for the
disconnection of drill string 52 from drill bit 30 and completing
while drilling apparatus 50.
[0032] Positioned between splined subassembly 64 and drill bit 30
is a float subassembly 66. Float subassembly 66 includes a valving
mechanism that allows drilling mud to travel from drill string 52
into drill bit 30. Once the interval of wellbore 32 has been
completed and production has commenced, however, the valving
mechanism of float subassembly 66 prevents formation fluids from
being produced though the fluid communication paths in drill bit
30. For example, the valving mechanism of float subassembly 66 may
be a one-way valve wherein fluids may travel from splined
subassembly 64 to drill bit 30 through float subassembly 66 but not
from drill bit 30 to splined subassembly 64 through float
subassembly 66. Alternatively, the valving mechanism of float
subassembly 66 may have multiple configurations wherein fluid can
initially pass through float subassembly 66 allowing fluid to
travel from splined subassembly 64 to drill bit 30 through float
subassembly 66 but will be prevented from traveling though float
subassembly 66 from drill bit 30 to splined subassembly 64 through
float subassembly 66 once float subassembly 66 has been operated
into its closed configuration.
[0033] Completing while drilling apparatus 50 is positioned around
drill string 52. Completing while drilling apparatus 50 includes an
upper latch 70. Upper latch 70 provides support between drill
string 52 and completing while drilling apparatus 50. In the
illustrated embodiment, upper latch 70 includes a static seal, such
as a cup seal, that prevents the flow of fluids between upper latch
70 and drill string 52. The static seal allows for relatively
translational movement between drill string 52 and completing while
drilling apparatus 50 so that the axial force placed on drill
string 52 during drilling operations wherein weight is placed on
drill bit 30 is not transferred to completing while drilling
apparatus 50. In other embodiments that do not include mud motor 50
and wherein drill string 52 is used to rotate drill bit 30, upper
latch 70 includes a dynamic seal, such as a bearing seal, that
maintains the required fluid sealing between drill string 52 and
upper latch 70 during such rotation and prevents the transfer of
any torque therebetween. Upper latch 70 includes a receiver 72 that
is designed to couple to lug 62 as explained in greater detail
below.
[0034] Adjacent to upper latch 70, completing while drilling
apparatus 50 includes a seal bore 74. Seal bore 74 is designed to
provide a receiving surface for a seal assembly that will be
carried on a tubing string installed within completing while
drilling apparatus 50 as explained below.
[0035] Next, completing while drilling apparatus 50 has a
suspension tool 76. When actuated, suspension tool 76 is designed
to support completing while drilling apparatus 50 within wellbore
32 and prevent the flow of fluids between completing while drilling
apparatus 50 and casing string 34 across suspension tool 76.
Suspension tool 76 may be a conventional liner hanger mechanism or
other device that provides suitable gripping and sealing service.
Suspension tool 76 may be actuated in a variety of known ways such
as mechanically shifting suspension tool 76 or hydraulically
actuating suspension tool 76.
[0036] In the illustrated embodiment, completing while drilling
apparatus 50 includes a plurality of sections of tubular members
78. Tubular members 78 are used as a liner for wellbore 32 that
extends from the lower end of casing 34 to the desired location
above formation 14. It should be apparent to those skilled in the
art that the use of directional terms such as top, bottom, above,
below, upper, lower, upward, downward, etc. are used in relation to
the illustrative embodiments as they are depicted in the figures,
the upward direction being toward the top of the corresponding
figure and the downward direction being toward the bottom of the
corresponding figure. As such, it is to be understood that the
downhole components described herein may be operated in vertical,
horizontal, inverted or inclined orientations without deviating
from the principles of the present invention.
[0037] Positioned below tubular members 78 within completing while
drilling apparatus 50 is a cone launcher 80. Cone launcher 80, is
used to provide room to operate an expansion tool from it running
position to its expansion position as described in greater detail
below.
[0038] Next, completing while drilling apparatus 50 has one or more
sections of expandable tubular members 82. The length of expandable
tubular members 82 can be any suitable length and will depend, in
part, on the length of tubular members 78 above cone launcher 80.
In some cases it may be desirable to line most of wellbore 32
between the lower end of casing 34 and formation 14 with expandable
tubular members 82 thereby allowing for expansion of expandable
tubular members 82 against the wall of the borehole. Alternatively,
in some cases it may be desirable to line most of wellbore 32
between the lower end of casing 34 and formation 14 with tubular
members 78, thereby not requiring expansion.
[0039] Coupled to the lower end of expandable tubular members 82 is
an expandable sand control screen assembly 84. Expandable sand
control screen assembly 84 may be of any suitable construction but
it preferably includes a perforated base pipe 86 that is
expandable. Positioned around base pipe 86 is an expandable filter
media 88 such as a fluid-porous, particulate restricting screen
such as a plurality of layers of a wire mesh that are diffusion
bonded or sintered together to form a porous wire mesh screen
designed to allow fluid flow therethrough but prevent the flow of
particulate materials of a predetermined size from passing
therethrough. Positioned exteriorly of filter media 88 is a
perforated outer shroud 90 that is also expandable. While a single
section of expandable sand control screen assembly 84 is depicted,
it should be understood by those skilled in the art that any number
of section of expandable sand control screen assemblies 84 may be
used as part of completing while drilling apparatus 50. The number
of sections of expandable sand control screen assemblies 84 will be
determined based upon the length of formation 14. When multiple
sections of expandable sand control screen assemblies 84 are used,
additional sections of expandable tubular members 82 may be
positioned between sections of expandable sand control screen
assemblies 84.
[0040] In the illustrated embodiment, below the lower end of
expandable sand control screen assemblies 84 and any sections of
expandable tubular members 82 positioned thereafter is a lower seal
bore 92. As explained in greater detail below, lower seal bore 92
may be used to determine when the expansion process of expandable
sand control screen assemblies 84 and expandable tubular members 82
is complete.
[0041] At the lower end of completing while drilling apparatus 50
there is a splined subassembly housing 94. Splined subassembly
housing 94 provides support between splined subassembly 64 and
completing while drilling apparatus 50. Splined subassembly housing
94 includes a dynamic seal that prevents the flow of fluids between
splined subassembly housing 94 and splined subassembly 64, such as
a bearing seal. The dynamic seal allows for relatively rotational
movement between splined subassembly housing 94 and splined
subassembly 64 so that the torsional force placed on splined
subassembly 64 during drilling operations wherein drill bit 30 is
rotated is not transferred to completing while drilling apparatus
50.
[0042] The operation of completing while drilling apparatus 50 will
now be described with reference to FIGS. 2-6. After the upper
section of wellbore 32 has been drilled and cased, the lower
section of wellbore 32 that traverses formation 14 may now be
drilled and completed. First, drill bit 30, float subassembly 66,
splined subassembly 64 including splined subassembly housing 94,
mud motor 54 and measurement while drilling tool 60 including lug
62 are assembled at the surface and coupled to drill string 52.
Thereafter, the reminder of completing while drilling apparatus 50
is assembled and attached to drill string 52. Specifically, seal
bore 92 is threadably attached to spline subassembly housing 94 and
the required number of sections of expandable sand control screen
assemblies 84 and expandable tubular members 82 are threadably
attached together in a conventional manner around drill string 52
as drill string 52 is threadably assembled and lowered into the
well as necessary.
[0043] Once the required length of sand control screen assemblies
84 and expandable tubular members 82 are in place around drill
string 52, cone launcher 80 is attached to the outer string forming
the lower section of completing while drilling apparatus 50. The
required length of non expandable tubular members 78 is then
attached to the outer string as additional sections of drill string
52 are threadably assembled and lowered into the well. In the
illustrated embodiment, to finish the assembly of completing while
drilling apparatus 50, suspension tool 76, seal bore 74 and upper
latch 70 are assembled.
[0044] The entire completing while drilling apparatus 50 is then
lowered downhole on drill string 52 until drill bit 30 reaches the
bottom of wellbore 32. Wellbore 32 can them be extended by rotating
drill bit 30 and advancing drill string 52. In the illustrated
embodiment, this is achieved by pumping drilling fluid, represented
by arrows 56, down drill string 52 and through mud motor 54. This
creates a rotation in mud motor 54 that in turn rotates the mating
members of splined subassembly 64 and drill bit 30. After rotating
mud motor 54, the drilling fluid passes through splined subassembly
64, float subassembly 66 and drill bit 30. The drilling fluid then
carries the cuttings created by drill bit 30 back to the surface as
indicated by arrows 58.
[0045] As splined subassembly 64 and splined subassembly housing 94
are coupled together via a dynamic bearing type seal, the rotation
of splined subassembly 64 is not transferred to completing while
drilling apparatus 50. Accordingly, no torque is transferred to
completing while drilling apparatus 50 due to the rotation of drill
bit 30 which protects expandable sand control screen assembly 84
from damage during drilling.
[0046] During the drilling operation, information may be recorded
or may be sent to the surface in real-time from tool 60 that may be
sensing one or more parameters relating to the drilling operation.
In fact, tool 60 may be used to determine when the drilling
operation should cease such that completing while drilling
apparatus 50 will be properly positioned relative to formation
14.
[0047] Once completing while drilling apparatus 50 has reached the
desired depth, as depicted in FIG. 2, the drilling portion of the
completing while drilling operation ceases. Importantly, completing
while drilling apparatus 50 is positioned within wellbore 32 during
the drilling operation. Accordingly, using completing while
drilling apparatus 50 assures that the completion equipment is
placed within wellbore 32 before wellbore 32 has an opportunity to
cave in.
[0048] At this point, suspension tool 76 may be hydraulically
actuated, as discussed in more detail below, to help support
completing while drilling apparatus 50. Alternatively, suspension
tool 76 may be mechanically or hydraulically actuated after
disconnecting and retrieving drill string 52 from drill bit 30 and
completing while drilling apparatus 50. In either case, drill
string 52 may now be disconnected from drill bit 30 and completing
while drilling apparatus 50.
[0049] In those embodiments wherein the valving mechanism within
float subassembly 66 is a one-way valve, no operation is required
to prevent fluid flow up through drill bit 30. In those embodiments
wherein the valving mechanism within float subassembly 66 requires
shifting to prevent fluid flow up through drill bit 30, the closing
operation may be achieved by appropriate upward or downward jarring
on float subassembly 66 or other suitable technique such as
dropping a ball to shift a sleeve, which may also be used to in the
disconnection process.
[0050] Drill string 52 is disconnected from drill bit 30 and
completing while drilling apparatus 50 at splined subassembly 64.
As explained above, splined subassembly 64 includes a pair of
mating members that are initially coupled together using shear pins
or other suitable means. Accordingly, suitable upward jarring on
splined subassembly 64 causes the shear pins to shear allowing for
the disconnection of drill string 52 from drill bit 30 and
completing while drilling apparatus 50.
[0051] Once drill string 52 is disconnected from drill bit 30 and
completing while drilling apparatus 50, drill string 52 may be
raised uphole until lugs 62 are received within receiver 72 of
upper latch 70. When lugs 62 are received, this causes the release
of upper latch 70 from seal bore 74 leaving drill bit 30 and
completing while drilling apparatus 50 in the hole, as best seen in
FIG. 3.
[0052] In the illustrated embodiment, the next step is to run an
expansion tool 100 downhole on a coiled tubing string 102.
Specifically, expansion tool 100 has a small diameter running
configuration such that it may be run through tubular members 78
and at least partially into cone launcher 80. Once in this
position, expansion tool 100 can be shifted into its larger
diameter expansion configuration suitable for expanding expandable
tubular members 82 and expandable sand control screen assembly 84,
as best seen in FIG. 4. Expansion tool 100 includes a tapered cone
section 104, a piston 106 and an anchor section 108. Anchor section
108 includes a receiver portion that is coupled to the lower end of
coiled tubing string 102.
[0053] In operation, a downward force is placed on expansion tool
100 by applying the weight of coiled tubing string 102 on expansion
tool 100. This downward force operates to stroke piston 106 to its
compressed position. Once piston 106 completes its downward stroke,
fluid is pumped down coiled tubing string 102 which sets anchor
section 108 creating a friction grip between anchor section 108 and
the interior of the surrounding tubular which prevents upward
movement of anchor section 108. As more fluid is pumped down coiled
tubing string 102, piston 106 operates to urge tapered cone section
104 downwardly such that tapered cone section 104 places a radially
outward force against the wall of expandable tubular members 82 and
expandable sand control screen assembly 84 causing these expandable
products to plastically deform increasing the diameter thereof.
[0054] This process continues in a step wise fashion wherein each
stroke of expansion tool 100 expands a section of expandable
tubular members 82 or expandable sand control screen assembly 84.
When expansion tool 100 contacts seal bore 92, the expansion
process is complete, as best seen in FIG. 5. Expansion tool 100 is
then returned to its running configuration such that coiled tubing
string 102 and expansion tool 100 may be retrieved to the
surface.
[0055] Following the expansion process, a tubing string 112 may be
run downhole to provide a conduit for formation fluids to travel
from formation 14 to the surface, as best seen in FIG. 6. In the
illustrated embodiment, a seal assembly 114 is carried on tubing
string 112 and is installed against the interior of seal bore 74 in
a known manner to prevent production fluids from flowing around the
exterior of tubing string 112.
[0056] Referring now to FIG. 7, therein is depicted another
embodiment of an apparatus for completing an interval of a wellbore
while drilling that is generally designated 150. As illustrated,
completing while drilling apparatus 150 is being used to lengthen
wellbore 132 beyond an upper section of wellbore 132 that includes
casing 134 that is cemented therein by cement 136. Completing while
drilling apparatus 150 includes a conventional drill string 152
that is used to apply weight on drill bit 130 as drill bit 130
rotates such that wellbore 132 may be extended. In the illustrated
embodiment, drill bit 130 is rotated using a downhole mud motor 154
which utilizes drilling fluid, indicated as arrows 156, to impart
rotation to drill bit 130. The drilling fluid, including the
cuttings created by drill bit 130, is then returned to the surface
around the exterior of completing while drilling apparatus 150 as
indicated by arrows 158.
[0057] Between drill string 152 and mud motor 154, completing while
drilling apparatus 150 may include a variety of other tools 160
such as measurement while drilling tools, logging while drilling
tools or the like. Mud motor 154 is coupled to drill bit 130 via a
splined subassembly 164. As described above, splined subassembly
164 includes mating members that transfer rotation from mud motor
154 to drill bit 130 and allow the flow of drilling mud
therethrough. The mating members of splined subassembly 164 are
initially coupled together using shear pins or other suitable means
that allow for the transfer of rotation between the mating members
and initially prevent relative translational movement
therebetween.
[0058] Positioned between splined subassembly 164 and drill bit 130
is a float subassembly 166. Float subassembly 166 includes a
valving mechanism that allows drilling mud to travel from drill
string 152 into drill bit 130 but prevents return fluid flow
through fluid communication paths in drill bit 130 during
subsequent operations such as gravel packing and production.
[0059] Completing while drilling apparatus 150 is positioned around
drill string 152. Completing while drilling apparatus 150 includes
a seal bore 174. Seal bore 174 is designed to provide a receiving
surface for various sealing mechanisms as explained below. Next,
completing while drilling apparatus 150 has a suspension tool 176
that is designed to support completing while drilling apparatus 150
within wellbore 132 and prevent the flow of fluids between
completing while drilling apparatus 150 and casing string 134
across suspension tool 176. In the illustrated embodiment,
suspension tool 176 is hydraulically actuated as described below.
Completing while drilling apparatus 150 also includes seal bore
178. Seal bore 178 is designed to provide a receiving surface for
various sealing mechanisms as explained below.
[0060] In the illustrated embodiment, completing while drilling
apparatus 150 includes crossover ports 180. Crossover ports 180 are
initially in a closed position during the drilling operation to
prevent fluid flow between the interior and exterior of completing
while drilling apparatus 150. As described below, crossover ports
180 are opened prior to a gravel packing operation to allow a
gravel packing slurry to travel from the interior to the exterior
of completing while drilling apparatus 150.
[0061] Next, completing while drilling apparatus 150 has one or
more sections of tubular members 182. Tubular members 182 are
designed to line wellbore 132 between the lower end of casing 134
and formation 114.
[0062] Coupled to the lower end of tubular members 182 is a sand
control screen assembly 184. Sand control screen assembly 184 may
be of any suitable construction but it preferably includes a
perforated base pipe 186. Positioned around base pipe 186 is a
filter media 188 such as a wire wrapped screen jacket that may
include a screen wire wrapped around a plurality of ribs such that
the screen wire forms a plurality of turns with gaps therebetween
through which formation fluids flow but which prevent the flow of
particulate materials of a predetermined size from passing
therethrough. Positioned exteriorly of filter media 188 is a
perforated outer shroud 190 that serves as a gravel packing
apparatus. Specifically, outer shroud 190 is designed to improve
the gravel pack by allowing for any sand bridges that form in the
annulus between the sand control screen and the borehole during a
gravel packing operation to be bypassed. In addition, one or more
channels may be positioned between outer shroud 190 and filter
media 188 to form slurry passageways. In either case, the sand
bridges are bypassed by the fluid slurry by passing through outer
shroud 190 into the annulus between outer shroud 190 and filter
media 188 or into the channels. After bypassing the sand bridge,
the fluid slurry passes back through outer shroud 190 to reenter
the annulus between outer shroud 190 and the borehole to complete
the gravel packing process.
[0063] While a single section of sand control screen assembly 184
is depicted, it should be understood by those skilled in the art
that any number of section of sand control screen assemblies 184
including outer shrouds 190 may be used as part of completing while
drilling apparatus 150. The number of sections of sand control
screen assemblies 184 will be determined based upon the length of
formation 114.
[0064] Below the lower end of sand control screen assemblies 184
there may be additional sections of tubular members 192. At the
lower end of completing while drilling apparatus 150 there is a
splined subassembly housing 194. Splined subassembly housing 194
provides support between splined subassembly 164 and completing
while drilling apparatus 150. Splined subassembly housing 194
includes a dynamic seal that prevents the flow of fluids between
splined subassembly housing 194 and splined subassembly 164, such
as a bearing seal. The dynamic seal allows for relatively
rotational movement between splined subassembly housing 194 and
splined subassembly 164 so that the torsional force placed on
splined subassembly 164 during drilling operations wherein drill
bit 130 is rotated is not transferred to completing while drilling
apparatus 150.
[0065] Positioned between drill string 152 and completing while
drilling apparatus 150 is a pair of seal members 196, 198 such as
cup seals. As explained below, seal members 196, 198 allow for the
hydraulic operation of suspension tool 176. Also positioned between
drill string 152 and completing while drilling apparatus 150 is a
release nut 200. Release nut 200 helps to support completing while
drilling apparatus 150 on drill string 152 then is operated to
release drill string 152 from completing while drilling apparatus
150.
[0066] The operation of completing while drilling apparatus 150
will now be described with reference to FIGS. 7-10. After the upper
section of wellbore 132 has been drilled and cased, the lower
section of wellbore 132 that traverses formation 114 may now be
drilled and completed. First, drill bit 130, float subassembly 166,
splined subassembly 164 including splined subassembly housing 194,
mud motor 154 and measurement while drilling tool 160 are assembled
at the surface and coupled to drill string 152. Thereafter, the
remainder of completing while drilling apparatus 150 is assembled
and attached to drill string 152. Specifically, the required number
of tubular members 192 are threadably attached to spline
subassembly housing 194 and the required number of sections of sand
control screen assemblies 184 with outer shrouds 190 are threadably
attached together in a conventional manner around drill string 152
as drill string 152 is threadably assembled and lowered into the
well as necessary.
[0067] Once the required length of sand control screen assemblies
184 are in place around drill string 152, the required length of
tubular members 182 is then attached to the outer string as
additional sections of drill string 152 are threadably assembled
and lowered into the well. To finish the assembly of completing
while drilling apparatus 150, seal bore 178, suspension tool 176
and seal bore 174 are assembled.
[0068] The entire completing while drilling apparatus 150 is then
lowered downhole on drill string 152 until drill bit 130 reaches
the bottom of wellbore 132. Wellbore 132 can them be extended by
rotating drill bit 130 and advancing drill string 152. In the
illustrated embodiment, this is achieved by pumping drilling fluid,
represented by arrows 156, down drill string 152 and through mud
motor 154. This creates a rotation in mud motor 154 that in turn
rotates the mating members of splined subassembly 164 and drill bit
130. After rotating mud motor 154, the drilling fluid passes
through splined subassembly 164, float subassembly 166 and drill
bit 130. The drilling fluid then carries the cuttings created by
drill bit 130 back to the surface as indicated by arrows 158.
[0069] As splined subassembly 164 and splined subassembly housing
194 are coupled together via a dynamic bearing type seal, the
rotation of splined subassembly 164 is not transferred to
completing while drilling apparatus 150. Accordingly, no torque is
transferred to completing while drilling apparatus 150 due to the
rotation of drill bit 130 which protects sand control screen
assembly 184 from damage during drilling.
[0070] During the drilling operation, information may be recorded
or may be sent to the surface in real-time from tool 160 that may
be sensing one or more parameters relating to the drilling
operation. In fact, tool 160 may be used to determine when the
drilling operation should cease such that completing while drilling
apparatus 150 will be properly positioned relative to formation
114.
[0071] Once completing while drilling apparatus 150 has reached the
desired depth, as depicted in FIG. 7, the drilling portion of the
completing while drilling operation ceases. Importantly, completing
while drilling apparatus 150 is positioned within wellbore 132
during the drilling operation. Accordingly, using completing while
drilling apparatus 150 assures that the completion equipment is
placed within wellbore 132 before wellbore 132 has an opportunity
to cave in.
[0072] At this point, suspension tool 176 may be hydraulically
actuated. Specifically, as best seen in FIG. 8, this is achieved by
dropping a ball 202 down drill string 152. Once ball 202 contacts
sleeve 204, drill string 152 is pressurized to shift sleeve 204 and
open ports 206. Once ports 206 are open, the fluid pressure within
drill string 152 may be communicated to suspension tool 176 between
seals 196, 198 to hydraulically actuate suspension tool 176 which
helps to support completing while drilling apparatus 150.
[0073] As discussed above, in those embodiments wherein the valving
mechanism within float subassembly 166 is a one-way valve, no
operation is required to prevent fluid flow up through drill bit
130. In those embodiments wherein the valving mechanism within
float subassembly 166 requires shifting to prevent fluid flow up
through drill bit 130, the closing operation may be achieved by
appropriate upward or downward jarring on float subassembly 166 or
other suitable technique such as dropping a ball to shift a sleeve,
which may also be used to in the disconnection process.
[0074] Drill string 152 is now ready to be disconnected from drill
bit 130 and completing while drilling apparatus 150. Specifically,
drill string 152 is disconnected from drill bit 130 and completing
while drilling apparatus 150 at splined subassembly 164. As
explained above, splined subassembly 164 includes a pair of mating
members that are initially coupled together using shear pins or
other suitable means. Accordingly, suitable upward jarring on
splined subassembly 164 causes the shear pins to shear allowing for
the disconnection of drill string 152 from drill bit 130 and
completing while drilling apparatus 150.
[0075] Once drill string 152 is disconnected from drill bit 130 and
completing while drilling apparatus 150, drill string 152 is
rotated at release nut 200 to complete the disconnection such that
drill string 152 may be raised uphole leaving drill bit 130 and
completing while drilling apparatus 150 in the hole.
[0076] In the illustrated embodiment, the next step is to run a
service tool 210 downhole to perform a gravel pack operation, as
best seen in FIG. 9. Specifically, service tool 210 includes a
crossover assembly 212 and a pair of seal members 214, 216 that are
positioned on opposite sides of crossover ports 180, which are now
open. Once in place, a fluid slurry containing gravel, sand or
proppants is pumped downhole within service tool 210 and through
crossover assembly 212, as indicated by arrows 218. The fluid
slurry then enters the annulus between completing while drilling
apparatus 150 and the borehole as indicted by arrows 220.
[0077] As stated above, outer shroud 190 forms a gravel packing
apparatus around filter media 188. Outer shroud 190 is used to
allow the fluid slurry to bypass any sand bridges that form during
the gravel packing operation such that the fluid slurry is
distributed to various locations within the interval to be gravel
packed. In the illustrated embodiment, the fluid slurry is injected
into the annulus then enters outer shroud 190 if sand bridging
occurs. Alternatively, the fluid slurry could be injected directly
into the annulus between outer shroud 190 and filter media 188.
Additionally, as stated above, one or more channels may be disposed
in the annulus between outer shroud 190 and filter media 188 to
form slurry passageways. In these embodiments, three independent
paths are established for the fluid slurry. Specifically, the
annulus between outer shroud 190 and the borehole, the area between
outer shroud 190 and filter media 188 defined by the channels and
the area between outer shroud 190 and filter media 188 not defined
by the channels.
[0078] In any of these embodiments, when the fluid slurry travels
from the interior to the exterior of outer shroud 190, a portion of
the gravel in the fluid slurry is deposited around outer shroud
190. This process progresses along the entire length of outer
shroud 190 as required until the annulus around outer shroud 190
becomes completely packed with the gravel. In addition, some of the
fluid slurry enters and remains inside in the portions of outer
shroud 190 that surround filter media 188. The fluid portion of the
slurry is allowed to pass through filter media 188, as indicated by
arrows 222, which leaves the gravel from the fluid slurry in this
region. Again, this process progresses along the entire length of
outer shroud 190 such that this region becomes completely packed
with the gravel. The fluid portion that travels through filter
media 188 then enters wash pipe 224 and travels through crossover
assembly 212 as indicated by arrows 226. The fluid then enters the
annulus between service tool 210 and completing while drilling
apparatus 150, as indicated by arrows 228, for return to the
surface. This process continues until the entire production
interval is completely packed with the gravel.
[0079] Following the gravel packing process, service tool 210 is
retrieved to the surface and a tubing string 230 may be run
downhole to provide a conduit for formation fluids to travel from
formation 114 to the surface, as best seen in FIG. 10. In the
illustrated embodiment, a seal assembly 232 is carried on tubing
string 230 and is expanded against the interior of seal bore 174 to
prevent production fluids from flowing around the exterior of
tubing string 230.
[0080] While this invention has been described with reference to
illustrative embodiments, this description is not intended to be
construed in a limiting sense. Various modifications and
combinations of the illustrative embodiments as well as other
embodiments of the invention, will be apparent to persons skilled
in the art upon reference to the description. It is, therefore,
intended that the appended claims encompass any such modifications
or embodiments.
* * * * *