Expandable filtering system for single packer systems

An arrangement having a body with at least one drain provided in the body is disclosed. The drain is configured to receive fluid when the body is expanded from a first unexpanded condition to a second expanded condition. At least one flowline is connectable to the drain. A screen is positioned over the drain and is configurable to expand from the first unexpanded condition to the second expanded condition.

BACKGROUND OF THE DISCLOSURE

While the disclosure is applicable outside the oil field industry, one such use of the disclosure is in sampling underground reservoir fluids. Sampling of underground fluids is typically beneficial in identifying underground fluid constituents and properties related thereto. For example, fluid sampling may be conducted by deploying a probe having a sampling port to receive formation fluid. The identification of fluid properties is beneficial for understanding the reservoir, planning extraction and production techniques, and even providing information on expected refinement requirements.

A wellbore is generally drilled prior to sampling the underground formation fluids. The probe is limited to providing a single fluid sample at a given depth and radial location of the wellbore. The probe must then be moved to a subsequent location in order to sample fluid at a different depth. The probe is extended from a tool and pressed against the wellbore formation to receive fluid. The fluid may be tested downhole or trapped and later tested at the surface.

Conventional sampling systems, such as the probe, not only receive formation fluid but also unwanted filtrate or contaminates. In many instances, the filtrate or contaminants may be large enough to clog a port of the sampling system. The clogging can prevent any further fluid from being received through the sampling port. Solutions to this have focused on methods to continue sampling rather than any solution related preventing the debris from invading the sampling port. Chief among these techniques is to increase the drawdown pressure at the sampling port with an underground pump. As can be expected, however, such a solution can cause additional dislodgement of particles, preventing further sampling.

Dealing with a clogged sampling port can cause additional rig time, which can be expensive, or even a failure to receive fluid samples, which can lead to inaccurate fluid property measurements, fluid models or other undesirable outcomes that are attempting to be prevented by the sampling operation. Improvements in sampling systems are beneficial in the industry to save expensive rig time and ensure quality formation sample measurements are obtained.

DETAILED DESCRIPTION

It will be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, this disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the subterranean formation of a first feature over or on a second feature in the description may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.

In accordance with the present disclosure, a wellsite with associated wellbore and apparatus is described in order to describe an embodiment of the disclosure, but not limiting or only arrangement of the subject matter of the disclosure. To that end, apparatus at the wellsite may be altered, as necessary, due to field considerations encountered.

The present disclosure illustrates a system and method for collecting formation fluid through a port or drain in the body of an inflatable or expandable packer. The collected formation fluid may be conveyed along an outer layer of the packer to a tool flow line and then directed to a desired collection location. Use of the packer to collect a sample enables the use of larger expansion ratios and higher drawdown pressure differentials. Additionally, because the packer uses a single expandable sealing element, the packer is better able to support the formation in a produced zone at which formation fluids are collected. This quality facilitates relatively large amplitude draw-downs even in weak, unconsolidated formations.

The packer is expandable across an expansion zone to collect formation fluids from a position along the expansion zone, i.e. between axial ends of the outer sealing layer. Formation fluid can be collected through one or more ports or drains comprising fluid openings in the packer for receiving formation fluid into an interior of the packer. The ports may be positioned at different radial and longitudinal distances. For example, separate ports can be disposed along the length of the packer to establish collection intervals or zones that enable focused sampling at a plurality of collecting intervals, e.g. two or three collecting intervals. The formation fluid collected may be directed along flow lines, e.g. along flow tubes, having sufficient inner diameter to transport the formation fluid. Separate flowlines can be connected to different drains to enable the collection of unique formation fluid samples. In other applications, sampling can be conducted by using a single drain placed between axial ends of the packer sealing element.

Referring generally toFIG. 1, one embodiment of a well system101is illustrated as deployed in a wellbore110. The well system101comprises a conveyance105employed to deliver at least one packer160into the wellbore110. In many applications, the packer160is used on a modular dynamics formation tester (MDT) tool deployed by the conveyance105in the form of a wireline. However, the conveyance105may have other forms, including tubing strings, such a coiled tubing, drill strings, production tubing, casing or other types of conveyance depending on the required application. In the embodiment illustrated, the packer160is an inflatable or extendable packer used to collect formation fluids from a surrounding formation115. The packer160is selectively expanded in a radially outward direction to seal across an expansion zone. For example, the packer160may be inflated by fluid, such as wellbore fluid, hydraulic fluid or other fluid. When the packer160is expanded to seal against the wellbore110, formation fluids can flow into the packer160. The formation fluids may then directed to a tool flow line and produced to a collection location, such as a location at a well site surface.

As shown inFIG. 1, the conveyance105may extend from a rig101into a zone of the formation115. In an embodiment, the packer160may be part of a plurality of tools125, such as a plurality of tools forming a modular dynamics formation tester. The tools125may collect the formation fluid, test properties of the formation fluid, obtain measurements of the wellbore, formation about the wellbore or the conveyance105, or perform other operations as will be appreciated by those having ordinary skill in the art. The tools125may be measurement while drilling or logging while drilling tools, for example such as shown by numerals6aand6b. In an embodiment, the downhole tools6aand6bmay be a formation pressure while drilling tool.

In an embodiment, the tools125may include logging while drilling (“LWD”) tools having a thick walled housing, commonly referred to as a drill collar, and may include one or more of a number of logging devices. The logging while drilling tool may be capable of measuring, processing, and/or storing information therein, as well as communicating with equipment disposed at the surface of the well site. As another example, the tools125include measurement while drilling (“MWD”) tools may include one or more of the following measuring tools a modulator, a weight on bit measuring device, a torque measuring device, a vibration measuring device, a shock measuring device, a stick slip measuring device, a direction measuring device, and inclination measuring device, and\or any other device. As yet another example, the tools125may include a formation capture device170, a gamma ray measurement device175and a formation fluid sampling tool610,710,810which may include a formation pressure measurement device6aand/or6b. The signals may be transmitted toward the surface of the earth along the conveyance105.

Measurements obtained or collected may be transmitted via a telemetry system to a computing system185for analysis. The telemetry system may include wireline telemetry, wired drill pipe telemetry, mud pulse telemetry, fiber optic telemetry, acoustic telemetry, electromagnetic telemetry or any other form of telemetering data from a first location to a second location. The computing system185is configurable to store or access a plurality of models, such as a reservoir model, a fluid analysis model, a fluid analysis mapping function.

The rig101or similar looking/functioning device may be used to move the conveyance105. Several of the components disposed proximate to the rig101may be used to operate components of the overall system. For example, a drill bit116may be used to increase the length (depth) of the wellbore. In an embodiment where the conveyance105is a wireline, the drill bit116may not be present or may be replaced by another tool. A pump130may be used to lifts drilling fluid (mud)135from a tank140or pits and discharges the mud135under pressure through a standpipe145and flexible conduit150or hose, through a top drive155and into an interior passage inside the conveyance105. The mud135which can be water or oil-based, exits the conveyance105through courses or nozzles (not shown separately) in the drill bit116, wherein it cools and lubricates the drill bit116and lifts drill cuttings generated by the drill bit116to the surface of the earth through an annular arrangement.

When the well110has been drilled to a selected depth, the tools125may be positioned at the lower end of the conveyance105if not previously installed. The tools125may be coupled to an adapter sub160at the end of the conveyance105and may be moved through, for example in the illustrated embodiment, a highly inclined portion165of the well110.

During well logging operations, the pump130may be operated to provide fluid flow to operate one or more turbines in the tools125to provide power to operate certain devices in the tools125. When tripping in or out of the well110, (turning on and off the mud pumps130) it may be in feasible to provide fluid flow. As a result, power may be provided to the tools125in other ways. For example, batteries may be used to provide power to the tools125. In one embodiment, the batteries may be rechargeable batteries and may be recharged by turbines during fluid flow. The batteries may be positioned within the housing of one or more of the tools125. Other manners of powering the tools125may be used including, but not limited to, one-time power use batteries.

An apparatus and system for communicating from the conveyance105to the surface computer185or other component configured to receive, analyze, and/or transmit data may include a second adapter sub190that may be coupled between an end of the conveyance105and the top drive155that may be used to provide a communication channel with a receiving unit195for signals received from the tools125. The receiving unit195may be coupled to the surface computer185to provide a data path therebetween that may be a bidirectional data path.

Though not shown, the conveyance105may alternatively be connected to a rotary table, via a Kelly, and may suspend from a traveling block or hook, and additionally a rotary swivel. The rotary swivel may be suspended from the drilling rig101through the hook, and the Kelly may be connected to the rotary swivel such that the Kelly may rotate with respect to the rotary swivel. The Kelly may be any mast that has a set of polygonal connections or splines on the outer surface type that mate to a Kelly bushing such that actuation of the rotary table may rotate the Kelly. An upper end of the conveyance105may be connected to the Kelly, such as by threadingly reconnecting the drill string105to the Kelly, and the rotary table may rotate the Kelly, thereby rotating the drill string105connected thereto.

FIG. 2illustrates an embodiment of a packer system200. For example, the packer system200may be the packer160as shown inFIG. 1or may be deployed into a wellbore for other uses. The packer system200may be described as a “packer” for brevity in some circumstances. The packer system200may be used to fluidly isolate one portion of a wellbore from another portion of a wellbore. The packer system200is conveyed to a desired downhole location and, in the non-limiting embodiment provided, inflated or expanded to provide a seal between the packer system200and the well110. For example, the packer system may prevent fluid communication from two portions of a wellbore by expanding or inflating circumferentially to abut the wellbore.

The packer system200may have one or more ports or sampling drains204,206for receiving fluid from the formation or the wellbore into the packer system200. In an embodiment, the packer system200has one or more guard ports204located longitudinally from one or more sample ports206. In the illustrated embodiment, the guard ports204are illustrated a closer longitudinal distance from ends of the packer system than a longitudinal distance of the one or more sample ports206to the ends of the packer system200. The ports204,206may be located at distinct radial positions about the packer system200such that the ports204,206contact different radial positions of the wellbore. The ports204,206may be embedded radially into a sealing element of outer layer of the packer system200. By way of example, sealing element may be cylindrical and formed of an elastomeric material selected for hydrocarbon based applications, such as nitrile rubber (NBR), hydrogenated nitrile butadiene rubber (HNBR), and fluorocarbon rubber (FKM). The packer system200may be expanded or inflated, such as by the use of wellbore fluid, hydraulic fluid, mechanical means or otherwise positioned such that the one or more sample ports206and the one or more guard ports204may abut the walls of the formation115to be sampled. The packer system200may be expanded or inflated from a first position to a second position such that the outer diameter of the packer system200is greater at the second position than the first position. In an embodiment, the second position may be the position in which the ports204,206abut the formation and the first position may be an unexpanded or deflated position. The packer system200may move to a plurality of positions between the first position and the second position. The packer system200may expand in the relative areas around the one or more guard ports204and the one or more sample ports206such that a tight seal is achieved between the exterior of the packer system200and wellbore, casing pipe or other substance external to the packer system200.

Operationally, the packer system200is positioned within the wellbore110to a sampling location. The packer system200is inflated or expanded to the formation through the expansion of the body202of the packer system200expanding with the internal diameter of the pipe or within the formation115. A pump may be utilized to draw fluid from the ports204,206and/or to transport fluid within or out of the packer system200. The pump may be incorporated into the packer system200or may be external to the packer system200. The fluid removed through the sample drain206and/or guard drains204may then be transported through the packer system200to a downhole tool, such as the tools125for example. In an alternative configuration, the packer system200may retain the fluid in an interior system for later analysis when the packer system200is deflated or unexpanded and retrieved. An outer seal layer212is provided around the periphery of the remainder of the packer system200to allow for mechanical wear of the unit as well as sealing capability to the formation115or inner wall of the wellbore. The packer system200may have an inner, inflatable bladder disposed within an interior of outer seal layer212.

Referring toFIG. 3, the packer system200is illustrated without the outer seal layer212. The guard ports204are positioned a longitudinal distance from the sample ports206and at different longitudinal distances from the relative outside positions/ends of the sample ports206. One or more flow lines208are in fluid communication with one or more of the guard ports204and/or the sample ports206. For example, one of the flow lines208may be connected to two of the guard ports204, and another one of the flow lines208may be connected only to one of the sample ports206. The flow lines208may be connected to a rotating tube210that allows for radial expansion of the packer system200without damaging the flow lines208. The rotating tubes210permit the flow lines208to be embedded within the packer system, such as embedded within the outer seal layer212and/or positioned along a longitudinal axis of the packer system200. For example, the rotating tubes210permit radial expansion of the packer system while permitting the flow lines208to maintain a longitudinal position with respect to the packer system200.

The initiation of flow through the one or more guard ports204and the one or more sample ports206may dislodge debris from the wellbore110and/or the formation115. Referring toFIG. 4, the packer system200is illustrated in side elevational view. As illustrated, one or more filters200are positionable about the guard ports204and/or the sample ports206to prevent debris from passing therethrough. The filters300are removable and may be replaceable based on a size of the debris. In the illustrated embodiment, the filters300abut the outer seal layer212to prevent materials from entering the packer drain systems without traveling through the screens300. The filters300may be located in grooves in the outer seal layer212.

Referring toFIG. 5, an exploded view of the screens300of the guard ports204and sample ports206is provided. In the illustrated embodiment, nine individual filters300are positioned around the periphery section illustrated, for approximately 180 degrees of the entire circumference of the packer system200. In an embodiment, the guard ports204and the sample ports206may have, for example, eighteen (18) total screen sections.

Referring toFIG. 6, a cross-section of the guard ports204and the sample ports206is illustrated. The flow lines208are provided below the screens300on the guard ports204and sample ports206to convey the fluid that enters the respective ports204,206. In the illustrated embodiment, fluid flow from the guard ports204is conveyed separately from fluid flow from the sample ports206.

Referring toFIG. 7, a perspective view of the packer system200ofFIG. 2, illustrating the connectors304is presented. The connectors304are used to connect the packer system200to the remainder of underground equipment, such as underground testing equipment or flow control devices. The connectors304are configured to separately convey fluids from the guard ports204and the sample ports206. In the illustrated embodiment, the flow from the guard ports204flow to one end310of the packer system200, while flow from the sample ports206flow to the other respective end312of the packer system200.

Referring toFIG. 8, a perspective view of the filter300of the packer system200ofFIG. 2before expansion is illustrated. The filter300comprises a non-compressible expandable material. In the illustrated example embodiment, the material comprises a ball or bead material316arranged such that spaces are formed between the material316. The spacing between each of the beads or balls allows fluid from the formation115to flow through while preventing larger material such as debris. In the illustrated embodiment, the material316may be metallic, such as stainless steel. The material316may be other materials depending on the environment, such as plastic. The material316may comprise other materials, such as a mechanical spring configuration, whereby the overall configuration provides filtering between coils of the spring after expansion. As another example, the material316may comprise a metallic braid configuration, the metallic braid is configured from metallic wires woven or braided together to form the matrix. In either configuration, mechanical spring or metallic braid, the filter300is configured to expand from a first deflated/unexpanded condition to a second inflated/expanded condition.

In an embodiment, the filters300are positioned in replaceable sections about the seal layer212of the packer200. Thus, the seal layer212may expand as well as the filter300, upon actuation, permitting the seal layer212to remain impervious to fluid intrusion, while the filter300allows flow through the expanded surface. For example, the filter300may increase in size, such as length or diameter, to substantially cover the respective guard port204or sample port206. The filter300may comprise a first section314and a second section318. The first section314may be movable with respect to the second section318. As the filter300increases in size, for example, the first section314and/or the second section318may move with respect to the other section. As an example, in the first position of the packer system200the first section314of the filter300may overlap the second section318of the filter300. As the packer system200moves form the first position to the second position, the first section314or the second section318may move such that the size of the filter300increases. As illustrated inFIG. 8, for example, the second portion318is at least partially underneath the first portion316. As the packer system200expands, the second portion318will be exposed to increase the size of the filter300.

Referring toFIG. 9, the filter300ofFIG. 8is illustrated in an expanded screen position. As provided, the ball material of the example embodiment allows for filtering of the fluid in the expanded condition of the packer200assembly. As there are two levels of ball material in the screen300, the screen300can approximately double in size, allowing the packer200to significantly expand. In the illustrated embodiment, the ball material expands to an essentially single layer from the two portions316,318inFIG. 8.

Referring toFIG. 10, the filters300ofFIG. 9are installed around the periphery of the packer system200such that the filters300fit the tubular shape. In the illustrated embodiment, there are eighteen of the filters300installed on the outside periphery. The filters300may contact or secure to connectors320that may be utilized to secure the filters300to the outer seal layer212and/or to each other. The number of filters300to be installed in the packer system200may be determined by dividing the entire circumference of 360 degrees by the number of units desired. In this manner, a greater or lesser number of screens around the periphery may be used. In the illustrated embodiment, each of the filters300represents a 60 degree radius.

Referring toFIG. 11, the filter300and associated one of the connectors320is illustrated in peripheral view. The filter300comprises the material316in substantially or completely enclosed or encapsulated by material399. The material399, in an embodiment, may comprise an anti-extrusion material, such as fibers, for example Kevlar fibers, carbon fibers or the anti-extrusive fibers. The material399may be expandable as the packer system300expands from the first position to the second position.

Referring toFIG. 12, the filter300ofFIG. 11is illustrated in cross-section. In the illustrated embodiment, two levels of bead material341are illustrated over an anti-extrusion fiber backing340. A fiber cap342is placed over the layers of bead material341to allow the bead materials to slide overtop of one another, while remaining within the respective filter300. The fiber cap342is constructed to allow for providing a restraining pressure on the ball material so that the restraining pressure is directed toward the central axis of the packer200. In an embodiment the fiber cap342may comprise a plurality of rod like devices placed side by side, such as metallic rods. The filter300may be provided with rounded corners343to prevent damage to other like units.

Referring toFIG. 13, a method for sampling is illustrated. In this method400, steps may include placing a packer200in a downhole environment as shown at step402. The method400may then proceed to the step of inflating or expanding the packer system200in the downhole environment so that an exterior surface of the packer system200contacts an interior diameter of the downhole environment, wherein during the expanding, a filter at least partially covering a fluid port204,206in the packer expands from a first unexpanded position to a second expanded position as shown at step404. The method then entails sampling the fluid through the filter300as shown at step406. The method may then end at step408.

As will be understood, sampling the fluid through the filter300is performed by drawing fluid into the port204,206. In an embodiment, vacuum from a pump may be used to draw formation fluid from a geotechnical formation through the port204,206. Additionally, sampling the fluid may entail drawing the fluid through both a guard drain204and the sample drain206of the packer system200. The method400may also include the step of transporting at least one of the fluids from the guard drain204and the sample drain206of the packer200to a remote location408. The arrangements described may be placed in the downhole environment through, for example, a drill string, a wireline or other method. Different conveyance may be used for the packer system200, including slickline, conventional wireline, logging while fishing systems, coiled tubing and tractor systems in addition to that described above.

In one embodiment, a system is disclosed. In this arrangement a body with at least one drain provided in the body, the drain configured to accept a fluid, the body configured to expand from a first unexpanded condition to a second expanded condition at least one tube connected to the at least one drain and at least one screen disposed over each of the at least one drain, the screen configured to expand from the first unexpanded condition to the second expanded condition are described.

In another embodiment, the system may be configured wherein the at least one filter disposed over the at least one drain is configured to expand from the first unexpanded condition to the second expanded condition by a first part of the at least one filter sliding upon a second part of the filter.

The foregoing outlines feature of several embodiments so that those skilled in the art may better understand the aspects of the disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structure for carrying out the sample purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.