Patent Publication Number: US-2019195049-A1

Title: System and method for guiding a tubular along a borehole

Description:
BACKGROUND 
     In the resource exploration and recovery industry, boreholes are formed in a formation for the purpose of locating and recovering various formation fluids. Boreholes extend to great depths and may include laterals that extend up to 10,000 feet (3,048-meters) or longer. Guiding tubulars, such as coiled tubing along such lengths can prove to be difficult. During insertion, friction between the coiled tubing and the formation may slow or stop downward progress at a coiled tubing lock-up depth which may vary depending upon formation conditions. 
     Various techniques have been developed that help operators overcome friction and allow coiled tubing to be directed to desired depths. For example, lubricants, such as drilling mud, may be employed to help reduce friction between coiled tubing and formation surfaces. Vibratory tools which may provide axial forces of between about 500 lbf (687-Joules) and about 5,000 lbf (6,799-Joules) may also be employed. Tractors, which may exert between 5,000 lbf and about 10,000 lbf (13,558-Joules) may also be used to pull coiled tubing to a desired depth. 
     Each of the above systems include advantages and disadvantages. For example, while lubricants have been shown to reduce friction by as much as about 40% to about 60%, continuous pumping is required. Further, a large volume of fluid must be stored and effectively managed. Vibratory tools such as a fluid hammer tool, may reduce friction by about 10% to about 20%. However, such tools are often less effective near or below the lock-up depth. Finally, tractors are less effective when the formation includes debris, proppant/sand or other issues that may reduce traction. Accordingly, the art would be appreciative of new methods and systems for guiding tubulars, such as coiled tubing, to desired depths in a formation. 
     SUMMARY 
     Disclosed is a system for monitoring and guiding a tubular downhole including a tubular including at least one sensor, a plurality of extended reach systems including at least two of a lubricant delivery system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular, and a controller operatively connected to the at least one sensor. The controller is configured and disposed to monitor parameters on the tubular and selectively activate one or more of the plurality of extended reach systems based on monitored parameters. 
     Also disclosed is a resource recovery and exploration system including a first system and, a second system including a tubular supporting a sensor. The tubular is fluidically connected to the first system. A plurality of extended reach systems including at least two of a lubricant delivery system arranged at the first system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular. A controller is operatively connected to the at least one force sensor. The controller is configured and disposed to monitor forces on the tubular and selectively activate one or more of the plurality of extended reach systems. 
     Further disclosed is a method of guiding a tubular into a formation including sensing a first force through a sensor operatively associated with a tubular moving into a borehole formed in a formation, activating a first one of a plurality extended reach systems based on the first force, detecting a second force on the tubular, and activating a second one of the plurality of extended reach systems based on the second force. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  depicts a resource exploration and recovery system having system for guiding a tubular along a borehole, in accordance with an exemplary embodiment; 
         FIG. 2  depicts a block diagram illustrating a tubular monitoring system, in accordance with an aspect of an exemplary embodiment; and 
         FIG. 3  depicts a flow chart illustrating a method of guiding a tubular along a borehole, in accordance with an aspect of an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     A resource exploration system, in accordance with an exemplary embodiment, is indicated generally at  10 , in  FIG. 1 . Resource exploration system  10  should be understood to include well drilling operations, resource extraction and recovery, CO 2  sequestration, and the like. Resource exploration system  10  may include a first system  14  operatively connected to a second system  16 . First system  14  may take the form of a surface system  20  including controls  24 , pumps  30  and a lubricant delivery system  32  that may be operatively connected to controls  24  and pumps  30 . Second system  16  may take the form of a downhole system  36  extending into a borehole  38  formed in a formation  40 . In an embodiment, borehole  38  may include a main bore  44  and one or more laterals  48 . 
     Second system  16  may include one or more tubulars  58  that extend into borehole  38 . Tubulars  58  may take the form of a coiled tubing  62  having a terminal end portion  66 . Tubular  58  is may include one or more sensors  70  and a tractor  74  coupled adjacent terminal end portion  66 . Sensors  70  may detect various forces on tubular  58  including pressure torque, strain, temperature and the like. Sensors  70  are operatively connected to controls  24  at first system  14 . Sensors  70  may be calibrated to downhole conditions including pressure, temperature, fluid type and the like to increase measurement accuracy. Sensors  70  may, for example, detect forces, that may include pressure and temperature, on tubular  58  associated with movement into borehole  38 , and particularly, into lateral  48 . More specifically, as tubular  58  travels further and further into borehole  38 , frictional forces develop that make progress difficult. 
     In accordance with an exemplary embodiment, resource exploration and recovery system  10  includes a tubular monitoring system  80  operatively connected to sensors  70  as well as a plurality of extended reach systems  90  as shown in  FIG. 2 . Extended reach systems  90  promote movement of tubular  58  into borehole  38  and may include lubricant delivery system  32 , tractor  74  as well as vibratory tools  92  which may include a fluid hammer  94 . Tubular monitoring system  80  may include a controller  110 , a CPU  112 , non-volatile memory  114  and an extended reach control module  116  which may be co-located or part of separate systems. Extended reach control module  116  may selectively control or may provide guidance for orchestrating selectively control of one or more of extended reach systems  90  as will be discussed herein. 
     Reference will now follow to  FIG. 3  in describing a method  200  of guiding a tubular along a borehole, in accordance with an aspect of an exemplary embodiment. In block  204  tubular  58  is guided into borehole  38  along main bore  44  and into lateral  48 . In block  206 , tubular monitoring system  80  senses forces on tubular  58 . If forces are below a selected threshold, tubular  58  is moved further into borehole  38 . However, if the sensed forces are above a first force threshold, control module  116  may activate a first one of extended reach systems  90  in block  208 . For example, control module  116  may activate lubricate delivery system  32 . It should be understood, that lubricant delivery system may also be activated as tubular  58  is introduced into borehole  38 . It should also be understood that the term “activate” includes providing guidance to an operator to activate lubricant delivery system  32 . 
     In further accordance with an exemplary aspect, in block  210  a determination is made, through data received from one or more of sensors  70 , whether forces on tubular  58  are above a second selected threshold. If the forces have not exceed the second threshold, tubular  58  may continue into borehole  38  with, for example, lubricant. If, however, the forces on tubular  58  have exceeded the second threshold, control module  116  may activate another of the plurality of extended reach systems  90 . For example, control module  116  may activate vibratory tools  92  in block  212 . Vibratory tools  92  may be active with or without lubricant delivery system  32  also being active. That is, depending upon forces on tubular  58 , a determination may be made that activation of vibratory tools  92  may be desired or, vibratory tools  92  together with lubricant may be helpful in guiding tubular  58  further into borehole  38 . It should also be understood that the term “activate” includes providing guidance to an operator to activate vibratory tools  92 . 
     In still further accordance with an exemplary aspect, in block  214  a determination is made, through data received from one or more of sensors  70 , whether forces on tubular  58  are above a third selected threshold. If the forces have not exceeded the third threshold, tubular  58  may continue into borehole  38  with, for example, vibratory tools  92  being active. Of course, lubricant delivery system  32  may also be active. If, however, the forces on tubular  58  have exceeded the third threshold, control module  116  may activate another of the plurality of extended reach systems  90 . For example, control module  116  may activate tractor  74  in block  218  to pull tubular  58  along, for example, lateral  48 . It should also be understood that the term “activate” includes providing guidance to an operator to activate tractor  74 . Tractor  74  may be a sole motive force acting upon tubular  58  or tractor  74  may be operated in connection with one or more additional ones of the plurality of extended reach systems  90 . 
     At this point it should be understood that the exemplary embodiments describe a system for motivating a tubular to a desired position within a borehole. The system senses forces at a downhole end of the tubular. or on a bottom hole assembly (BHA) located at the downhole end of the tubular, and determines which extended reach systems may be most helpful when activated singly and/or in combination to achieve the desired position. The system may employ thresholds based on prior operations and/or pre-job calculation to determine in which order, and/or in which combination extended reach tools may be activated to reduce stresses on the tubular and achieve the selected position. 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1 
     A system for monitoring and guiding a tubular downhole including a tubular including at least one sensor, a plurality of extended reach systems including at least two of a lubricant delivery system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular and a controller operatively connected to the at least one sensor, the controller being configured and disposed to monitor parameters on the tubular and selectively activate one or more of the plurality of extended reach systems based on monitored parameters. 
     Embodiment 2 
     The system according to any prior embodiment, wherein the plurality of extended reach systems includes each of the lubricant delivery system, the vibratory tool operatively connected to the tubular, and the tractor mechanically connected to the tubular. 
     Embodiment 3 
     The system of any prior embodiment, wherein the tubular comprises coiled tubing having a terminal end portion. 
     Embodiment 4 
     The system of any prior embodiment, wherein the plurality of extended reach systems includes the tractor operatively connected adjacent the terminal end portion of the coiled tubing. 
     Embodiment 5 
     The system of any prior embodiment, wherein the controller is configured to sequentially selectively control the plurality of extended reach systems. 
     Embodiment 6 
     The system according to any prior embodiment, wherein the controller monitors the at least one force sensor and selectively controls the plurality of extended reach systems in real time. 
     Embodiment 7 
     A resource recovery and exploration system including a first system, a second system including a tubular supporting a sensor, the tubular being fluidically connected to the first system, a plurality of extended reach systems including at least two of a lubricant delivery system arranged at the first system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular and a controller operatively connected to the at least one force sensor, the controller being configured and disposed to monitor forces on the tubular and selectively activate one or more of the plurality of extended reach systems. 
     Embodiment 8 
     The resource recovery and exploration system according to any prior embodiment, wherein the plurality of extended reach systems includes each of the lubricant delivery system, the vibratory tool operatively connected to the tubular, and the tractor mechanically connected to the tubular. 
     Embodiment 9 
     The resource recovery and exploration system of any prior embodiment, wherein the tubular comprises coiled tubing having a terminal end portion. 
     Embodiment 10 
     The resource recovery and exploration system of any prior embodiment, wherein the plurality of extended reach systems includes the tractor operatively connected adjacent the terminal end portion of the coiled tubing. 
     Embodiment 11 
     The resource recovery and exploration system of any prior embodiment, wherein the controller is configured to sequentially selectively control the plurality of extended reach systems. 
     Embodiment 12 
     The resource recovery and exploration system according to any prior embodiment, wherein the controller monitors the at least one force sensor and selectively controls the plurality of extended reach systems in real time. 
     Embodiment 13 
     A method of guiding a tubular into a formation including sensing a first force through a sensor operatively associated with a tubular moving into a borehole formed in a formation, activating a first one of a plurality extended reach systems based on the first force, detecting a second force on the tubular and activating a second one of the plurality of extended reach systems based on the second force. 
     Embodiment 14 
     The method any prior embodiment, further including sensing a third force on the tubular and activating a third one of the plurality of extended reach systems based on the third force. 
     Embodiment 15 
     The method of any prior embodiment, wherein activating the first, second, and third one of the plurality of extended reach systems includes responding in real time to forces experienced by the tubular moving into the borehole. 
     Embodiment 16 
     The method of any prior embodiment, further including calibrating the sensor to downhole conditions. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity). 
     The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.