Patent Publication Number: US-11028673-B2

Title: Thru-tubing operations

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application Ser. No. 62/718,061, filed Aug. 13, 2018. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to well intervention and completion. 
     BACKGROUND 
     Problems can develop in a producing well (for example, a hydrocarbon producing well) that can negatively affect operations, production, and ultimately revenue generated. Examples of problems are failure of mechanical equipment, changes in production characteristics, plugging, and increases in injection pressure. After a well begins production, such events may occur, which can require modification of the well in order to achieve production. This modification is called well intervention. Well intervention is any operation carried out on a well (for example, a hydrocarbon well) during its productive life. The operation can alter the state of the well or the well geometry, provide well diagnostics, or manage production of the well. 
     SUMMARY 
     This disclosure describes technologies relating to well operations, and more specifically, thru-tubing intervention and thru-tubing completion operations. Certain aspects of the subject matter described here can be implemented as an apparatus including a conduit and an expandable mandrel positioned within the conduit. The conduit is configured to be positioned within a subterranean zone. The conduit has an inner surface and an outer surface. The conduit defines an opening extending from the inner surface to the outer surface. At least a portion of the expandable mandrel is smaller than the opening. A longitudinal length of the expandable mandrel is longer than a longitudinal length of the opening. The expandable mandrel, when actuated, is configured to move in a radial direction with respect to the conduit, such that the portion of the expandable mandrel smaller than the opening moves through the opening and extends beyond the outer surface of the conduit. 
     This, and other aspects, can include one or more of the following features. 
     The apparatus can include a well tool coupled to and positioned within the expandable mandrel. 
     The well tool can include a device selected from a group consisting of a sensor, an energy harvesting tool, a computer, and a flow control device. 
     The expandable mandrel can include slotted ends configured to mate with the opening to secure a position of the expandable mandrel relative to the conduit. 
     The expandable mandrel can be coupled to the conduit by a flexible material. The flexible material can be configured to harden to secure a position of the expandable mandrel relative to the conduit. 
     The inner surface can define an inner volume of the conduit. The expandable mandrel, when actuated, can be configured to move in the radial direction, such that the expandable mandrel is positioned outside the inner volume. 
     Certain aspects of the subject matter described here can be implemented as a method. An apparatus is deployed through a production tubing of a well formed in a subterranean zone. The apparatus includes a conduit and an expandable mandrel positioned within the conduit. The conduit has an inner surface and an outer surface. The conduit defines an opening extending from the inner surface to the outer surface. At least a portion of the expandable mandrel is smaller than the opening. The apparatus is positioned at a desired location within the subterranean zone. After positioning the apparatus at the desired location, the expandable mandrel is moved in a radial direction with respect to the conduit, such that the portion of the expandable mandrel smaller than the opening moves through the opening and extends beyond the outer surface of the conduit. After moving the expandable mandrel through the opening, a position of the expandable mandrel relative to the conduit is secured. 
     This, and other aspects, can include one or more of the following features. 
     The apparatus can include a well tool coupled to and positioned within the expandable mandrel. 
     A property of the subterranean zone can be measured with the well tool. 
     Power can be generated within the subterranean zone with the well tool. 
     Data can be transmitted with the well tool from the subterranean zone to a surface location. 
     Fluid flow from the subterranean zone can be controlled with the well tool. 
     Moving the expandable mandrel through the opening can include pushing a tool through the conduit and against the movement to move the expandable mandrel through the opening. 
     Moving the expandable mandrel through the opening can include flowing a fluid into the conduit to increase pressure within the conduit and move the expandable mandrel through the opening. 
     Securing the position of the expandable mandrel relative to the conduit can include mating slotted ends of the expandable mandrel to the opening to secure the position of the expandable mandrel relative to the conduit. 
     The inner surface can define an inner volume of the conduit. Moving the expandable mandrel in the radial direction can include moving the expandable mandrel, such that the expandable mandrel is positioned outside the inner volume. 
     The well tool can be decoupled from the expandable mandrel. The well tool can be removed from the subterranean zone. 
     The expandable mandrel can be coupled to the conduit with a flexible material. 
     Securing the position of the expandable mandrel relative to the conduit can include hardening the flexible material to secure the position of the expandable mandrel relative to the conduit. 
     The details of one or more implementations of the subject matter of this disclosure are set forth in the accompanying drawings and the description. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims. 
    
    
     
       DESCRIPTION OF DRAWINGS 
         FIGS. 1A and 1B  are longitudinal views of an example apparatus. 
         FIGS. 1C and 1D  are cross-sectional views of an example apparatus. 
         FIGS. 2A, 2B, and 2C  show an example apparatus within an example subterranean zone. 
         FIGS. 3A and 3B  are schematic diagrams of an example system. 
         FIG. 4  is a flow chart of an example method for a thru-tubing well operation. 
         FIG. 5  is a block diagram of an example computer system. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter described in this disclosure can be implemented to install equipment within a well, retrieve equipment from a well, or both, by thru-tubing operations. The apparatus described can be used, for example, for thru-tubing completion operations and for thru-tubing intervention operations. The apparatus described can have an initial outer diameter that is small enough for the apparatus to be run and deployed downhole through the production tubing of a well. In some implementations, the apparatus is expandable, such that once the apparatus has been run to a desired location within the well, the apparatus can expand, for example, by moving an inner expandable mandrel of the apparatus to extend outside the boundary defined by the initial outer diameter of the apparatus. Once expanded, the apparatus does not impose any detectable spatial restriction to the tubular borehole, thereby enabling upstream access and further production of wellbore fluids through the apparatus. For example, once expanded, the inner diameter of the apparatus can be large enough to allow for intervention or completion strings to pass through. Once expanded, the apparatus can also optionally be retrieved to the surface by pulling the expanded apparatus out of the wellbore. 
     Optimized production and oil recovery are in demand for operators worldwide. Many oil wells are drilled as long horizontal wells and facilitate a larger connectivity with hydrocarbon reservoirs. Often, however, hydrocarbon reservoirs are not homogeneous nor stable over their productive lifetime. Thus, special completions equipment may be necessary to install in order to control and optimize hydrocarbon production. Conventional methods for retrofitting lower completion equipment typically employ workover rigs and pulling out upper completion tubing. This can be costly and time-consuming. On the other hand, thru-tubing operation enables running of equipment through upper completion tubing, thereby eliminating the need for workover rigs and also allowing for lighter rig ups to be used, such as coiled tubing or wireline. 
       FIG. 1A  shows a longitudinal view of an apparatus  100 , according to some implementations. The apparatus  100  includes a conduit  101  and an expandable mandrel  105  positioned within the conduit  101 . The conduit is configured to be positioned within a subterranean zone. The subterranean zone can include, for example, a formation, a portion of a formation, or multiple formations in a hydrocarbon-bearing reservoir from which recovery operations can be practiced to recover trapped hydrocarbons. In some implementations, the subterranean zone includes an underground formation of naturally fractured or porous rock containing hydrocarbons (for example, oil, gas, or both). In some implementations, the well can intersect other suitable types of formations, including reservoirs that are not naturally fractured in any significant amount. The apparatus  100  can be positioned and used within a wellbore (formed in the subterranean zone) that has any orientation, such as horizontal, vertical, or otherwise at any other angle that deviates from a horizontal or vertical orientation. 
     The conduit  101  has an inner surface  101   a  and an outer surface  101   b . The conduit  101  defines an opening  103  extending from the inner surface  101   a  to the outer surface  101   b . At least a portion of the expandable mandrel  105  is smaller than the opening  103 . Therefore, the portion of the expandable mandrel  105  that is smaller than the opening  103  can fit through the opening  103 . The expandable mandrel  105  has a longitudinal length that is longer than a longitudinal length of the opening  103 . When actuated, the expandable mandrel  105  can move in a radial direction with respect to the conduit  101  (that is, a direction that is transverse to a longitudinal axis  102  of the conduit  101 ), such that the portion of the compartment  101  that is smaller than the opening  103  moves through the opening  103  and extends beyond the outer surface  101   b  of the conduit  101 . 
     The apparatus  100  can include a well tool  150  that is coupled to and positioned within the expandable mandrel  105 . The well tool  150  can include at least one sensor (for example, a temperature sensor, a pressure sensor, or both), an energy harvesting system (for example, a turbine coupled to an electric generator), a wireless communication system (for example, an acoustic or electromagnetic based transmitting and receiving system), a computer (for example, a microcontroller system with memory), a power storage system (for example, a battery), and a flow control device (for example, a flow valve). The expandable mandrel  105  is configured to move through the opening  103  in a direction transverse to a longitudinal axis  102  of the conduit  101 , such that at least a portion of the expandable mandrel  105  extends outside the conduit. The expandable mandrel  105  can be moved, for example, by mechanical force or hydraulic force. For example, a tool (such as a wedge) can be pushed through the conduit  101  and against the expandable mandrel  105  to move the expandable mandrel  105  through the opening  103 . As another example, a fluid can be flowed into the conduit  101  to increase pressure within the conduit  101  and move the expandable mandrel  105  through the opening  103 . In some implementations, the apparatus  100  includes an inflatable packer positioned within the conduit that can be inflated (for example, by flowing a fluid into the inflatable packer) to move the expandable mandrel  105  through the opening  103 . After the expandable mandrel  105  has been moved through the opening  103 , the inflatable packer can be deflated and removed. 
       FIG. 1B  shows a longitudinal view of the apparatus  100  shown in  FIG. 1A , after the apparatus  100  has been expanded. The expandable mandrel  105  can couple to the conduit  101  at the opening  103  of the conduit  101 . In some implementations, the expandable mandrel  105  includes slotted ends  107  that are configured to mate with the opening  103  of the conduit  101  to secure the position of the expandable mandrel  105  relative to the conduit  101 . In some implementations, the expandable mandrel  105  can mate with a metal-to-metal sealing surface located around the circumference of the opening  103 . The mating material can be made of, for example, a ductile metal that is resistant to corrosion from exposure to wellbore fluids. In some implementations, the mating material can deform and upon deformation, permanently seal between the opening  103  of the conduit  101  and the contacting surface of the expandable mandrel  105 . The expandable mandrel  105  can include one or more sealing elements configured to form a seal between the conduit  101  and the expandable mandrel  105 . In some implementations, the expandable mandrel  105  includes sealing rings around the circumference of the opening  103 . The sealing reals can be made of a material that can withstand downhole conditions, for example, the associated downhole temperature, corrosive fluids that may be present downhole, and debris. 
       FIG. 1C  shows a cross-sectional view of the apparatus  100 , according to some implementations. The expandable mandrel  105  can be coupled to the conduit  101  by a flexible material  109 , such as rubber, or a permanently deformable material, such as ductile metal. In some implementations, the flexible material  109  is hardened after the expandable mandrel  105  has been moved through the opening  103 , so that the position of the expandable mandrel  105  relative to the conduit  101  can be secured. When the flexible material  109  is made of ductile metal, the flexible material  109  can be folded to compress the flexible material  109 . The flexible material  109  can be strained to its material yield point in the direction opposite of which the expandable mandrel  105  is to be expanded when deployed in the wellbore. In such implementations, the apparatus  100  can include a retaining device configured to secure the expandable mandrel  105  in an unexpanded state within the opening  103 . The retaining device can be configured to withstand the spring force exerted by the flexible material  109  when the flexible material  109  is compressed. In some implementations, the retaining device is provided in the form of shear studs oriented along the longitudinal axis  102  of the conduit  101 . When the expandable mandrel  105  is expanded (for example, by mechanical or hydraulic force), the shear studs can shear off and release the expandable mandrel  105 , such that the expandable mandrel  105  can move through the opening  103 . 
     In some implementations, the flexible material  109  includes a hardening fluid that can be hardened after the expandable mandrel  105  has been moved through the opening  103 , so that the position of the expandable mandrel  105  relative to the conduit  101  can be secured. In some implementations, a hardening fluid is flowed into the flexible material  109  after the expandable mandrel  105  has been moved through the opening  103 , and then the hardening fluid is allowed to harden, so that the position of the expandable mandrel  105  relative to the conduit  101  can be secured. The hardening fluid can be a fluid that naturally hardens after some time. The hardening fluid can be a fluid that hardens in response to an external stimulus, such as heat or pressure. In some implementation, the pressure of the wellbore, the temperature of the wellbore, or both the pressure and the temperature of the wellbore cause the hardening fluid to harden within the flexible material  109 . The hardening fluid can be, for example, a cement, a thermoset (also referred as thermosetting plastic or thermosetting polymer), or a resin. Hardening of the hardening fluid can include a chemical reaction, cross-linking, homopolymerization, or a combination of these. In some implementations, a hardening agent (or a curing agent) can be flowed into the flexible material  109 , and the hardening agent can react with the hardening fluid to harden (or cure) the hardening fluid. In some implementations, the hardening agent and the hardening fluid are flowed into the flexible material  109  simultaneously. In some implementations, the hardening agent and the hardening fluid are flowed into the flexible material  109  separately. In some implementations, the flexible material  109  contains the hardening fluid before the apparatus  100  is positioned within the well. In some implementations, fluid is flowed into the flexible material  109 , for example, by a pump after the apparatus  100  is positioned within the well. 
       FIG. 1D  shows a cross-sectional view of the apparatus  100  shown in  FIG. 1C , after the apparatus  100  has been expanded. The inner surface  101   b  of the conduit  101  can define an inner volume  104  of the conduit  101 . In some implementations (and as shown in  FIG. 1D ), after the apparatus  100  has been expanded (that is, the expandable mandrel  105  has been moved through the opening  103 ), the expandable mandrel  105  is positioned outside the inner volume  104 . The position of the expandable mandrel  105  relative to the conduit  101  can then be secured, so that the inner volume  104  of the conduit  101  remains unrestricted by the expandable mandrel  105 . In some implementations, a portion of the expandable mandrel  105  can be positioned within the inner volume  104 . 
       FIGS. 2A, 2B, and 2C  show the apparatus  100 , according to some implementations, positioned within an example subterranean zone  200 . The apparatus  100  can be deployed downhole to a desired location within the subterranean zone  200 . The apparatus  100  can be supported (that is, secured or anchored) by a landing zone  202  formed within the subterranean zone.  FIG. 2A  shows the apparatus  100  positioned within the subterranean zone  200  and supported by the landing zone  202 , before the apparatus  100  has expanded.  FIG. 2B  shows the apparatus  100  positioned within the subterranean zone  200  and supported by the landing zone  202 , after the apparatus  100  has expanded.  FIG. 2C  shows a cross-sectional view of the apparatus  100  positioned within the subterranean zone  200  and supported by the landing zone  202 , after the apparatus  100  has expanded. As shown in  FIG. 2C , the apparatus  100  can include a well tool  150  coupled to and positioned within an expandable mandrel  105 . 
       FIGS. 3A and 3B  are schematic diagrams of a well completion system, according to some implementations, positioned within a subterranean zone  200 . The well completion system can include multiple apparatuses  100   a  and  100   b  supported by multiple landing zones  202   a  and  202   b , respectively. The apparatuses  100   a  and  100   b  can be substantially the same as the apparatus  100  described before. For example, both apparatuses  100   a  and  100   b  can be the same implementation of the apparatus  100  described before. As another example, apparatus  100   a  can be a certain implementation of the apparatus  100  described before, and apparatus  100   b  can be another implementation of the apparatus  100  described before. Additional apparatuses (similar to or the same as the apparatus  100 ) can be deployed downhole and supported by additional landing zones (such as the landing zone  202   c ). Each apparatus can be provided in a variety of configures depending on the desired application. Some non-limiting examples of applications include isolated water producing zones, high permeability hydrocarbon producing zones, and gas producing zones. 
     The wellbore can include multiple producing zones. A producing zone (often called a compartment in the wellbore) can be defined as the zone between two landing zones (for example, between landing zones  202   a  and  202   b ). By including a flow control device in the well tool  150  positioned within the producing zones, production control can be achieved, thereby enabling choking and shut in of the respective producing zone. This feature can improve hydrocarbon recovery from the well. 
     As mentioned before, the apparatus  100  can allow access of intervention or completion tools when the apparatus  100  is expanded. Such tools can be used to retrieve well tools (such as well tool  150 ), replace well tools, or both. For example, a kick-over intervention tool can be used to retrieve and replace gas lift tools that are located in side pocket mandrels (such as the expandable mandrel  105 ). By enabling upstream access of tools through the expanded apparatus  100 , service and modification of well tools and well completion system architecture can be achieved even for multiple installations of the apparatus  100  in the wellbore. 
       FIG. 4  is a flow chart of an example method  400  for thru-tubing well operation. The method  400  can be applicable, for example, to the apparatus  100 . At step  402 , the apparatus  100  is deployed through a production tubing of a well formed in a subterranean zone  200 . As mentioned before, the apparatus  100  includes a conduit  101  defining an opening  103  on a lateral side of the conduit  101  and an expandable mandrel  105  positioned within the conduit  101 . The apparatus  100  can include a well tool  150  coupled to and positioned within the expandable mandrel  105 . At step  404 , the apparatus  100  is positioned at a desired location within the subterranean zone  200 . The apparatus  100  can be secured by a landing zone  202 , so that the apparatus  100  remains in place at the desired location within the subterranean zone  200 . 
     After positioning the apparatus  100  within the subterranean zone at step  404 , the expandable mandrel  105  is moved through the opening in a direction transverse to a longitudinal axis  102  of the conduit  101  at step  406 , such that at least a portion of the expandable mandrel  105  extends outside the conduit  101 . The expandable mandrel  105  can be moved by mechanical force at step  406  by pushing a tool (such as a wedge) through the conduit  101  and against the expandable mandrel  105  to move the expandable mandrel  105  through the opening  103 . The expandable mandrel  105  can be moved by hydraulic force at step  406  by flowing a fluid into the conduit  101  to increase pressure within the conduit  101  and move the expandable mandrel  105  through the opening  103 . 
     After moving the expandable mandrel  105  at step  406 , a position of the expandable mandrel  105  relative to the conduit  101  is secured at step  408 . For example, the position of the expandable mandrel  105  can be secured at step  408  by mating slotted ends  107  of the expandable mandrel  105  to the opening  103 . The expandable mandrel  105  can be coupled to the conduit  101 . For example, the expandable mandrel  105  is coupled to the conduit  101  with a flexible material  109 . The flexible material  109  can be hardened to secure the position of the expandable mandrel  105  relative to the conduit  101  at step  408 . In some implementations, the expandable mandrel  105  can be moved through the opening  103 , such that the expandable mandrel  105  is positioned outside an inner volume  104  defined by an inner surface  101   b  of the conduit  101 . 
     The well tool  150  can be used to measure a property of the subterranean zone (such as pressure or temperature). The well tool  150  can be used to generate power within the subterranean zone. The well tool  150  can be used to transmit data from the subterranean zone to a surface location. The well tool  150  can be used to control fluid flow from the subterranean zone into the well, for example, by commands received from a surface location or in response to a measured downhole condition. The well tool  150  can also be retrieved, for example, in the case that the well tool  150  malfunctions and needs to be repaired, replaced, or upgraded. In such cases, the well tool  150  can be decoupled from the expandable mandrel  105 , and the well tool  150  can be removed from the subterranean zone (as described before). The well tool  150  can then be repaired and re-run downhole through the conduit  101  to be re-coupled to the expandable mandrel  105  within the subterranean zone, or a new well tool can be run downhole through the conduit  101  to be coupled to the expandable mandrel  105  within the subterranean zone. 
       FIG. 5  is a block diagram of an example computer system  500  used to provide computational functionalities associated with described algorithms, methods, functions, processes, flows, and procedures, as described in this disclosure, according to some implementations. For example, the well tool  150  can include the computer system  500 . The computer  502  includes a processor  505 . Although illustrated as a single processor  505  in  FIG. 5 , two or more processors may be used according to particular needs, desires, or particular implementations of the computer  502 . Generally, the processor  505  executes instructions and manipulates data to perform the operations of the computer  502  and any algorithms, methods, functions, processes, flows, and procedures as described in this specification. 
     The computer  502  can also include a database  506  that can store data for the computer  502  or other components (or a combination of both) that can be connected to the network. Although illustrated as a single database  506  in  FIG. 5 , two or more databases (of the same or combination of types) can be used according to particular needs, desires, or particular implementations of the computer  502  and the described functionality. While database  506  is illustrated as an integral component of the computer  502 , database  506  can be external to the computer  502 . 
     The computer  502  also includes a memory  507  that can store data for the computer  502  or other components (or a combination of both) that can be connected to the network. Although illustrated as a single memory  507  in  FIG. 5 , two or more memories  507  (of the same or combination of types) can be used according to particular needs, desires, or particular implementations of the computer  502  and the described functionality. While memory  507  is illustrated as an integral component of the computer  502 , memory  507  can be external to the computer  502 . The memory  507  can be a transitory or non-transitory storage medium. 
     The memory  507  stores computer-readable instructions executable by the processor  505  that, when executed, cause the processor  505  to perform operations, such as transmitting data (for example, temperature or pressure data from one or more sensors of the well tool  150 ) from the subterranean zone to a surface location. The computer  502  can also include a power supply  514 . The power supply  514  can include a rechargeable or non-rechargeable battery that can be configured to be either user- or non-user-replaceable. The power supply  514  can be hard-wired. There may be any number of computers  502  associated with, or external to, a computer system containing computer  502 , each computer  502  communicating over the network. Further, the term “client,” “user,” “operator,” and other appropriate terminology may be used interchangeably, as appropriate, without departing from the scope of this specification. Moreover, this specification contemplates that many users may use one computer  502 , or that one user may use multiple computers  502 . 
     In this disclosure, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed in this disclosure, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section. 
     In this disclosure, “approximately” means a deviation or allowance of up to 10 percent (%) and any variation from a mentioned value is within the tolerance limits of any machinery used to manufacture the part. 
     Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “0.1% to about 5%” or “0.1% to 5%” should be interpreted to include about 0.1% to about 5%, as well as the individual values (for example, 1%, 2%, 3%, and 4%) and the sub-ranges (for example, 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “X, Y, or Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise. “About” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range. 
     While this disclosure contains many specific implementation details, these should not be construed as limitations on the scope of the subject matter or on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this disclosure in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any suitable sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination. 
     Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results. 
     Accordingly, the previously described example implementations do not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.