Patent Publication Number: US-9835023-B2

Title: Barrier testing method

Description:
This application is the U.S. national phase of International Application No. PCT/EP2013/072699 filed 30 Oct. 2013 which designated the U.S. and claims priority to EP Patent Application No. 12190841.2 filed 31 Oct. 2012, the entire contents of each of which are hereby incorporated by reference. 
     FIELD OF THE INVENTION 
     The present invention relates to a barrier testing method for testing a production casing in a borehole. Furthermore, the invention relates to a completion system for oil production from a well and to an oil production facilitated by the method barrier testing method. 
     BACKGROUND ART 
     The Deepwater Horizon oil spill, also referred to as the oil spill in the Gulf of Mexico oil or the Macondo blowout, is an oil spill which flowed unabated for three months in 2010. This blowout is considered one of the largest accidental marine oil spills in the history of the petroleum industry, and the spill stemmed from a sea-floor oil gush that resulted from the 20 Apr. 2010 explosion of the Deepwater Horizon rig which drilled on the Macondo Prospect. It is guessed that one of the primary reasons for the cause of the blowout is a defective cement job during completion of the well. Cement is used to seal between a first tubular and a borehole wall and between the first tubular and the next tubular. The cement is injected, and for some reason, the cement settles in the intended space, and during this process, unwanted pockets are formed in the cement or the cement disappears in an unexpected fracture in the formation. If the cement does not sufficiently fill the annular space, e.g. between the first tubular and the borehole wall, the oil may leak during production and gush through the cement or along the tubular, and an oil spill disaster may be the next step. 
     After the Macondo blowout, ensuring well integrity has been an increased focus of governments around the world, and thus also of the oil industry. To this effect, the downhole barrier systems incorporated in the well completion designs have been brought into focus to improve the well integrity. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to wholly or partly overcome the above disadvantages and drawbacks of the prior art. More specifically, it is an object to provide an improved barrier testing method of barriers to be applied in a completion before initiating production in a well. 
     The above objects, together with numerous other objects, advantages, and features, which will become evident from the below description, are accomplished by a solution in accordance with the present invention by a barrier testing method for testing a production casing in a borehole, the method being applied before initiating production in a well, and the method comprising the steps of:
         connecting a drill pipe with a first end of a first production casing having annular barriers, which annular barriers comprise a tubular part forming part of the casing and an expandable sleeve circumferenting the tubular part, thereby defining an expandable space,   inserting the drill pipe and the first production casing via a drill head arranged at a top of the well into an intermediate casing extending in a first part of the borehole closest to the top of the well and at least part of the first production casing into a second part of the borehole,   sealing a second end of the first production casing,   pressurising the first production casing from within and expanding one or more of the expandable sleeves of the annular barriers to abut a wall of the borehole,   pressurising the first production casing from within to a predetermined pressure, and   testing the first production casing after expansion by measuring if the predetermined pressure is kept constant during a predetermined time period.       

     In an embodiment, the barrier testing method may further comprise the steps of setting a first barrier packer between the first production casing and the intermediate casing; disconnecting the drill pipe; pressurising the first production casing and the intermediate casing from within to a second predetermined pressure; and testing the first barrier packer by measuring if the second predetermined pressure is kept constant during a predetermined time period. 
     Furthermore, the barrier testing method may further comprise the steps of setting a first barrier packer between the first production casing and the intermediate casing; pressurising the intermediate casing from within to a second predetermined pressure; and testing the first barrier packer by measuring if the second predetermined pressure is kept constant during a predetermined time period. 
     In addition, the barrier testing method may further comprise the steps of inserting a second production casing into the well, the second production casing having a plug arranged within the second production casing and a downhole safety valve arranged within the second production casing closer to the top of the well than the plug; setting a second barrier packer in an annular space between the second production casing and the intermediate casing; pressurising the annular space from within to a third predetermined pressure; and testing the second barrier packer by measuring if the third predetermined pressure is kept constant during a predetermined time period. 
     Moreover, the barrier testing method may further comprise the steps of opening the downhole safety valve, pressurising the second production casing from within to a fourth predetermined pressure; and testing the plug by measuring if the fourth predetermined pressure is kept constant during a predetermined time period. 
     Additionally, the barrier testing method may further comprise the steps of closing the downhole safety valve, pressurising the second production casing above the downhole safety valve from within to a fifth predetermined pressure; and testing the downhole safety valve by measuring if the fifth predetermined pressure is kept constant during a predetermined time period. 
     Further, the barrier testing method may further comprise the steps of replacing the drill head with a well head, pressurising the annular space from within to a sixth predetermined pressure; and testing the second barrier packer by measuring if the sixth predetermined pressure is kept constant during a predetermined time period. 
     The third and sixth predetermined pressures may be identical. 
     Also, the barrier testing method may comprise further the steps of pressurising the second production casing above the downhole safety valve from within to a seventh predetermined pressure, and testing the downhole safety valve by measuring if the seventh predetermined pressure is kept constant during a predetermined time period. 
     In an embodiment, cement is provided between the intermediate casing and the borehole and the intermediate casing comprises at least two annular barriers, and before the first production casing is arranged in the well, the annular barriers of the intermediate casing are expanded to abut the wall of the borehole, thereby displacing the non-cured cement so that a pressure increase is created between the annular barriers, the method comprising the step of testing the annular barriers by monitoring the pressure increase for a period of time. 
     Furthermore, the intermediate casing may comprise an annular barrier, and before the first production casing is arranged in the well, the annular barriers of the intermediate casing are expanded to abut a second intermediate casing arranged outside the intermediate casing, whereby a second annular space is provided above and between the intermediate barriers and the second intermediate barrier, the method comprising the steps of pressurising the second annular space from within to an eight predetermined pressure, and testing the annular barrier by measuring if the eight predetermined pressure is kept constant during a predetermined time period. 
     The barrier testing method may further comprise the step of rotating the first production casing while inserting the same. 
     Moreover, the second end of the first production casing may comprise exterior edges adapted to function as a “drill head” during the insertion of the production casing into the second part of the borehole. 
     In addition, before the step of sealing the second end of the first production casing is initiated, the first production casing may be pressurised with a flushing fluid so that the flushing fluid is injected from the second end of the first production casing for flushing drilling mud outside the first production casing. 
     Furthermore, the flushing fluid may be any kind of fluid, such as well fluid, water or sea water. 
     In an embodiment of the barrier testing method the step of pressurising may be performed by pressurising fluid into the well from the top of the well. 
     Also, the step of sealing the second end of the first production casing may be performed by dropping a ball into the first production casing, the ball being adapted to seal off an opening provided at the second end of the first production casing. 
     Additionally, the step of sealing the second end of the first production casing may be performed by inserting a plug into the opening at the second end of the first production casing. 
     The barrier testing method may further comprise the step of removing the plug arranged in the second production casing. 
     Moreover, the barrier testing method may further comprise the step of providing apertures in the first production casing to allow fluid communication between the borehole and the casing. 
     In addition, the apertures may be provided by punching, drilling, pulling, sliding sleeves, perforating the first production casing or a combination thereof. 
     Also, the expandable sleeve may be made of metal. 
     Further, the tubular part of the annular barrier may comprise an opening. 
     Additionally, the intermediate casing and the first and second production casings may be made of metal. 
     In an embodiment, the barrier testing method may further comprise the step of injecting stimulation fluid out through the apertures into the borehole to perform stimulation of the borehole. 
     Moreover, the stimulation fluid may be an acid. 
     Furthermore, the barrier packer may be an expandable annular barrier. 
     In addition, the drill pipe may be connected with the first production casing by means of a running tool. 
     Also, the plug may be a glass plug or a formation isolation valve (FIV). 
     The barrier testing method may further comprise the steps of storing data from the testing of the first production casing, the first barrier packer, the second barrier packer, the plug, the downhole safety valve and the annular barriers, respectively, for documenting an overall integrity of the well before oil production. 
     The present invention furthermore relates to a completion system for oil production from a well, adapted for carrying out the method according to any of the preceding claims. 
     Finally, the present invention relates to an oil production facilitated by the method described above. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which 
         FIG. 1  shows a cross-sectional view of a first production casing being inserted into a borehole of a well, 
         FIG. 2  shows a cross-sectional view of the first production casing having annular barriers being expanded to pressure against a wall of the borehole, 
         FIG. 3  shows a cross-sectional view of the well in which a first barrier packer has been set between an intermediate casing and the first production casing, 
         FIG. 4  shows a cross-sectional view of the well in which a second production casing has been installed in the intermediate casing and a second barrier packer has been set between the intermediate casing and the second production casing, 
         FIG. 5  shows a cross-sectional view of the well in which a drill head at the top of the well has been removed before being replaced with a well head, 
         FIG. 6  shows a cross-sectional view of the well in which the drill head has been replaced with the well head, 
         FIG. 7  shows a cross-sectional view of the well in which the first casing has been provided with openings and production of hydrocarbon containing fluid flows through the openings in two production zones between expanded annular barriers, 
         FIG. 8A  shows a cross-sectional view of the top of an embodiment of the well in which two annular barriers arranged surrounding the intermediate casing have been expanded into the surrounding cement in order to provide a well barrier, 
         FIG. 8B  shows a cross-sectional view of the top of another embodiment of the well in which two annular barriers arranged surrounding a first intermediate casing have been expanded into the surrounding cement in order to provide a well barrier between two intermediate casings, 
         FIG. 9  shows a cross-sectional view of the well, illustrating the first production casing being rotated while being inserted into the borehole, and 
         FIG. 10  shows a cross-sectional view of an expanded annular barrier. 
     
    
    
     All the figures are highly schematic and not necessarily to scale, and they show only those parts which are necessary in order to elucidate the invention, other parts being omitted or merely suggested. 
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows a completion system  100  being completed. The drill head  6  is arranged at a top  7  of the well in a first part  18  of a borehole  4  and on top of a conductor pipe  8 . The conductor pipe  8  is cemented to form a seal against an inner wall  9  of the borehole  4  and is at its top connected with the drill head  6 . Inside the conductor pipe  8 , an intermediate casing  11  is arranged, still at the top  7  of the well. The intermediate casing  11  is also cemented to form a seal between the conductor pipe  8  and the intermediate casing. The intermediate casing  11  is also at its top end  12  connected with the drill head  6 . A drill pipe  10  is connected at a first end  13  with a first end  20  of a first production casing  3 . A second end  14  is connected with a pump (not shown) for pressurising the drill pipe  6  and thus the first production casing  3 . The production casing  3  and the drill pipe  10  are connected by means of a running tool  15  or a similar connection. The first production casing  3  comprises several annular barriers  17  which in  FIG. 1  are unexpanded while being inserted through the drill head  6  down into the intermediate casing  11 , and a main part of the first production casing  3  is introduced in a second part  19  of the borehole, forming an annulus  16  with the inner wall  9  of the borehole  4  and thus the formation  2 . While inserting the first production casing  3  in the borehole  4 , a second end  21  of the first production casing  3  furthest away from the top  7  of the well is open. 
     Subsequently, the annular barriers  17  are expanded to abut against the inner wall  9  of the borehole  4 , as illustrated in  FIG. 10 .  FIG. 10  shows an enlarged view of the annular barrier  17  in its expanded condition, where an expandable sleeve  22  surrounding a tubular part  23  abuts and pressures against the inner wall  9  of the borehole  4 . The expanded annular barrier  17  thus creates a seal between the casing and the inner wall  9  of the borehole  4  and divides the annulus  16  into a first production zone  24  and a second production zone  25 . The expandable sleeve  22  is connected with the tubular part  23  by means of two connection parts  26  and forms an expandable space  27  into which fluid flows from an inside of the tubular part through an opening  28  and into the space to expand the expandable sleeve  22  and thus the annular barrier  17 . The expandable sleeve  22  may be made of metal and have circumferential seals arranged on its outer face. 
     In  FIG. 2 , the second end  21  of the first production casing  3  is sealed by dropping a ball  29  into the fluid  30  in the drill pipe  10 . The ball  29  flows down the well until it seats in a seat  42  arranged in the second end  21  of the first production casing  3 . Subsequently, the first production casing  3  and the drill pipe  10  are pressurised from within, creating an increased pressure expanding the expandable annular barriers  17  until they abut the inner wall  9  of the borehole  4  and thus divide the annulus  16  into several production zones. In order to test if the first production casing  3  is still tight when the annular barriers  17  have been expanded, the drill pipe  10  and the first production casing  3  are pressurised to a first predetermined pressure, and the first production casing  3  is tested by measuring if the first predetermined pressure is kept constant during a predetermined time period. If the pressure drops during this time period, it means that the first production casing  3  is leaking, and if the pressure is maintained without having to pump any further, it means that the first production casing  3  is tight and forms a so-called “solid casing”, and that it is thus comparable with just a plain metal casing without any implemented components, such as sleeve, barriers or the like. 
     After testing the first production casing  3 , the drill pipe  10  must be disconnected, but before doing so, a first barrier packer  31  is set between the first production casing and the intermediate casing  11 , as shown in  FIG. 3 , if it was not already set before testing the first production casing  3 . Then, the drill pipe  10  is disconnected and the first production casing  3  and the intermediate casing  11  are pressurised from within to a second predetermined pressure, and the first barrier packer  31  is tested by measuring if the second predetermined pressure is kept constant during a predetermined time period. 
     In another embodiment, the intermediate casing  11  is pressurised from within to a second predetermined pressure so that the annular space  32  between the intermediate casing  11  and the drill pipe  10  is pressurised to the second predetermined pressure for a period of time, and the first barrier packer  31  is tested by measuring if the second predetermined pressure is kept constant during a predetermined time period. 
     In known well completion technology, packers and other “barriers” are set, but they are not tested, and it is therefore uncertain whether they are in fact barriers. 
     After confirming that the first barrier packer  31  is in fact a barrier, a second production casing  33  having a plug  34  and a downhole safety valve  36  is inserted into the well, as shown in  FIG. 4 . The plug  34  and the downhole safety valve  36  are both arranged within the second production casing  33 , and the downhole safety valve  36  is arranged closer to the top  7  of the well than the plug  34 . The downhole safety valve  36  is arranged approximately 200-300 meters down the second production casing from the top of the well. The second production casing  33  is arranged above the first production casing  3  and is thus closer to the top  7  of the well than the first production casing  3 . A second barrier packer  35  is subsequently set in an annular space  39  between the second production casing  33  and the intermediate casing  11 . In order to test the second barrier packer  35 , the annular space  39  is pressurised from within to a third predetermined pressure, and the second barrier packer  35  is tested by measuring if the third predetermined pressure is kept constant during a predetermined time period. The plug  34  may a conventional glass plug or a formation isolation valve, also called a formation isolation valve (FIV). 
     When it has been confirmed that the second barrier packer  35  is a barrier, the downhole safety valve  36  is opened and the second production casing  33  is pressurised from within to a fourth predetermined pressure, and the plug  34  is tested by measuring if the fourth predetermined pressure is kept constant during a predetermined time period. If the pressure is maintained during the predetermined period of time, it means that the plug  34  is a tight barrier. Subsequently, the downhole safety valve  36  is closed again, and now, five barriers have been tested. 
     After closing the downhole safety valve  36 , the second production casing  33  above the downhole safety valve  36  is pressurised from within to a fifth predetermined pressure, and the downhole safety valve  36  is tested by measuring if the fifth predetermined pressure is kept constant during a predetermined time period and thus if the downhole safety valve  36  is tight and consequently a barrier. 
     A downhole safety valve  36  proven to be a barrier closes the well sufficiently to replace the drill head with the well head which is to be used during production, as shown in  FIG. 5  where the drill head has been removed. When the well head  37  has been properly connected with the top of the well, as shown in  FIG. 6 , the annular space  39  between the second production casing  33  and the intermediate casing  11  is pressurised from within to a sixth predetermined pressure, and the second barrier packer  35  is tested again after replacing the drill head. This is done in the same way as described above, i.e. by measuring if the sixth predetermined pressure is kept constant during a predetermined time period, and if the pressure is maintained, it means that the well head  37  has been successfully connected with the intermediate casing  11 . Before removing the drill head, the space above the downhole safety valve  36  and/or the plug  34  may be filled with a so-called heavy fluid in order to prevent a blowout. The heavy fluid is subsequently sucked out after having replaced the drill head with the well head  37 . 
     Subsequently, the second production casing  33  above the downhole safety valve  36  is pressurised from within to a seventh predetermined pressure, and the downhole safety valve  36  is tested by measuring if the seventh predetermined pressure is kept constant during a predetermined time period. If both the sixth and the seventh pressure are maintained during the corresponding predetermined period of time, it means that the well head  37  has been successfully connected, as shown in  FIG. 6 . 
     In  FIG. 8A , cement is provided between the intermediate casing  11  and the borehole  4 , and in this embodiment, the intermediate casing  11  comprises two annular barriers  17 . Before the first production casing is arranged in the well, the annular barriers  17  of the intermediate casing  11  are expanded to abut the inner wall  9  of the borehole  4 , displacing the non-cured cement so that a pressure increase is created in the barrier space  40  between the annular barriers  17 . To determine if the annular barriers  17  abutting the borehole  4  provide a barrier, the annular space  44  is pressurised from within to an eight predetermined pressure, and the annular barriers  17  are tested by measuring if the eight predetermined pressure is kept constant for a period of time, e.g. by means of a sensor arranged in the barrier space  40 . The sensor may subsequently be loaded for information about a tool inserted into the well. By arranging the annular barriers  17  in the cement abutting the borehole, a defective cement job does not jeopardise the well safety since the annular barriers arranged between the intermediate casing  11  and the borehole wall provide a sufficient seal. 
     At least one annular barrier  17  may also be arranged between the intermediate casing  11  and a second intermediate casing  41 . In  FIG. 8B , two annular barriers  17  are shown. The barriers  17  are tested by pressurising the annular space  44  between the first intermediate casing  11  and second intermediate casing  41  and monitoring if the pressure drops during a predetermined period of time. In another embodiment, the space below the annular barriers of  FIG. 8B  is filled with cement. 
     The well has now been completed and the components and their mutual connections have been tested to confirm that the barriers are in fact barriers, and the well is now ready for initiating production, as shown in  FIG. 7 . In order to initiate production, the plug  34  arranged in the second production casing  33  is removed. Furthermore, apertures  38  need to be provided in the first production casing  3 . The apertures  38  are provided by punching or drilling holes in the wall of the first production casing  3  to provide access from the inside of the casing and the annulus  16 . In another embodiment, the first production casing  3  has sliding sleeves (not shown) covering the aperture already present in the casing, and thus, the sliding sleeves need to be activated to provide access to the annulus  16 , e.g. by inserting a key tool pulling and sliding the sleeves to its open position. The first production casing  3  may also be perforated by a conventional perforating tool, however, such perforations may injure the barriers tested as described above. 
     When access has been provided to the annulus  16  and thus the formation, the well may need to be stimulated before being able to produce properly. The stimulation of the well is performed by injecting stimulation fluid out through the apertures  38  and into the borehole  4 . The stimulation fluid may be a fracking fluid used to provide fractures in the formation, and the fracking fluid may comprise proppants. The stimulation fluid may also be an acid. 
     As shown in  FIG. 9 , the first production casing  3  may be rotated while inserting the first production casing in order to easily force the casing forward in the borehole  4 . Furthermore, the second end  21  of the first production casing  3  comprises exterior edges  43  which are adapted to function as a “drill head” during the insertion of the production casing  3  into the second part  19  of the borehole  4 . 
     Furthermore, the first end  20  of the first production casing  3  may have an enlarged diameter (not shown), enabling the end of the second production casing  33  to fit inside the first end of the first production casing. The end of the second production casing may thus be “snuck-fitted” into the first production casing  3 . Having such a fitted connection between the production casings prevents a tool, e.g. a tool connected with a downhole tractor, submerged in later operation from getting stuck in the gap between the two production casings, as shown in  FIG. 7 . 
     Before sealing the second end  21  of the first production casing  3 , a flushing fluid may be injected from the second end of the first production casing  3  to perform a clean-out by flushing most of the drilling mud outside the first production casing  3  along the outside of the first production casing  3  and along the outside of the drill pipe. 
     The second end  21  of the first production casing  3  may also be sealed by inserting a plug, such as a swellable plug or another type drop device, into the opening at the second end  21  of the first production casing  3 . 
     The intermediate casing  11  and the first and second production casings  3 ,  33  are made of metal like the annular barriers  17 . The first and/or second barrier packers  31 ,  35  may be an expandable annular barrier  17 . 
     To document the overall integrity of the well before production, the data obtained during testing of the first production casing  3 , the first barrier packer  31 , the second barrier packer  35 , the plug  34 , the downhole safety valve  36  and the annular barriers  17 , respectively, are stored. 
     The well shown in  FIG. 7  is thus a completion system  100  obtained by the method described above. The invention also relates to the oil production facilitated by the above method. 
     By fluid or well fluid is meant any kind of fluid that may be present in oil or gas wells downhole, such as natural gas, oil, oil mud, crude oil, water, etc. By gas is meant any kind of gas composition present in a well, completion, or open hole, and by oil is meant any kind of oil composition, such as crude oil, an oil-containing fluid, etc. Gas, oil, and water fluids may thus all comprise other elements or substances than gas, oil, and/or water, respectively. 
     By a casing is meant any kind of pipe, tubing, tubular, liner, string etc. used downhole in relation to oil or natural gas production. 
     In the event that the tool is not submergible all the way into the casing, a downhole tractor can be used to push the tool all the way into position in the well. The downhole tractor may have projectable arms having wheels, wherein the wheels contact the inner surface of the casing for propelling the tractor and the tool forward in the casing. A downhole tractor is any kind of driving tool capable of pushing or pulling tools in a well downhole, such as a Well Tractor®. 
     Although the invention has been described in the above in connection with preferred embodiments of the invention, it will be evident for a person skilled in the art that several modifications are conceivable without departing from the invention as defined by the following claims.