WO2024116001A1

WO2024116001A1 - Agent file reference:casing connection make-up with top drive and casing running tool

Info

Publication number: WO2024116001A1
Application number: PCT/IB2023/061449
Authority: WO
Inventors: Rainer RUEHMANN; Michael Wiedecke; Bjoern Thiemann
Original assignee: Weatherford Technology Holdings, Llc
Priority date: 2022-11-30
Filing date: 2023-11-13
Publication date: 2024-06-06

Abstract

A method of running a casing string (16) into a subterranean well that includes connecting a casing running tool (18) to a top drive (12), thereby enabling transmission of torque and rotation outputs of the top drive (12) to the casing running tool (18), connecting a casing string section (16a) to the casing running tool (18), threading an end of the casing string section (16a) to another casing string section (16b), thereby forming a connection between the casing string sections (16a, 16b), and controlling the torque and rotation outputs of the top drive (12), based on at least one indication of torque level applied to the connection from the top drive (12) via the casing running tool (18).

Description

CASING CONNECTION MAKE-UP

WITH TOP DRIVE AND CASING RUNNING TOOL

TECHNICAL FIELD

This disclosure relates generally to equipment utilized and operations performed in conjunction with a subterranean well and, in an example described below, more particularly provides for make-up of casing connections with a top drive and a casing running tool.

BACKGROUND

It is important for connections between sections of a casing string in a well to be properly made-up. After installation in the well, the casing connections must be capable of isolating an interior of the casing string from an exterior of the casing string exposed to formation pressures and temperatures. Well integrity is dependent upon proper casing connection make-up procedures.

Therefore, it will be readily appreciated that improvements in casing connection make-up are continually needed. It is among the objects of the present disclosure to provide such improvements to the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representative elevational view of an example of a well system and associated method which can embody principles of this disclosure.

FIG. 2 is a representative elevational view of a portion of the FIG. 1 well system with an example of an automated connection controller. FIG. 3 is a representative flowchart for an example of a method of making- up a casing connection.

FIG. 4 is a representative graph of torque versus time for an example of a casing connection.

DETAILED DESCRIPTION

Representatively illustrated in FIG. 1 is a system 10 for use with a subterranean well, and an associated method, which can embody principles of this disclosure. However, it should be clearly understood that the system 10 and method are merely one example of an application of the principles of this disclosure in practice, and a wide variety of other examples are possible. Therefore, the scope of this disclosure is not limited at all to the details of the system 10 and method described herein and/or depicted in the drawings.

In the FIG. 1 example, a top drive 12 is used to handle various tubulars and to make-up connections between the tubulars. A conventional top drive is typically mounted to generally vertical parallel rails (not shown) of a well rig 14. The top drive is displaced along the rails to thereby raise or lower a tubular string suspended from the top drive. The rig 14 may be land-based or water-based.

As depicted in FIG. 1 , the top drive 12 is being used to handle sections 16a,b of a casing string 16, and to make-up a connection between the casing string sections. A casing running tool 18 is connected between the top drive 12 and the upper casing string section 16a.

The casing running tool 18 selectively grips the upper casing string section 16a and enables transmission of torque and rotation from the top drive 12 (e.g., via a quill 20 of the top drive) to an upper end of the upper casing string section. In some examples, the casing running tool 18 may grip an interior surface of the casing string section 16a, and in other examples the casing running tool may grip an exterior surface of the casing string section. A conventional casing running tool can also include external safety bails (not shown) to prevent inadvertent release of the casing string section from the casing running tool. The casing running tool 18 also provides for circulation of fluid through the casing string 16 as it is being run into the well. In this example, the casing running tool 18 also includes a torque sensor (such as, a load cell) and a turns or rotation sensor (not shown in FIG. 1 , see FIG. 2). In other examples, the torque and rotation sensors may be included in a separate tool (sometimes referred to as a “torque sub”). The torque sensor provides an indication of torque output by the top drive 12, and the rotation sensor provides an indication of rotation output by the top drive.

In the FIG. 1 example, the lower casing string section 16b is gripped and suspended in the well by a casing spider 22 mounted to a floor 24 of the rig 14. When the upper casing string section 16a is gradually lowered and rotated by the top drive 12 via the casing running tool 18, a lower threaded end of the upper casing string section is threaded into an upper threaded end of the lower casing string section 16b, so that a threaded connection is formed between the casing string sections.

The torque and rotation outputs of the top drive 12 are used to make-up the connection between the casing string sections 16a,b according to specific requirements. For example, a specification for the connection may require that a certain number of turns of the upper casing string section 16a must be accomplished, after the connection is shouldered-up (e.g., shoulders of the threaded ends of the casing string sections 16a,b come into physical contact). As another example, a specification for the connection may require that the torque applied to the connection is at least a minimum torque level, and no greater than a maximum torque level.

The specification for the connection defines the parameters for the connection to be considered acceptable. The specification may be provided by an industry association (such as, the American Petroleum Institute), or by a designer or manufacturer of the threaded components.

The term “casing” as used herein indicates a tubular protective well lining and can include various types of tubulars known to those skilled in the art as casing, liner or pipe. As depicted in FIG. 1 , each of the casing string sections 16a, b comprises a single “joint” of casing that includes a length of casing and a coupling threaded to an upper end of the length of casing. In other examples, a casing string section can include multiple joints of casing, forming a “stand” of casing. In further examples, a separate coupling may not be used with each length of casing.

Referring additionally now to FIG. 2, a more detailed view of certain components of the system 10 are representatively illustrated, apart from the rig 14 of FIG. 1. The components of the system 10 depicted in FIG. 2 may be used with the rig 14 of FIG. 1 , or they may be used with other rigs or other components.

In the FIG. 2 example, the top drive 12 includes a motor 26 for producing rotation of the quill 20 and application of torque. Operation of the motor 26 is controlled by a conventional top drive control system 28 in this example, but in other examples the top drive control system can be combined with an automated connection controller 30 described more fully below. Prior automated connection controllers are described in US patent nos. 8,297,347 and 10,422,450, which are incorporated herein in their entireties for all purposes by this reference.

In conventional use of a top drive to make-up more robust connections (such as, drill string connections), the top drive control system 28 is sufficient to control operation of the top drive with inputs 31 , for example, from a driller. However, a top drive is not conventionally used to make-up casing string connections, because these connections are less robust, and are more critical for well integrity. It is difficult for a driller to precisely control the torque and rotation outputs of the top drive with manual inputs.

In the FIG. 2 example, the automated connection controller 30 receives the torque and rotation indications from the torque and rotation sensors 32, 34 and automatically controls operation of the top drive motor 26 (via the top drive control system 28), so that the casing string connection is acceptably made-up. As depicted in FIG. 2, the sensors 32, 34 are included in a torque sub 36 connected between the casing running tool 18 and the casing string section 16a, but in other examples the sensors can be included in the casing running tool (as in the FIG. 1 example).

The automated connection controller 30 can include hardware, software, memory, and input and output components to enable it to perform its function of controlling the connection make-up process. The hardware can include one or more processors and/or programmable logic controllers. The software can include data and instructions, which may be supplemented by inputs 38 provided locally (such as, from an operator, either via wired or wireless communication) or remotely (such as, via satellite or internet communication). Outputs 40 (such as, the torque and rotation indications or other data) can be provided to local or remote locations via any form of communication, and may be provided in real time (during the connection make-up process) or in recorded form at conclusion of the connection make-up process.

In some examples, the automated connection controller 30 software can be capable of evaluating whether the casing connection is acceptable (such as, whether the connection complies with a specification for the connection). The connection evaluation may be performed in real time or at the conclusion of the connection make-up process. If the evaluation is performed in real time, an unacceptable connection make-up process can be terminated immediately, thereby saving time.

The inputs 38 provided to the automated connection controller 30 can include information regarding the casing string 16 (such as, dimensions, threads, material, etc.) and regarding the specification for the casing connection (such as, minimum, optimum and maximum torque levels, and/or turns after shoulder-up).

Referring additionally now to FIG. 3, a flowchart for an example of a method 50 of running a casing string into a well is representatively illustrated. For convenience, the method 50 is described below as it may be used with the system 10 of FIGS. 1 or 2, but it should be understood that the method may be used with other systems without departing from the scope of this disclosure. In an initial step 52, torque levels corresponding to the specification for the casing connection are input to the automated connection controller 30. For example, minimum, optimum and maximum torque levels may be input to the automated connection controller 30. In other examples, a specified number of turns after shoulder-up may be input.

In step 54, the casing connection is initiated. This step involves “stabbing” the lower end of the upper casing string section 16a into the upper end of the lower casing string section 16b, so that rotation of the upper casing string section by the top drive 12 will cause the threads on the lower end of the upper casing string section to engage the threads in the upper end of the lower casing string section.

In step 56, the casing connection is “spun-in.” The engaged threads of the casing string sections 16a,b are threaded further together, but the torque applied to the connection does not significantly increase during spin-in.

After the threads are substantially engaged, torque in the connection will begin to gradually increase as indicated, for example, by the torque sensor 32. Representatively illustrated in FIG. 4 is a graph 70 of torque versus time for an example of a casing connection. In the FIG. 4 graph 70, the gradual torque increase is depicted at a portion 72 of the graph. Eventually, the casing connection will shoulder-up (depicted at portion 74 of the graph 70). After shoulder-up, the torque will increase relatively rapidly (depicted at portion 76 of the graph 70).

It is important in this example that, in order to achieve an acceptable connection, the torque applied to the connection should be at least a minimum torque level 78 and no greater than a maximum torque level 80. Ideally, the maximum applied torque should be at an optimum torque level 82.

To achieve such an acceptable connection, the automated connection controller 30 is programmed to control the torque and rotation outputs of the top drive 12 in response to the indications provided by the sensors 32, 34. In the FIG. 4 example, the automated connection controller 30 is programmed to cause the rotational speed of the top drive 12 to decrease when the torque applied to the connection reaches the specified minimum torque level 78. In the FIG. 4 graph 70, it may be seen that the rate of increase of the applied torque decreases as a result of the decreased rotational speed (at portion 84 of the graph). This reduced rate of torque increase enables more precise control of the applied torque as it approaches the optimum torque level 82.

Note that it is not necessary in keeping with the scope of this disclosure for the rotational speed of the top drive 12 to decrease when the applied torque reaches the minimum torque level 78. In other examples, the rotational speed of the top drive 12 could be decreased in response to the applied torque being at another predetermined level less than the optimal torque level 82.

Referring again to FIG. 3, in step 58, the upper casing section 16a continues to be rotated by the top drive 12 as the applied torque indicated by the torque sensor 32 increases. In step 60, the torque level indicated by the torque sensor 32 is continually monitored to determine whether the applied torque has reached a level at which the rotational speed is to be reduced. If the applied torque has not yet reached this speed reduction level, the rotational speed is maintained.

In step 62, the rotational speed is reduced when the applied torque reaches the minimum torque level. In step 64, the top drive 12 continues to rotate the upper casing section 16a at the reduced speed. The applied torque as indicated by the torque sensor 32 continues to increase.

In step 66, the applied torque is continually monitored to determine whether the optimum torque level has been reached. In other examples, it may be desired for the applied torque to increase to the maximum torque level, instead of the optimum torque level. In step 68, the top drive 12 ceases to rotate the upper casing section 16a when the applied torque reaches the optimum torque level (or the maximum torque level in some examples).

In step 70, the applied torque is reduced when rotation is stopped due to the applied torque reaching the optimum torque level 82. In this example, the automated connection controller 30 is programmed to cause the top drive 12 to decrease the applied torque to fifty percent of the optimum torque level 82 in response to an indication from the torque sensor 32 that the optimum torque has been applied to the connection. This torque decrease ensures that the maximum torque level 80 is not exceeded, while still maintaining torque in the connection (so that the connection does not inadvertently back-off). In other examples, the automated connection controller 30 may be programmed to cause the top drive 12 to reduce the applied torque in response to an indication from the torque sensor 32 that the optimum torque level has been exceeded by a predetermined amount. In further examples, the automated connection controller 30 may be programmed to reduce the applied to torque to a level other than fifty percent of the optimum torque level (such as, forty percent or sixty percent).

Note that it is not necessary in keeping with the scope of this disclosure for the maximum applied torque to exactly match the optimum torque level 82. In various examples, the maximum applied torque may be greater or less than the optimum torque level 82. The casing connection in this example can be considered acceptable, as long as the maximum torque applied to the connection is not less than the minimum torque level 78, and is not greater than the maximum torque level 80.

In step 72, the applied torque is gradually reduced to zero (at portion 88 of the graph 70). This further reduction of the applied torque may be under the control of the driller or another operator. Alternatively, the automated connection controller 30 may be programmed to control the combined applied torque reductions of steps 58 and 60.

In step 74, the automated connection controller 30 performs an evaluation of the connection using at least the torque and/or rotation indications provided by the torque and rotation sensors 32, 34 (the rotation indications may be used in the evaluation, for example, if the specification for an acceptable connection requires a certain number of rotations after shoulder-up). As mentioned above, this evaluation may be performed at the conclusion of the connection make-up process and/or in real time during the connection make-up process. If the connection is acceptable, the casing spider 22 can be operated to release its grip on the lower casing section 16b, the top drive 12 can lower the casing string 16 further into the well, the casing spider can grip the upper casing string section 16a, the top drive and casing running tool 18 can be released from the upper casing string section, and another casing string section can be gripped by the casing running tool to begin another connection make-up process.

It may now be fully appreciated that the above disclosure provides significant advancements to the art of making-up casing connections. In examples described above, the torque and rotation outputs of the top drive 12 can be controlled, based on indications of applied torque and/or rotation provided by the sensors 32, 34, so that an acceptable casing connection is achieved. The connection make-up and connection evaluation processes are automated, so that the possibility of human error in the processes is eliminated.

The above disclosure provides to the art a casing make-up system 10 for use with a subterranean well. In one example, the casing make-up system 10 can comprise: a casing running tool 18 configured to grip a first casing string section 16a and transmit torque and rotation from a top drive 12 to the first casing string section 16a; and an automated connection controller 30 configured to automatically control the torque and rotation output by the top drive 12.

The automated connection controller 30 may be further configured to evaluate whether a connection between the first casing string section 16a and a second casing string section 16b is acceptable, based on a record of the torque applied to the first casing string section 16a. The automated connection controller 30 may be further configured to evaluate whether the connection between the first and second casing string sections 16a,b is acceptable, based on a record of the rotation applied to the first casing string section 16a.

The casing make-up system 10 may include a torque sensor 32 in communication with the automated connection controller 30. The torque sensor 32 may be incorporated into the casing running tool 18, or it may be included in a separate torque sub 36. The automated connection controller 30 may be configured to reduce a speed of the rotation output of the top drive 12 in response to a first torque level indication output of the torque sensor 32. The first torque level may comprise a minimum acceptable connection torque level 78.

The automated connection controller 30 may be further configured to reduce the torque output of the top drive 12 in response to a second torque level indication output of the torque sensor 32. The second torque level may comprise an optimum connection torque level 82.

The automated connection controller 30 may be further configured to terminate the torque output of the top drive 12 in response to a third torque level indication output of the torque sensor 32. The third torque level may comprise a torque level greater than a maximum acceptable connection torque level 80.

The above disclosure also provides to the art a method 50 of running a casing string 16 into a subterranean well. In one example, the method 50 can comprise: connecting a casing running tool 18 to a top drive 12, thereby enabling transmission of torque and rotation outputs of the top drive 12 to the casing running tool 18; connecting a first casing string section 16a to the casing running tool 18; threading an end of the first casing string section 16a to a second casing string section 16b, thereby forming a connection between the first and second casing string sections 16a,b; and controlling the torque and rotation outputs of the top drive 12, based on at least one indication of torque level applied to the connection from the top drive 12 via the casing running tool 18.

The method 50 may include connecting a torque sensor 32 to an automated connection controller 30. The torque sensor 32 may be adapted to output the “at least one” indication of torque level.

The method 50 may include connecting the automated connection controller 30 to the top drive 12, thereby enabling the automated connection controller 30 to control the torque and rotation outputs of the top drive 12.

The step of connecting the automated connection controller 30 to the top drive 12 may include connecting a top drive control system 28 between the automated connection controller 30 and the top drive 12, the top drive control system 28 being adapted to control operation of a motor 26 of the top drive 12.

The “at least one” indication of torque level may comprise a first torque level indication, and the controlling step may include reducing a speed of the rotation output of the top drive 12 in response to the first torque level indication. The first torque level may comprise a minimum acceptable connection torque level 78.

The “at least one" indication of torque level may further comprise a second torque level indication, and the controlling step may include reducing the torque output of the top drive 12 in response to the second torque level indication. The second torque level may comprise an optimum connection torque level 82.

The “at least one” indication of torque level may further comprise a third torque level indication, and the controlling step may include terminating the torque output of the top drive 12 in response to the third torque level indication. The third torque level may comprise a torque level greater than a maximum acceptable connection torque level 80.

Although various examples have been described above, with each example having certain features, it should be understood that it is not necessary for a particular feature of one example to be used exclusively with that example. Instead, any of the features described above and/or depicted in the drawings can be combined with any of the examples, in addition to or in substitution for any of the other features of those examples. One example’s features are not mutually exclusive to another example’s features. Instead, the scope of this disclosure encompasses any combination of any of the features.

Although each example described above includes a certain combination of features, it should be understood that it is not necessary for all features of an example to be used. Instead, any of the features described above can be used, without any other particular feature or features also being used.

It should be understood that the various embodiments described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of this disclosure. The embodiments are described merely as examples of useful applications of the principles of the disclosure, which is not limited to any specific details of these embodiments.

The terms “including,” “includes,” “comprising,” “comprises,” and similar terms are used in a non-limiting sense in this specification. For example, if a system, method, apparatus, device, etc., is described as “including” a certain feature or element, the system, method, apparatus, device, etc., can include that feature or element, and can also include other features or elements. Similarly, the term “comprises” is considered to mean “comprises, but is not limited to.”

Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the disclosure, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to the specific embodiments, and such changes are contemplated by the principles of this disclosure. For example, structures disclosed as being separately formed can, in other examples, be integrally formed and vice versa. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the invention being limited solely by the appended claims and their equivalents.

Claims

WHAT IS CLAIMED IS:

1 . A casing make-up system for use with a subterranean well, the casing make-up system comprising: a casing running tool configured to grip a first casing string section and transmit torque and rotation from a top drive to the first casing string section; and an automated connection controller configured to automatically control the torque and rotation output by the top drive.

2. The casing make-up system of claim 1 , in which the automated connection controller is further configured to evaluate whether a connection between the first casing string section and a second casing string section is acceptable, based on a record of the torque applied to the first casing string section.

3. The casing make-up system of claim 2, in which the automated connection controller is further configured to evaluate whether the connection between the first and second casing string sections is acceptable, based on a record of the rotation applied to the first casing string section.

4. The casing make-up system of claim 1 , further comprising a torque sensor in communication with the automated connection controller.

5. The casing make-up system of claim 4, in which the automated connection controller is configured to reduce a speed of the rotation output of the top drive in response to a first torque level indication output of the torque sensor.

6. The casing make-up system of claim 5, in which the first torque level comprises a minimum acceptable connection torque level.

7. The casing make-up system of claim 5, in which the automated connection controller is further configured to reduce the torque output of the top drive in response to a second torque level indication output of the torque sensor.

8. The casing make-up system of claim 7, in which the second torque level comprises an optimum connection torque level.

9. The casing make-up system of claim 7, in which the automated connection controller is further configured to terminate the torque output of the top drive in response to a third torque level indication output of the torque sensor.

10. The casing make-up system of claim 9, in which the third torque level is greater than a maximum acceptable connection torque level.

11 . A method of running a casing string into a subterranean well, the method comprising: connecting a casing running tool to a top drive, thereby enabling transmission of torque and rotation outputs of the top drive to the casing running tool; connecting a first casing string section to the casing running tool; threading an end of the first casing string section to a second casing string section, thereby forming a connection between the first and second casing string sections; and controlling the torque and rotation outputs of the top drive, based on at least one indication of torque level applied to the connection from the top drive via the casing running tool.

12. The method of claim 11 , further comprising connecting a torque sensor to an automated connection controller, the torque sensor being adapted to output the at least one indication of torque level.

13. The method of claim 12, further comprising connecting the automated connection controller to the top drive, thereby enabling the automated connection controller to control the torque and rotation outputs of the top drive.

14. The method of claim 12, in which the connecting the automated connection controller to the top drive comprises connecting a top drive control system between the automated connection controller and the top drive, the top drive control system being adapted to control operation of a motor of the top drive.

15. The method of claim 11 , in which the at least one indication of torque level comprises a first torque level indication, and the controlling comprises reducing a speed of the rotation output of the top drive in response to the first torque level indication.

16. The method of claim 15, in which the first torque level comprises a minimum acceptable connection torque level.

17. The method of claim 15, in which the at least one indication of torque level further comprises a second torque level indication, and the controlling further comprises reducing the torque output of the top drive in response to the second torque level indication.

18. The method of claim 17, in which the second torque level comprises an optimum connection torque level.

19. The method of claim 17, in which the at least one indication of torque level further comprises a third torque level indication, and the controlling further comprises terminating the torque output of the top drive in response to the third torque level indication.

20. The method of claim 19, in which the third torque level is greater than a maximum acceptable connection torque level.