Debris Exclusion Tool, System and Method

The application is a continuation of and claims priority to U.S. patent application Ser. No. 18/422,414, entitled “DEBRIS EXCLUSION TOOL, SYSTEM AND METHOD,” by John G. STACH et al., filed Jan. 25, 2024, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 63/508,839, entitled “DEBRIS EXCLUSION TOOL, SYSTEM AND METHOD,” by John G. STACH et al., filed Jun. 16, 2023, all of which are assigned to the current assignee hereof and incorporated herein by reference in their entireties.

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 a debris exclusion tool, system and method.

Referring to, it is sometimes advantageous to install a tubing stringin a well, with a distal end of the tubing string sealed off. A pump-out plugsecured in the end of the tubing stringwith shear pinsmay be used for this purpose. A production packermay be used to seal off an annulusformed between the tubing stringand a wellbore, which may be lined with casingand cement.

Various purposes may be served by including the pump-out plugin the tubing string. For example, it may be desired to pressure test the tubing stringbefore placing the well in production. After the tubing stringhas been pressure tested, pressure in the tubing string can be increased, in order to shear the shear pinsand displace the pump-out plugout of the tubing string.

It will be appreciated that improvements are continually needed in the art of conducting well operations. This disclosure provides such improvements to the art. The improvements may be used in a wide variety of different well operations, including but not limited to operations in which a tubing string is pressure tested and operations in which a pump-out plug is displaced from an end of the tubing string, although the principles of this disclosure are not necessarily used with such operations.

The present inventors have recognized that debriscan accumulate in the interior of the tubing stringat or near its distal end in the well. This accumulated debriscan possibly prevent transmission of increased pressure (for example, applied to the interior of the tubular string at the surface) to the pump-out plug. In this circumstance, it will be impossible or very difficult to discharge the pump-out plugfrom the distal end of the tubing string without first removing the debris(which is expensive and time-consuming).

In order to prevent the accumulation of debris in a tubular string from preventing a pump-out plug from being discharged from the tubular string, the present inventors have devised certain improvements described more fully below. Additional improvements may be used in circumstances where it is not desired to discharge a pump-out plug from a tubular string.

Representatively illustrated inis a systemfor use with a subterranean well, and an associated method, which can embody principles of this disclosure. However, it should be clearly understood that the systemand 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 systemand method described herein and/or depicted in the drawings.

In theexample, a tubular stringis positioned in a wellbore. The wellboreis lined with casingand cement, but in other examples the tubular stringcould be positioned in an uncased or open hole section of the wellbore. As depicted in, the wellboreis vertical, but in other examples the wellbore could be inclined or deviated from vertical.

The tubular stringincludes a packerthat seals off an annulusformed between the tubular stringand the wellbore. A pump-out plugis releasably secured in a distal end of the tubular stringwith shear pins, shear screws or another type of releasable retainer. The pump-out plugcan be discharged from the distal end of the tubular stringif a predetermined pressure differential is applied from an interior of the tubular string to the wellbore.

In some examples, the pump-out plugcan be in the form of a ceramic burst disc, or another form of frangible barrier. Increased pressure applied in the tubular stringwill cause the frangible barrier to break or burst, thereby opening the distal end of the tubular string. Thus, the term “pump-out plug” as used herein includes any form of releasable plug or barrier that selectively blocks fluid flow through a tubular string.

In some examples, the tubular stringmay not extend uphole from the packer(such as, from the packer to the surface). For example, if an electric submersible pump is used to pump produced fluids to the surface, the fluids can be pumped through the casingabove the packer. In these cases, pressure can still be applied to the interior of the tubular stringbelow the packerby applying the increased pressure to the casingat the surface to discharge the pump-out plug(or other type of releasable barrier).

In order to ensure that increased pressure applied to the interior of the tubular string(for example, from the surface) will be communicated to the pump-out plug, the systemincludes a debris exclusion toolconnected in the tubular string. The debris exclusion toolincludes a couplingconnected as part of the tubular stringabove the pump-out plug. A flow passageextends axially through the coupling.

The flow passageis in communication with an interior of a tubeextending upwardly from the coupling. In this example, a lower end of the tubeis secured to the couplingand an upper end of the tube extends upwardly into the packer. As depicted in, the upper end of the tubeextends to an upper end of an inner mandrelof the packer.

The upper end of the tubeis closed off with a debris exclusion plug. The debris exclusion plugprevents debrisfrom falling into the interior of the tube. Instead, any debristhat falls inside the tubular stringwill be diverted to an annulusformed between the tubeand the tubular string.

The debriswill accumulate in the annulus, without affecting an ability of increased pressure applied to the interior of the tubular stringto be transmitted to the pump-out plugvia the flow passage. The couplingblocks a lower end of the annulus, so that the debriscannot pass into the tubular stringbelow the coupling.

In theexample, portsare formed through a sidewall of the tubebelow the debris exclusion plug. The portsprovide fluid communication between an interior and an exterior of the tube. Thus, increased pressure applied to the interior of the tubular stringwill be communicated through the portsto the interior of the tube, and through the flow passageto the pump-out plug. In other examples, the portscould be formed in another component (such as, the debris exclusion plugor a collar(see)).

In some examples, the tubular stringmay not extend uphole from the packer(such as, from the packer to the surface). For example, if an electric submersible pump is used to pump produced fluids to the surface, the fluids can be pumped through the casingabove the packer. In these cases, pressure can still be applied to the interior of the tubular stringbelow the packerby applying the increased pressure to the casingat the surface to discharge the pump-out plug(or other type of releasable barrier).

Referring additionally now to, a cross-sectional view of an example of the debris exclusion toolis representatively illustrated. Only an upper end portion of the debris exclusion toolis depicted in.

In theexample, the upper end of the tubeis threaded into a collar. The debris exclusion plugis received in an upper end of the collar. The debris exclusion plugis secured in the collarwith fasteners, which are threaded through the upper end of the collar and into an annular grooveformed in the debris exclusion plug.

In some examples, the debris exclusion plugcan be made of a dissolvable or otherwise degradable material. In this manner, the upper end of the tubecan eventually be unblocked, for example, to provide a larger flow area for production, or to provide for physical access to the wellborebelow the tubular string(see) after the pump-out plughas been discharged from the tubular string.

The degradable materialmay dissolve in well fluid after a predetermined amount of time. Alternatively, the degradable materialcould corrode, melt or otherwise degrade in response to contact with a certain fluid pH range, temperature, etc. The scope of this disclosure is not limited to use of any particular type of degradable material.

Referring additionally now to, a cross-sectional view of another example of the debris exclusion toolin the systemis representatively illustrated. Components of thesystemthat are the same as, or similar to, those of thesystemare indicated inusing the same reference numerals.

In theexample, the distal end of the tubular stringis not blocked by the pump-out plug. Instead, the debris exclusion toolprevents fluid communication through the tubular stringbelow the packer. The debris exclusion plugseals off the upper end of the tube, and the portsare not provided through the sidewall of the tube. Thus, initially there is no fluid communication between the interior and the exterior of the tube.

When it is desired to establish fluid communication between the interior and the exterior of the tube(for example, to place the well in production), a predetermined pressure differential can be applied from the interior to the exterior of the tubeto discharge the debris exclusion plugfrom the upper end of the tube. Alternatively, the debris exclusion plugmay dissolve or otherwise degrade to unblock the upper end of the tube.

To apply the predetermined pressure differential from the interior to the exterior of the tube, pressure can be allowed to build up in the wellborebelow the packer. For example, pressure from an earth formation penetrated by the wellborecan be communicated to the wellbore via perforations (not shown) formed through the casingand cement. Alternatively, pressure in the interior of the tubular stringabove the debris exclusion plugcan be reduced. The scope of this disclosure is not limited to any particular manner of applying the predetermined pressure differential across the debris exclusion plugor from the interior to the exterior of the tube.

When the predetermined pressure differential is applied across the debris exclusion plug, shear pins, shear screws, a snap ring or another type of releasable member that previously secured the debris exclusion plug in the upper end of the tubewill shear or otherwise release, thereby allowing the debris exclusion plug to be discharged from the upper end of the tube. The debris exclusion plugwill then no longer block the upper end of the tube, and fluid communication and physical access will be provided to the wellborebelow the debris exclusion toolvia the interior of the tube.

Referring additionally now to, a cross-sectional view of another example of the debris exclusion toolis representatively illustrated. This example of the debris exclusion toolmay be used with thesystemexample. Only an upper end portion of the debris exclusion toolis depicted in.

In theexample, the debris exclusion plugis releasably secured in the collarby the fasteners, which may comprise shear pins, shear screws, a snap ring, collets or other type of releasable devices. An annular sealseals between the debris exclusion plugand the collar.

A predetermined pressure differential applied across the debris exclusion plug(i.e., from the interior to the exterior of the tube) will cause the fastenersto shear or otherwise release. The debris exclusion plugwill then be discharged from the collarat the upper end of the tube. Alternatively, the debris exclusion plugmay dissolve or otherwise degrade as described above for theexample.

In theexamples, only a single tubeis depicted in the drawings. It will be appreciated, however, that the tubecan comprise any number of individual sections connected together to form the tube. Thus, as used herein, the term “tube” can include a segmented or a continuous tubular structure made up of multiple or a single component, respectively. The collarmay be considered a part of the tube.

It may now be fully appreciated that the above disclosure provides to the art a variety of improvements that may be useful for certain well operations. In examples described above, the debris exclusion plugprevents debrisfrom interfering with well operations.

The above disclosure provides to the art a debris exclusion toolfor use in a subterranean well. In one example, the debris exclusion toolcomprises a debris exclusion plug, and a tubehaving first and second opposite ends. The debris exclusion plugis releasably secured at the tubefirst end and prevents debrisfrom falling into the tubefirst end. The tubesecond end is configured to secure in a tubular stringin the well with the second end being below the first end.

The debris exclusion toolmay include a portthat provides fluid communication between an interior and an exterior of the tube. The portmay be formed through a sidewall of the tube.

Fluid communication between an interior and an exterior of the tubemay be prevented by the debris exclusion plug. The debris exclusion plugmay be configured to release from the first end of the tubeand permit fluid communication between the interior and the exterior of the tubein response to a predetermined pressure differential from the interior to the exterior of the tube.

The debris exclusion plugmay comprise a degradable material. The degradable materialmay be configured to degrade in a predetermined amount of time in a well environment. The debris exclusion plugmay be configured to dissolve in well fluid.

The debris exclusion toolmay include a couplingconfigured for connection as part of a tubular string. The couplingmay include a flow passageextending axially through the coupling. The tubemay be secured to the couplingwith the flow passagein fluid communication with an interior of the tube.

Also provided to the art by the above disclosure is a method of establishing fluid communication through a tubular stringin a subterranean well. In one example, the method can include: blocking a first end of a tubewith a debris exclusion plug; and positioning the tubewithin the tubular string. A second end of the tubeis positioned below the first end, and an annulusis formed between the tubeand the tubular string.

The method may include providing fluid communication between an interior and an exterior of the tubevia at least one port. The method may include forming the portthrough a sidewall of the tube.

The positioning step may include securing the second end in the tubular stringabove a pump-out plugthat blocks fluid flow through a distal end of the tubular string. The method may include applying increased pressure through an interior of the tube, thereby discharging the pump-out plugfrom the distal end of the tubular string.

The positioning step may include connecting the second end to a couplingconnected in the tubular string. A flow passagemay extend axially through the coupling. The connecting step may include providing fluid communication between the flow passageand an interior of the tube.

The method may include applying a predetermined pressure differential from an interior to an exterior of the tube, thereby discharging the debris exclusion plugfrom the first end of the tube. The method may include the debris exclusion plugdegrading or dissolving in the well.

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.