APPARATUS AND METHOD FOR TESTING DYNAMIC SEALABILITY OF FLUID IN THE DOWNHOLE MINOR LEAKS

Abstract

A method and apparatus for determining the sealability of an oil & gas well sealant fluid, whereby a cylindrical cell assembly capable of withstanding high temperature and high pressure with an electromagnetic heater positioned radially outside the cell body while partly filled with said sealant fluid. A minor-leak assembly in connection to said cylindrical cell assembly allows said sealant fluid to continuously flow through a leak sample at a desired differential pressure, and the residual fluid is drained into said cell by a cycling pipeline system. The real-time pressure may be recorded to transmitted to a control system comprised of data acquisition and control units so as to monitor and measure the sealability of fluid in the downhole minor leaks.

Claims

1. A sealability testing apparatus, said tester comprising: a minor-leak assembly having an upper cap, a leak sample, a retainer, a visual bottom cup, wherein the said components are axial; an upper cap having a fluid inlet and pressure sensor on its upper end, wherein said pressure sensor may record and transmit the pressure data to a control panel by pressure data wire; a leak sample with different size of pores being secured into said upper cap for simulating downhole string leakage on-site; a retainer in connection with the lower end of said upper cap, said retainer used to fix said leak sample; and a visual bottom cup made of quartz glass, said visual bottom cup being opened on the bottom, and being temperature- and pressure-resistant for observing the plugging process when sealant flows across said leak sample.

2. The sealability tester of claim 1, further including: a cylindrical cell assembly having a cover and a cell body, wherein said cell body partially filled with a sealant fluid; an inlet in the upper part of said cell body for permitting sealant fluid circulate; an outlet in the bottom of said cell body being connected with a pressurization pump; an electromagnetic heater being positioned radially outside said cell body for heating an sealant fluid; and a temperature sensor being aligned in said cell body for measuring and transmitting the cell temperature.

3. The sealability tester of claim 1, further including: a cycling pipeline system having a fluid feeding pipeline, a overflow pipeline, and a fluid return pipeline; a fluid feeding pipeline including a pressurization pump, a pressure gauge, and two stop valves; a pressurization pump in contact with said cell outlet, which is applied as a pressurization tool to drive circulation of sealant fluid in cycling pipeline; a set of stop valves being arranged on the said feeding pipeline to control injection pressure of sealant fluid; an overflow pipeline in contact with said cell body for return of overflow fluid, which is helpful to control pipeline pressure; and a fluid return pipeline in contact with said cell body for return of fluid across said leak sample, wherein a flowmeter is arranged for measuring flow rate.

4. The sealability tester of claim 1, further including: a control panel incorporated into a data acquisition system and an operation software, wherein said data acquisition system is connected with said tester by means of a set of data wires such as pressure data wire, temperature data wire, and flowmeter data wire.

5. The sealability tester of claim 4, further including: a measurement device in contact with said minor-leak assembly for measuring the pressure encountered when the sealant flows through leak site.

6. The sealability tester of claim 4, further including: a measurement device in contact with said cell for measuring the sealant temperature encountered when the sealant rotates in said cycling pipeline.

7. The sealability tester of claim 4, further including: a measurement device in contact with said pressurization pump for measuring the sealant pressure prior to circulation.

8. A method for determining the plugging property of sealant fluid in the specific leak site, the method comprising the steps of: pouring sealant fluid into said cell; closing said stop valve prior to said minor-leak assembly; pumping sealant fluid in the fluid feeding pipeline to pressurize the sealant; opening said stop valve to allow sealant sample circulatively flow through minor-leak assembly at the desired fluid pressure; observing seal formed in the leak site from said visual cup; measuring pressures related to formation of seal across leaks; and analyzing dynamic plugging property of said sealant sample.

9. The method of claim 8, further comprising the step of: setting pressure of said sealant fluid in the fluid feeding pipeline.

10. The method of claim 8, further comprising the step of: setting temperature of said sealant fluid in the fluid feeding pipeline.

11. A method for determining the plugging property of sealant fluid in the specific leak site, the method comprising the steps of: providing a sealability testing apparatus comprising: a minor-leak assembly having an upper cap, a leak sample, a retainer, and a visual bottom cup; said retainer used to fix said leak sample; said visual bottom cup in connection with said upper cap; a cylindrical cell assembly in connection with said minor-leak assembly for returning a sealant sample; a pressurization pump in connection with said cylindrical cell for circulating sealant sample in the cycling pipeline; operating said pump so that a desired pressure may be attained; circulating sealant sample to be tested under a desired pressure; recording pressure variation when sealant sample flows through a leak site; and analyzing dynamic plugging property of said sealant sample.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Other objects, features and advantages will be clear from the following detailed description of the preferred embodiment taken in conjunction with accompanying drawings in which:

[0046] FIG. 1 is a cross-section view of borehole leakage assembly in the preferred embodiment of the invention

[0047] FIG. 2 is a set of cross-section and top views of leak sample 22 (left: pores; right: crack) in FIG. 1

[0048] FIG. 3 is an overview of the main units of the invention

[0049] FIG. 4 is a cross-section view of cell body 30 with a cover

[0050] FIG. 5 is dynamic plugging curves of pressure vs. time for sealant examples in different leak samples.

REFERENCE NUMERALS IN DRAWINGS

[0051] 1—pressure gauge; 2—first stop valve; 3—pressurization pump; 4—second stop valve; 5—check valve; 6—cylindrical cell, 7—flowmeter; 8—bottom cup; 9—micro-leak assembly; 10—third stop valve; 11—upper cap; 12—pressure sensor; 13—flow sensor; 14—fourth stop valve; 15—heater; 16—control wire; 17—temperature sensor; 18—temperature data wire; 19—panel; 20—screen; 21—pressure data wire; 22—leak sample; 23—retainer; 24—first O-ring; 25—first snap ring; 26—second O-ring; 27—second snap ring; 28—leakage pore; 29—cover; 30—cell body.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0052] The primary embodiment of the invention can be best understood by reference to this specification and to the appended drawings.

[0053] FIG. 1—Borehole Minor-Leak Assembly Embodiment

[0054] FIG. 1 is a cross-section view of borehole leak assembly in the preferred embodiment of the invention. This leak assembly comprises the upper cap 11 and transparent bottom cup 8. An inlet is arranged in the upper part of cap 11, which is connected with the third stop valve 10, providing means for inlet of sealant fluid and control of injection pressure. In addition, the pressure sensor 12 is fixed in the upper part of the cap 11 by the second snap ring 27. Pressure data can be collected and transmitted to the control panel 19. The bottom cap 11 is hollow that allows the leak sample 22 to be screwed onto the bottom end. The leak sample 22 can be further screwed by the retainer 23 via the thread. The O-ring 26 and 24 assure against leakage around the leak sample 22.

[0055] FIG. 2—Leak Sample Embodiment

[0056] FIG. 2 is a detailed close-up of leak sample 22, which is screwed onto the bottom of cap 11 by the retainer 23 via the thread. The leak sample 22 has array holes 28 with different size and shape so as to exactly simulate the different types of minor-leaks. The transient bottom cup 8 is secured to the upper cap 11 via the thread and to press against retainer 23. An opening is presented in the bottom of cup 8 to admit the sealant fluid into cylindrical cell 6. To satisfy the temperature- and pressure-resistant requirement, the bottom cup 8 is made of a suitable material such as transient quartz glass, with which the plugging process can be directly observed.

[0057] FIG. 3—Cylindrical Cell Embodiment

[0058] FIG. 3 is a cross-section view of cylindrical cell 6. Cell 6 comprises cover 29, temperature sensor 17, electromagnetic heater 15, and three control valves. Cover 29 is installed onto cylindrical cell 6 via the thread. Temperature sensor is aligned in the bottom of cell 6, which can record and transmit the temperature data to the control panel 19 by data wire 18. Two stop valves located in the upper part of cylindrical cell 6 are arranged to separately permit overflow and circulation of fluid upon plugging. Heater 15 is a special electromagnetic heating device, which is positioned radially outside the cell body to ensure stable and accurate temperature adjustment.

[0059] FIG. 4—Main Tester Units Embodiment

[0060] FIG. 4 is an overview of the main components of the present invention. The apparatus comprises the minor-leak assembly, cycling pipeline, data wire, functional valves, flowmeter 7, pressure gauge 1 and cylindrical cell 6. The inlet and outlet of minor-leak assembly are connected with pressurization pump 3 and cell 6, respectively, by means of cycling pipeline. Flowmeter 7 is arranged on the liquid return pipeline after the minor-leak assembly, and pressure gauge 1 is arranged on the liquid feeding pipeline before the minor-leak assembly. The sealant fluid enters the minor-leak assembly under a certain differential pressure, and then flows back into the cylindrical cell 6 through cycling pipeline installed with flowmeter 7 and pressure gauge 1. In the process, the plugging property of sealant in the downhole environment can be truly simulated. By utilizing the pressurization pump 3, the sealant fluid can be dynamically circulated, and a continuous plugging can come until that a seal is realized. In addition, an overflow unit is incorporated between cylindrical cell 6 and the first stop valve 2, so as to enable a better control of pressure upon plugging. The overflow fluid can flow into cylindrical cell 6 by opening the check valve 5, which is also helpful to adjust the pipeline pressure. Therefore, this apparatus can test a sealant under dynamic conditions encountered in the field.

[0061] In FIG. 4, all data wires such as temperature data wire, pressure data wire, and flow rate data wire are connected with the control panel 19. Meanwhile, the data acquisition system and operation software are incorporated in the panel 19 and, thus, the plugging test can be conveniently operated. Data from the run is recorded and plugging property and other characteristics of sealant fluid may be systematically evaluated.

[0062] Operation—FIG. 1-4

[0063] To perform a run of the sealability tester, a suitable leak sample 22 that corresponds exactly to actual leak status on-site should be firstly selected. Install retainer 23, and screw leak sample 22 onto the lower end of the upper cap 11. Install the visual bottom cup 8 onto the upper cap 11 via the thread and press against retainer 23. Pour sealant fluid into cylindrical cell 6, and screw cover 29 onto the cell body 30 via the thread. Close check valve 5 and the third stop valve 10. Turn on the electricity power of sealability tester. Adjust temperature as desired by activating heater 15. Open the pressurization pump 3, which is the power of the circulating sealant. Adjust the pressurization rate and make the pressure of the liquid feeding pipeline increase up to the predetermined value. If the pressure exceeds the desired value, then open check valve 5 and relieve the pressure by the overflow pipeline. While the pressure of the liquid feeding pipeline is stable, close the first stop valve 2, and open the third stop valve 10. The sealant fluid will inject through leak sample 22 under the condition of the desired pressure, which simulates virtually real-world circumstance encountered in the downhole leakage. As sealant fluid continuously flow through the leak, a plugging reaction linked with liquid-solid jamming transmission can happen along leak path. The pressure sensor 12 records variation of leak pressure and real-time curve of pressure can be presented in monitoring screen 20. Meanwhile, plugging process can be directly observed by the transient bottom cup 8. Flowmeter 7 records the flow velocity of sealant across minor-leak assembly. The sealant fluid that flows across leak site can return into cylindrical cell 6 by the return pipeline. Once a seal across the leak is formed, then the pressure recorded by pressure sensor 12 will be constant. If the seal is not formed, the first stop valve 2 can be opened to allow sealant fluid to circulate in the tester, through which a dynamic circulated plugging process may be simulated in the present invention. In addition, the pressure can be further increased by adjusting the pressurization pump 3 to examine the pressure-bearing capability of the formed seal.

Method of Testing Fluid Sealability

[0064] The specific testing steps of the present invention is as follows:

[0065] 1. Assembling Minor-Leak Components

[0066] Select a suitable leak sample 22 that can simulate the downhole string and borehole leakage. Screw leak sample 22 onto the bottom of upper cap 11. Install retainer 23 and make it press tightly on leak sample 22. Screw visual bottom cup 8 to upper cap 11 via the thread. Pour the sealant into cell body 30. Screw cover 29 onto cell body 30 via the thread.

[0067] 2. Adjusting Cycling Pipeline System

[0068] Open the first stop valve 2 and the second stop valve 4 in the fluid feeding pipeline. Open the fourth stop valve 14 in the fluid return pipeline. Close check valve 5 in the overflow pipeline. Close the third stop valve 10 before the minor-leak assembly.

[0069] 3. Controlling the Temperature and Pressure

[0070] Turn on the electricity power of tester. Set the testing temperature to the desired value and activate heater 15. Make sealant temperature arrive to the predetermined value. Open the pressurization pump 3, and adjust pump rate and make the sealant pressure reach the predetermined value. Pressure can be monitored by pressure gauge 1. In this process, check valve 5 can be used to cooperatively control pressure.

[0071] 4. Testing Fluid Sealability

[0072] Maintain the desired pressure value. Open the third stop valve 10, and allow the sealant continuously flow through minor-leak assembly. Record the pressure variation by pressure sensor 12, which can reflect the plugging process. The sealant that flows across leak sample 22 returns cylindrical cell 6, which may be circulated by pressurization pump 3 to facilitate continuous plugging test. The real-time pressure data can be recorded and transmitted to control panel 19 so that the plugging property can be completely analyzed.

[0073] 5. Cleaning the Testing Apparatus

[0074] Turn off the power of tester. Cool down cylindrical cell 6 to the ambient temperature. Take out the leak sample 22 from minor-leak assembly to further examine characteristic of seal formed in the leak site. Drain the sealant fluid from the cell 6. Pour the flush into the cell body. Open pressurization pump 3 to circulate flush for cleaning the tester.

[0075] The present disclosure is described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the disclosure as otherwise described and claimed herein. Modification and variations from the descried embodiments exist. In minor-leak assembly, for example, the bottom cup may be made of metals rather than visual quartz glass. In addition, in alternative embodiments, the electromagnetic heater positioned radially outside the pressure cell may be changed with an electric heater, and the valves may be electrically or pneumatically completely inverted.

[0076] More specifically, the following examples are given as a specific illustration of embodiments of the claimed disclosure. It should be understood that the invention is not limited to the specific details set forth in the example.

Application

Example 1

[0077] A differential pressure sealant A purchased from Jingzhou Jiahua Tech. Co., Ltd was used to measure the plugging property by means of the present invention. To simulate downhole pipe leakage on-site, a leak sample 1 with single pore whose diameter is 0.5 mm was selected. According to the operation steps described above, the test of plugging property of sealant A was conducted at 80° C. The real-time pressure variation is given in FIG. 5.

Example 2

[0078] The differential pressure sealant A purchased from Jingzhou Jiahua Tech. Co., Ltd was further used to measure the plugging property by means of the present invention. To simulate downhole pipe leakage on-site, another leak sample 2 with single square hole (length×width×depth=0.5 mm×0.5 mm×10 mm) was specifically selected. According to the operation steps described above, plugging property of sealant A was tested at 80° C., and the real-time pressure variation is shown in FIG. 5.

Example 3

[0079] A differential pressure sealant B purchased from Jingzhou Jiahua Tech. Co., Ltd was further employed to evaluate its plugging property using the present invention. Note that, sealant B is added the solid sealing material such as fiber to reinforce its sealalibity. To simulate downhole pipe leakage on-site, another leak sample 3 with a single rectangular hole (length×width×depth=1.0 mm×0.5 mm×10 mm) was comparatively selected. According to the operation steps described above, plugging test was conducted at 80° C. The real-time pressure variation is given in FIG. 5.

[0080] It is clear in FIG. 5 that the real-time pressure variation is well consistent for three sealant fluids, including four stages such as preparatory, pressurization, decline, and stabilization, all of which are closely related with plugging process. For example, the preparatory stage corresponds exactly to heating operation, and pressurization is linked with pumping operation. The residual stages of decline and stabilization can accurately disclose the plugging property of sealant. In principle, the shorter the decline stage lasts, the more quickly a seal forms across leak, the stronger the sealability of fluid is. It should be pointed out that the final stabilization stage can disclose a successful seal. Therefore, it can be concluded that sealant A exhibits excellent sealability to leak sample 1 & 2. Also, sealant B displays a strong plugging capability. Compared with sealant A, sealant B obviously possesses much stronger sealability, due to its successful seal on larger leakage of sample 3.