-by-

Mike Bock, Travis W. Massey, Zachary S. Trine, and Ryan Mogensen

BACKGROUND OF THE DISCLOSURE

[0001] During completion of a wellbore, casing is cemented in a borehole using cement. The bottom hole assembly (BHA) of the casing typically has a shoe track, which includes a float collar, a length of tubing, and a float shoe on the casing’s toe. Once a cementing operation is done, the shoe track is drilled out using a drill string run down the casing to drill out the float shoe, the cement plugs, and residual cement in the shoe track.

[0002] For example, Figs. 1 A-1 D illustrate successive stages of performing a cementing operation using an assembly 10 according to the prior art. The assembly 10 includes a casing string 12 disposed in a borehole 15. The bottom hole assembly of the casing string 12 includes a shoe track T having a float collar 30, a length of tubing 14, and a float shoe 20 on the toe of the casing string 12. During the cementing operation as shown in Fig. 1A, a bottom plug 40 is pumped down the casing string 12 followed by a spacer fluid S and cement slurry C. The bottom plug 40 can include an internal barrier 42, valve, or the like to separate the spacer fluid S from the borehole fluids ahead of the bottom plug 40.

[0003] Eventually as shown in Fig. 1 B, the bottom plug 40 lands at the float collar 30, which includes a check valve 32. The internal barrier 42 of the bottom plug 40 is then opened so the spacer fluid S and cement slurry C can flow through the passage 44 of the plug 40, through the check valve 32 of the float collar 30, and out of the float shoe 20 to the borehole 15. As shown, the float shoe 28 may also have a check valve 22. [0004] Behind the cement slurry C, a top wiper plug 50 is pumped down the casing string 12 with a displacement fluid D. The wiper plug 50 keeps the displacement fluid D from mixing with the cement slurry C, and the plug 50 wipes the interior of the casing string 12. As shown in Fig. 1 C, the wiper plug 50 eventually engages with the bottom plug 40 to close off fluid communication through the plug’s passage 44.

[0005] In some installations, operators can determine that the toe of the assembly 10 and the shoe track T have been properly cemented by detecting a bump indication when the wiper plug 50 engages the bottom plug 40. For example, a calculated volume of displacement fluid D is pumped behind the wiper plug 50 and the cement C during operation. Assuming the cementing operation is successful, the wiper plug 50 reaches the bottom plug 40 when the calculated volume of the displacement fluid D has been pumped. In response, operators can determine that the cementing job is done and that the shoe track T is full of cement. At this point, operators can achieve a positive casing test (performed on the wet cement).

[0006] As can be seen in the standard operating procedure outlined above, the shoe track T having the length of tubing 14 between the float collar 30 and float shoe 20 is filled with cement. This is typically desired as part of the standard procedures so operators can ensure that the cement in the annulus of the borehole 15 toward the toe of the casing 12 is well cemented. In many installations, the shoe track T can encompass a length L of about 120 ft of tubing 14 filled with cement. The plugs 40, 50 used during the cementing operation are cemented in place.

[0007] In the end, operators want the toe to be competently cemented so a wash-out zone can be minimized and so a competent formation integrity test (FIT) can be performed against a newly drilled formation below the cemented casing 12. For this reason, the standard operating procedure discussed above fills the shoe track T with cement to reduce the chance of having a wet shoe form after cementing. Additionally, filling the shoe track T with cement allows operators to obtain reliable results from a casing integrity test after the cementation is done.

[0008] Finally, as shown in Fig. 1 D, the bottom hole assembly is drilled out to remove the check valves 32, 22 of the collars 30 and the shoe 20, to remove the plugs 40, 50, and to remove the residual cement in the tubing 14 of the shoe track T. Any wash-up must also be drilled out and can be about ±60 ft. As a result, the conventional shoe track T that needs to be drilled out can extend 45 to 130 ft. This drill out of the cement- filled shoe track T can take between 7 to 10 hours of rig time to complete. After drill out, operators can then perform the formation integrity test (FIT) before drilling the next interval of the borehole beyond the cemented casing string 12.

[0009] As will be appreciated, rig time presents one of the highest costs for a drilling operation so reducing rig time brings significant value to the operators. The conventional shoe track T full of cement currently produced in the standard procedures requires an extending period of rig time and can lead to excess bit wear inside the casing string 12. What is needed is a way to reduce the rig time required once a cementing operation is completed.

[0010] The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.

SUMMARY OF THE DISCLOSURE

[0011] Some implementations disclosed herein relate to a method, such as a method used for cementing casing in a borehole with cement. For example, the method may include pumping at least one plug down the casing behind the cement. The casing can have a shoe track between a float valve and a shoe of the casing. The method may also include landing the at least one plug at the float valve. The method may furthermore include releasing an internal component of the float valve by building-up pressure in the casing behind the internal component up to a release threshold. The method may in addition include displacing at least some of the cement in the shoe track out of the shoe to the borehole by pumping the at least one plug and the internal component toward the shoe. Other embodiments of this aspect include corresponding systems, apparatus, and devices, each configured to perform the actions of the methods.

[0012] The described implementations may also include one or more of the following features. The method may include landing the internal component at the shoe of the casing. In the method, landing the internal component at the shoe of the casing may include detecting a bump indication at surface. Landing the internal component at the shoe of the casing may include latching the internal component in a locator at the shoe. [0013] The method may include performing a positive casing test against the at least one plug and the internal component landed at the shoe.

[0014] The method may include drilling out the at least one plug and the internal component at the shoe. Method may include performing a formation integrity test.

[0015] The at least one plug may include a bottom plug and a top plug, and pumping the at least one plug down the casing behind the cement and landing the at least one plug at the float valve installed on the casing may include: pumping the bottom plug down the casing ahead of the cement; landing the bottom plug at the float valve; establishing circulation of the cement through the bottom plug to the shoe track downhole from the float valve; pumping the top plug down the casing behind the cement; and landing the top plug on the bottom plug. [0016] In the method, landing the bottom plug at the float collar valve may include detecting a bump indication at surface, and landing the top plug on the bottom plug may include detecting another bump indication at surface.

[0017] In the method, establishing circulation of the cement through the bottom plug to the shoe track downhole from the float valve may include opening a passage through the bottom plug.

[0018] Landing the at least one plug at the float valve may include performing a positive casing test against the at least one plug landed at the float valve.

[0019] Releasing the internal component of the float valve by building up the pressure in the casing behind the internal component up to the release threshold may include shifting a collet; releasing a dog; breaking a detent ring; shearing a shear screw, a pin, or element; or shearing a shouldered material.

[0020] Displacing at least some of the cement in the shoe track out of the shoe to the borehole may include squeezing the cement from another float valve at the shoe.

[0021] Some implementations disclosed herein relate to an assembly, such as an assembly used for cementing casing in a borehole with cement. For example, the assembly may include a float collar configured to install on the casing. The float collar can have an internal component with a one-way valve, and the one-way valve can be configured to permit downhole fluid communication and to prevent uphole fluid communication.

[0022] The assembly may also include a shoe configured to install downhole of the float collar on a shoe track of the casing. The assembly may furthermore include at least one plug configured to land at the float collar and configured to close the downhole fluid communication through the one-way valve. The assembly may in addition include a temporary retainer configured to temporarily retain the internal component in the float collar. The temporary retainer may be configured to release the internal component from the float collar in response to a release threshold. The internal component may be configured to displace at least a portion of the cement from the shoe track out of the shoe.

[0023] The described implementations may also include one or more of the following features. The shoe may include another one-way valve configured to permit the downhole fluid communication and to prevent the uphole fluid communication. The shoe may include a locator; and the internal component may include a latch configured to latch in the locator.

[0024] The float collar may include a housing configured to install on the casing. The internal component may include a shell having a filler disposed therein, and the filler can support the one-way valve.

[0025] The temporary retainer may include at least one shearable element engaged between the shell and the housing. The at least one shearable element can be configured to shear in response to the release threshold.

[0026] The at least one plug may include: a bottom plug configured to land at the float collar, the bottom plug having a passage with a breachable barrier; and a top plug configured to land at the bottom plug.

[0027] The temporary retainer may include a shiftable collet, a releasable dog, a breakable detent ring, a shearable element, a shear pin, a shear screw, or a shearable shoulder.

[0028] The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figs. 1 A-1 D illustrate successive stages of performing a cementing operation using an assembly according to the prior art.

[0030] Figs. 2A-2E illustrate successive stages of performing a cementing operation using an assembly according to the present disclosure.

[0031] Figs. 3A-3D illustrate successive stages of performing a cementing operation using one arrangement of the disclosed assembly.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0032] Figs. 2A-2E illustrate successive stages of performing a cementing operation using an assembly 100 according to the present disclosure. The assembly 100 includes a casing string 12 disposed in a borehole 15. The bottom hole assembly on the casing string 12 includes a shoe track T having a float collar 110, a length of tubing 14, and a float shoe 20 on the toe of the casing string 12. In many installations, the shoe track T can encompass a length L of about 120 ft of the tubing 14. Although the float shoe 20 is shown herein having a check valve 22, other arrangements can instead use a casing shoe 20 lacking a valve.

[0033] In many installations, multiple plugs are used during the cementing operations, including a bottom plug 40 used ahead of cement slurry pumped down the casing string 12, and a top plug 50 used behind the cement slurry. This type of installation using two plugs 40, 50 is described here. Different installations can more generally use one or more plugs. Accordingly, the teachings of the present disclosure can be applied to installations that use at least one plug for the cementing operation.

[0034] During the cementing operation as shown in Fig. 2A, the bottom plug 40 is pumped down the casing string 12 followed by a spacer fluid S and cement slurry C. The bottom plug 40 can include a breachable barrier 42, bust disk, valve, or the like to separate the spacer fluid S from the borehole fluids ahead of the plug 40.

[0035] Eventually as shown in Fig. 2B, the bottom plug 40 lands at the float collar 110, which includes a check valve 122. (As will be appreciated, the check valve 122 is typically a one-way valve configured to permit downhole fluid communication through the valve 122 and to prevent uphole fluid communication through valve 122. More than one check valve 122 can be used in the float collar 110.) The internal barrier 42 of the bottom plug 40 is then opened using pressure behind the barrier 42 so the spacer fluid S and the cement slurry C can flow through the passage 44 of the plug 40, through the check valve 122 of the float collar 110, and out of the float shoe 20 to the borehole 15. [0036] The top wiper plug 50 is pumped behind the cement slurry C with a displacement fluid D. The wiper plug 50 keeps the displacement fluid D from mixing with the cement slurry C and wipes the interior of the casing string 12. As shown in Fig. 2C, the wiper plug 50 eventually engages with the bottom plug 40 to close off fluid communication through the plug’s passage 44.

[0037] When the wiper plug 50 bumps on the float collar 110, a bump indication assures the operator that the shoe track T and the toe of the casing string 12 have been cemented. For example, during proper operations, the wiper plug 50 is pumped to the float collar 110 using a calculated volume of displacement fluid D. When the wiper plug 50 has been pumped with an acceptable value of this calculated volume, a pressure response is detected at surface, which can indicate to the operators that the wiper plug 50 has bumped/located on the bottom plug 40. This in turn indicates that the shoe track T is full of cement. At this point, operators can then achieve a positive casing test performed on the wet cement.

[0038] Should operators not see a bump indication from the wiper plug 50 engaging the float collar 110, the operators can pump a calculated displacement volume equal to half of the shoe track T in capacity. If a bump indication still does not occur, then there is likely no pressure containment point to perform a pressure test of the casing against. Remedial actions would be necessary because some form of a leak is present.

[0039] In the present assembly 100, the float collar 110 includes an internal component 120 having the check valve 122 and other features. The internal component 120 can be released from the float collar 110 by releasing a temporary support or retainer 124 between the internal component 120 and the external housing of the float collar 110. Releasing the temporary retainer 124 can involve shifting collets; releasing dogs; breaking detent rings; shearing screws, pins, or other elements; or shearing a shouldered material.

[0040] Continuing with the operations as shown in Figs. 2C-2D, operators build up the pressure of the displacement fluid D to a release threshold (e.g., shear value) for the temporary retainer 124 of the float collar 110. Eventually, the internal component 120 of the float collar 110 is released from (e.g., is shears out of) the collar’s housing. The plugs 40, 50 and the internal component 120 are then displaced down the casing string 12 to a locator 25 machined into the shell of the float shoe 20. This displaces the volume of wet cement in the shoe track T so the cement is squeezed out of the float collar 20 and into the toe of the borehole 15.

[0041] A second bump/location indication can then be obtained at surface when the float collar’s internal component 120 engages the float shoe 20. Ultimately, the internal component 120 can latch in the locator 25 in the float shoe 20 to provide a secondary barrier. For example, the internal component 120 can include a latch ring, a locator dog, or other locking feature that engages in a profile, slot, or the like in the float shoe 20. In response to the second bump indication, operators can determine that the cementing job is done. As a result of the procedures performed with this assembly 100, a considerably shorter shoe track T of about 2 to 4 ft. is left to be drilled out, instead of the conventional shoe track of 45 to 130 ft that needs to be drilled out when standard procedures are used. [0042] Once landed, the float collar’s internal component 120 and the plugs 40, 50 can once again hold back pressure. Once the cement sets, operators can then achieve another positive casing test on the competent cement by using a drilling BHA in the hole. Finally, as shown in Fig. 2E, the bottom hole assembly is drilled out to remove the 8 to 10 ft length having the plugs 40, 50, the float collar’s internal component 120, and the float shoe 20 from the shoe track T. Any wash up is also drilled out. This drill-out operation may take only about 1 to 3 hours of rig time to complete. A formation integrity test (FIT) can finally be performed before drilling the next interval.

[0043] As noted in the background, the standard procedure leaves the conventional shoe track full of cement to reduce the chances of having a wet shoe. In contrast, the assembly 100 of the present disclosure reduces the length of the shoe track T that needs to be drilled out while giving operators bump/location indications to assess proper cementing of the toe of the casing string 12. The assembly 100 still includes both the float collar 110 and the float shoe 20, but the assembly 100 transitions the shoe track T from the conventional length of about 130 ft. down to about 3 to 5 ft.

[0044] Figs. 3A-3D illustrate one particular arrangement of the assembly 100 in some more detail. Similar components to those discussed above have the same reference numerals so similar details may not be repeated here. Operation of the assembly 100 is also similar and may not be fully described again with reference to Figs. 3A-3D.

[0045] In this arrangement, the top and bottom plugs 40, 50 are part of a sub-surface release system (not shown) having a landing string disposed further uphole in the casing string 12. Top and bottom darts 46, 56 are used to activate and launch the respective top and bottom plugs 40, 50 from the release system. To do this, the darts 46, 56 separate fluids in the landing string of the release system (not shown) and activate a releasing mechanism in the respective plugs 40, 50 to launch them in the casing string 12.

[0046] Initially, the bottom dart 46 is pumped from the surface through the system’s landing string in front of the cement slurry. The dart 46 latches into the bottom plug 40 in the sub-surface release system (not shown), and the bottom plug 40 is released to pass through the casing string 12 to land on the float collar 110, as shown in Fig. 3A. The bottom plug 40 includes a breachable barrier, such as a rupture disk 42. After the plug 40 lands on the float collar 110, the rupture disk 42 is opened so circulation can be re-established in the casing string 12 to pump the cement slurry into the annulus between the borehole 15 and casing string 12.

[0047] Eventually, the top dart 56 is pumped through the system’s landing string behind the cement slurry. The dart 56 latches into the top plug 50 in the sub-surface release system (not shown) to release the top plug 50. After release, the top plug 50 wipes the casing string 12 before landing/bumping on top of the bottom plug 40, as shown in Fig. 3B. As noted, this can provide a positive indication of the cement’s displacement, and operators can then achieve a positive casing test performed on the wet cement.

[0048] As best shown in Figs. 3B-3C, the float collar 110 includes an internal component 120 disposed in a housing 112 coupled to the casing 12. In the present configuration, the internal component 120 includes a shell 126 having a filler 128 that supports a check valve 122 therein. The shell 126 can be composed of a metal or other support material suitable for drilling out, and the filler 128 can be composed of cement or other drillable material. The shell 126 is supported in the housing 112 using the temporary retainer 124, which includes shearable elements as shown here, engaged between the shell 126 and the external housing 112 of the float collar 110. The shell 126 can also be sealed in the housing 112 as appropriate.

[0049] In other configurations, the internal component 120 may not have a separate shell 126 and filler 128 of different materials. Instead, the internal component 120 can be composed of a suitable material that can support the check valve 122, can be displaced from the housing of the float valve 120, and can be drilled out at the end of operations.

[0050] Continuing with the operations as shown in Figs. 3C-3D, operators build up pressure behind the seated plugs 40, 50 in the float collar 110 to a release threshold (e.g., shear value) for the shearable elements 124 to release the internal component 120 from the housing 112 of the float collar 110. With the elements 124 sheared, the plugs 40, 50 and the internal component 120 are displaced down the casing string 12 to the float shoe 20. This displaces the volume of cement in the shoe track T so the cement can be squeezed out the float shoe 20 and into the toe of the borehole 15.

[0051] A second bump/location indication can then be obtained at surface when the internal component 120 and plugs 40, 50 engage the float shoe 20. Ultimately, a latch 125, such as a latch ring, a locator dog, or other locking feature, on the shell 126 can latch in a locator profile 25 or the like in the housing of the float shoe 20.

[0052] Once the cement sets, the shell 126, the filler 128, the check valve 122, and the plugs 40, 50 can once again hold back pressure so operators can achieve a positive casing test on competent cement by using a drilling BHA DB in the casing string 12.

The entire bottom hole assembly can then be drilled out to remove the plugs 40, 50, the shell 126, the filler 128, the check valve 122, and the float shoe’s valve 22 from the shoe track T.

[0053] The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. It will be appreciated with the benefit of the present disclosure that features described above in accordance with any embodiment or aspect of the disclosed subject matter can be utilized, either alone or in combination, with any other described feature, in any other embodiment or aspect of the disclosed subject matter.

[0054] In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.