US20040011534A1 - Apparatus and method for completing an interval of a wellbore while drilling - Google Patents

Abstract

An apparatus and method for completing an interval of a wellbore while drilling comprises a drill string (52) having a drill bit (30) mounted on the lower end thereof. A completion assembly (50) is positioned around a section of the drill string (52) such that when the wellbore (32) is extended by rotating the drill bit (30) and advancing the drill string (52), the completion assembly (50) does not rotate. The advancement of the drill string (52) and rotation of the drill bit (30) is ceased when the completion assembly (50) has reached the desired interval of the wellbore (32). Thereafter, the drill string (52) is disconnected from the drill bit (30) for retrieval to the surface leaving the completion assembly (50) and the drill bit (30) downhole.

Description

TECHNICAL FIELD OF THE INVENTION
• This invention relates, in general, to drilling and completing a well that traverses a hydrocarbon bearing subterranean formation and, in particular, to an apparatus and method for completing an interval of a wellbore while drilling.[0001]
BACKGROUND OF THE INVENTION
• Without limiting the scope of the present invention, its background will be described with reference to producing fluid from a subterranean formation, as an example.[0002]
• After drilling each of the sections of a subterranean wellbore and retrieving the drill bit and drilling string to the surface, individual lengths of relatively large diameter metal tubulars are typically secured together to form a casing string that is positioned within each section of the wellbore. This casing string is used to increase the integrity of the wellbore by preventing the wall of the hole from caving in. In addition, the casing string prevents movement of fluids from one formation to another formation. Conventionally, each section of the casing string may be cemented within the wellbore before the next section of the wellbore is drilled. Accordingly, each subsequent section of the wellbore must have a diameter that is less than the previous section.[0003]
• For example, a first section of the wellbore may receive a conductor casing string having a 20-inch diameter. The next several sections of the wellbore may receive intermediate casing strings having 16-inch, 13⅜ inch and 9⅝-inch diameters, respectively. The final sections of the wellbore may receive production casing strings having 7-inch and 4½-inch diameters, respectively. Each of the casing strings may be hung from a casing head near the surface. Alternatively, some of the casing strings may be in the form of liner strings that extend from near the setting depth of previous section of casing. In this case, the liner string will be suspended from the previous section of casing on a liner hanger.[0004]
• It has been found, however, that rig time can be reduced by utilizing the casing string as the drill string for rotating a drill bit. As this procedure, referred to as casing while drilling, does not require the use of a separate liner or casing string to be run downhole after the retrieval of the drill bit and drill string, the time needed to drill, case and cement a section of wellbore can be reduced. Typically, when the casing string operates as the drill string to rotate the drill bit, particularly robust casing must be utilized.[0005]
• Whether conventionally drilled or after performing as casing while drilling operation, once the well construction process is finished, the various steps of the completion process may begin. For example, hydraulic openings or perforations are typically made through the production casing string, the cement, if any, and a short distance into the desired formation or formations so that production fluids may enter the interior of the wellbore. In addition, the completion process may involve formation stimulation to enhance production, gravel packing to prevent sand production and the like. The completion process also includes installing a production tubing string within the well that extends from the surface to the production interval or intervals. The tubing may include sand control screen sections that are positioned adjacent to the perforated intervals.[0006]
• It would be desirable to further reduce rig time by minimizing the number of trips downhole required to drill and complete a well. Accordingly, it would be desirable to combine certain aspects of the drilling operation and the completion operation into the same trip downhole. Therefore, a need has arisen for an apparatus and a method for completing an interval of a wellbore while drilling.[0007]
SUMMARY OF THE INVENTION
• The present invention disclosed herein comprises an apparatus and a method that allow for a reduction in rig time by minimizing the number of trips downhole required to drill and complete a well. The apparatus and the method of the present invention achieve this result by combining certain aspects of the drilling operation and the completion operation into the same trip downhole, thereby providing for the completion of an interval of a wellbore while drilling.[0008]
• The apparatus of the present invention comprises a drill string having a drill bit mounted on the lower end thereof. A completion assembly is positioned around a section of the drill string such that when the wellbore is extended by rotating the drill bit and advancing the drill string, the completion assembly is not rotated. Once the completion assembly has reached the desired position adjacent to a production interval traversed by the wellbore, the advancement of the drill string is ceased. Thereafter, the drill string is disconnected from the completion assembly and the drill bit such that the drill string may be retrievable to the surface leaving only the completion assembly and the drill bit downhole. Accordingly, using the completion assembly of the present invention assures that the completion equipment is placed within the wellbore before the wellbore has an opportunity to cave in.[0009]
• In one embodiment of the present invention, the completion assembly may include an expandable screen. In this embodiment, the expandable screen is expanded after the completion assembly has reached the desired depth on the same trip or a subsequent trip into the wellbore. In another embodiment, the completion assembly may include a sand control screen with a gravel packing assembly positioned therearound. In this embodiment, after the completion assembly has reached the desired depth, a gravel packing operation may be performed wherein the wellbore around the sand control screen and the gravel packing apparatus is filled with gravel.[0010]
• In one embodiment of the present invention, the completion assembly includes a seal member that is coupled to the drill string to prevent fluid migration therebetween. Additionally or alternatively, the completion assembly may include a rotatable coupling that is coupled to the drill string to prevent torque transfer therebetween.[0011]
• In one embodiment of the present invention, the rotation of the drill bit may be generated with a downhole motor that is driven by drilling fluid. In another embodiment, the rotation of the drill bit may be generated by rotating the drill string from the surface.[0012]
• In another aspect, the present invention comprises a method of completing a wellbore while drilling. The method involves disposing a drill bit on an end of a drill string, positioning a completion assembly around a section of the drill string, extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly, ceasing the advancement of the drill string when the completion assembly has reached a desired depth, disconnecting the drill string from the drill bit and retrieving the drill string to the surface leaving only the completion assembly and the drill bit downhole.[0013]
BRIEF DESCRIPTION OF THE DRAWINGS
• For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:[0014]
• FIG. 1 is a schematic illustration of an offshore oil and gas platform performing a completion while drilling operation according to the present invention;[0015]
• FIG. 2 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned within a wellbore during a drilling operation;[0016]
• FIG. 3 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned within a wellbore after the drill string has been retrieved to the surface;[0017]
• FIG. 4 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned within a wellbore before an expansion operation;[0018]
• FIG. 5 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned within a wellbore after the expansion operation;[0019]
• FIG. 6 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned within a wellbore and ready for production;[0020]
• FIG. 7 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned within a wellbore during a drilling operation;[0021]
• FIG. 8 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned with a wellbore during a suspension tool actuation operation;[0022]
• FIG. 9 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned within a wellbore during a gravel packing operation; and[0023]
• FIG. 10 is a half sectional view of a completing while drilling apparatus according to the present invention that is positioned within a wellbore and ready for production.[0024]
DETAILED DESCRIPTION OF THE INVENTION
• While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.[0025]
• Referring initially to FIG. 1, an apparatus for completing an interval of a wellbore while drilling of the present invention is being installed from an offshore oil and gas platform that is schematically illustrated and generally designated[0026]10. Asemi-submersible platform12 is centered over a submerged oil andgas formation14 located belowsea floor16. Asubsea conduit18 extends fromdeck20 ofplatform12 towellhead installation22 including subsea blow-outpreventers24.Platform12 has a hoistingapparatus26 and aderrick28 for raising and lowering pipe strings such as a drill string (not pictured) used to rotatedrill bit30 during the drilling operation used to lengthenwellbore32 throughformation14.
• As illustrated, an upper portion of[0027]wellbore32 includes acasing34 that is cemented therein bycement36. A lower portion ofwellbore32 that traversesformation14 is not cased but rather includes a completing while drillingapparatus38 suspended fromcasing34 viasuspension tool40. As explained in greater detail below, completing whiledrilling apparatus38 is initially positioned around a section of the drill string such that when wellbore32 is being extended throughformation14 by rotatingdrill bit30 and advancing the drill string, completing whiledrilling apparatus38 is not rotated. Once the desired depth is reached and the extension ofwellbore32 ceases, the drill string is disconnected fromdrill bit30 andcompletion assembly38 then retrieved to the surface. Thereafter, as illustrated, anexpansion tool42 is run in the hole, for example, carried on the lower end of a coiledtubing44 or other suitable conveyance including, but not limited to, jointed pipe or composite tubing, to expand portions of completing whiledrilling apparatus38 such as an expandable sandcontrol screen assembly46.
• Even though FIG. 1 depicts a vertical well, it should be noted by one skilled in the art that the completing while drilling apparatus of the present invention is equally well-suited for use in deviated wells, inclined wells or horizontal wells. Also, even though FIG. 1 depicts an offshore operation, it should be noted by one skilled in the art that the apparatus for gravel packing an interval of a wellbore of the present invention is equally well-suited for use in onshore operations.[0028]
• Referring now to FIG. 2, therein is depicted one embodiment of an apparatus for completing an interval of a wellbore while drilling that is generally designated[0029]50. As illustrated, completing whiledrilling apparatus50 is being used to lengthenwellbore32 beyond an upper section ofwellbore32 that includescasing34 that is cemented therein bycement36. Completing whiledrilling apparatus50 includes a conventional drill string52 that is used to apply weight ondrill bit30 asdrill bit30 rotates such thatwellbore32 may be extended.Drill bit30 may be conventionally rotated by drill string52 but is preferably rotated using a downhole mud motor54 which utilizes drilling fluid, indicated asarrows56, to impart rotation to drillbit30. The drilling fluid including the cuttings created bydrill bit30 are then returned to the surface around the exterior of completing whiledrilling apparatus50 as indicated by arrows58.
• Between drill string[0030]52 and mud motor54, completing whiledrilling apparatus50 may include a variety of other tools60 such as measurement while drilling tools, logging while drilling tools or the like. Completing whiledrilling apparatus50 also includes a lug62, the operation of which is explained below.
• Mud motor[0031]54 is coupled to drillbit30 via asplined subassembly64.Splined subassembly64 includes mating members that transfer rotation from mud motor54 to drillbit30 and allow the flow of drilling mud therethrough. The mating members ofsplined subassembly64 are initially coupled together using shear pins or other suitable means. The shear pins allow for the transfer of rotation between the mating members and initially prevent relative translational movement therebetween. As explained below, shearing of the shear pins insplined subassembly64 allows for the disconnection of drill string52 fromdrill bit30 and completing whiledrilling apparatus50.
• Positioned between[0032]splined subassembly64 anddrill bit30 is a float subassembly66. Float subassembly66 includes a valving mechanism that allows drilling mud to travel from drill string52 intodrill bit30. Once the interval ofwellbore32 has been completed and production has commenced, however, the valving mechanism of float subassembly66 prevents formation fluids from being produced though the fluid communication paths indrill bit30. For example, the valving mechanism of float subassembly66 may be a one-way valve wherein fluids may travel fromsplined subassembly64 to drillbit30 through float subassembly66 but not fromdrill bit30 tosplined subassembly64 through float subassembly66. Alternatively, the valving mechanism of float subassembly66 may have multiple configurations wherein fluid can initially pass through float subassembly66 allowing fluid to travel fromsplined subassembly64 to drillbit30 through float subassembly66 but will be prevented from traveling though float subassembly66 fromdrill bit30 tosplined subassembly64 through float subassembly66 once float subassembly66 has been operated into its closed configuration.
• Completing while[0033]drilling apparatus50 is positioned around drill string52. Completing whiledrilling apparatus50 includes an upper latch70. Upper latch70 provides support between drill string52 and completing whiledrilling apparatus50. In the illustrated embodiment, upper latch70 includes a static seal, such as a cup seal, that prevents the flow of fluids between upper latch70 and drill string52. The static seal allows for relatively translational movement between drill string52 and completing whiledrilling apparatus50 so that the axial force placed on drill string52 during drilling operations wherein weight is placed ondrill bit30 is not transferred to completing whiledrilling apparatus50. In other embodiments that do not includemud motor50 and wherein drill string52 is used to rotatedrill bit30, upper latch70 includes a dynamic seal, such as a bearing seal, that maintains the required fluid sealing between drill string52 and upper latch70 during such rotation and prevents the transfer of any torque therebetween. Upper latch70 includes a receiver72 that is designed to couple to lug62 as explained in greater detail below.
• Adjacent to upper latch[0034]70, completing whiledrilling apparatus50 includes a seal bore74. Seal bore74 is designed to provide a receiving surface for a seal assembly that will be carried on a tubing string installed within completing whiledrilling apparatus50 as explained below.
• Next, completing while[0035]drilling apparatus50 has a suspension tool76. When actuated, suspension tool76 is designed to support completing whiledrilling apparatus50 withinwellbore32 and prevent the flow of fluids between completing whiledrilling apparatus50 andcasing string34 across suspension tool76. Suspension tool76 may be a conventional liner hanger mechanism or other device that provides suitable gripping and sealing service. Suspension tool76 may be actuated in a variety of known ways such as mechanically shifting suspension tool76 or hydraulically actuating suspension tool76.
• In the illustrated embodiment, completing while[0036]drilling apparatus50 includes a plurality of sections oftubular members78.Tubular members78 are used as a liner forwellbore32 that extends from the lower end of casing34 to the desired location aboveformation14. It should be apparent to those skilled in the art that the use of directional terms such as top, bottom, above, below, upper, lower, upward, downward, etc. are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. As such, it is to be understood that the downhole components described herein may be operated in vertical, horizontal, inverted or inclined orientations without deviating from the principles of the present invention.
• Positioned below[0037]tubular members78 within completing whiledrilling apparatus50 is acone launcher80.Cone launcher80, is used to provide room to operate an expansion tool from it running position to its expansion position as described in greater detail below.
• Next, completing while[0038]drilling apparatus50 has one or more sections of expandabletubular members82. The length of expandabletubular members82 can be any suitable length and will depend, in part, on the length oftubular members78 abovecone launcher80. In some cases it may be desirable to line most ofwellbore32 between the lower end ofcasing34 andformation14 with expandabletubular members82 thereby allowing for expansion of expandabletubular members82 against the wall of the borehole. Alternatively, in some cases it may be desirable to line most ofwellbore32 between the lower end ofcasing34 andformation14 withtubular members78, thereby not requiring expansion.
• Coupled to the lower end of expandable[0039]tubular members82 is an expandable sandcontrol screen assembly84. Expandable sandcontrol screen assembly84 may be of any suitable construction but it preferably includes aperforated base pipe86 that is expandable. Positioned aroundbase pipe86 is anexpandable filter media88 such as a fluid-porous, particulate restricting screen such as a plurality of layers of a wire mesh that are diffusion bonded or sintered together to form a porous wire mesh screen designed to allow fluid flow therethrough but prevent the flow of particulate materials of a predetermined size from passing therethrough. Positioned exteriorly offilter media88 is a perforatedouter shroud90 that is also expandable. While a single section of expandable sandcontrol screen assembly84 is depicted, it should be understood by those skilled in the art that any number of section of expandable sandcontrol screen assemblies84 may be used as part of completing whiledrilling apparatus50. The number of sections of expandable sandcontrol screen assemblies84 will be determined based upon the length offormation14. When multiple sections of expandable sandcontrol screen assemblies84 are used, additional sections of expandabletubular members82 may be positioned between sections of expandable sandcontrol screen assemblies84.
• In the illustrated embodiment, below the lower end of expandable sand[0040]control screen assemblies84 and any sections of expandabletubular members82 positioned thereafter is a lower seal bore92. As explained in greater detail below, lower seal bore92 may be used to determine when the expansion process of expandable sandcontrol screen assemblies84 and expandabletubular members82 is complete.
• At the lower end of completing while[0041]drilling apparatus50 there is asplined subassembly housing94.Splined subassembly housing94 provides support betweensplined subassembly64 and completing whiledrilling apparatus50.Splined subassembly housing94 includes a dynamic seal that prevents the flow of fluids betweensplined subassembly housing94 andsplined subassembly64, such as a bearing seal. The dynamic seal allows for relatively rotational movement betweensplined subassembly housing94 andsplined subassembly64 so that the torsional force placed onsplined subassembly64 during drilling operations whereindrill bit30 is rotated is not transferred to completing whiledrilling apparatus50.
• The operation of completing while[0042]drilling apparatus50 will now be described with reference to FIGS.2-6. After the upper section ofwellbore32 has been drilled and cased, the lower section ofwellbore32 that traversesformation14 may now be drilled and completed. First,drill bit30, float subassembly66,splined subassembly64 includingsplined subassembly housing94, mud motor54 and measurement while drilling tool60 including lug62 are assembled at the surface and coupled to drill string52. Thereafter, the reminder of completing whiledrilling apparatus50 is assembled and attached to drill string52. Specifically, seal bore92 is threadably attached to splinesubassembly housing94 and the required number of sections of expandable sandcontrol screen assemblies84 and expandabletubular members82 are threadably attached together in a conventional manner around drill string52 as drill string52 is threadably assembled and lowered into the well as necessary.
• Once the required length of sand[0043]control screen assemblies84 and expandabletubular members82 are in place around drill string52,cone launcher80 is attached to the outer string forming the lower section of completing whiledrilling apparatus50. The required length of non expandabletubular members78 is then attached to the outer string as additional sections of drill string52 are threadably assembled and lowered into the well. In the illustrated embodiment, to finish the assembly of completing whiledrilling apparatus50, suspension tool76, seal bore74 and upper latch70 are assembled.
• The entire completing while[0044]drilling apparatus50 is then lowered downhole on drill string52 untildrill bit30 reaches the bottom ofwellbore32.Wellbore32 can them be extended by rotatingdrill bit30 and advancing drill string52. In the illustrated embodiment, this is achieved by pumping drilling fluid, represented byarrows56, down drill string52 and through mud motor54. This creates a rotation in mud motor54 that in turn rotates the mating members ofsplined subassembly64 anddrill bit30. After rotating mud motor54, the drilling fluid passes throughsplined subassembly64, float subassembly66 anddrill bit30. The drilling fluid then carries the cuttings created bydrill bit30 back to the surface as indicated by arrows58.
• As splined[0045]subassembly64 andsplined subassembly housing94 are coupled together via a dynamic bearing type seal, the rotation ofsplined subassembly64 is not transferred to completing whiledrilling apparatus50. Accordingly, no torque is transferred to completing whiledrilling apparatus50 due to the rotation ofdrill bit30 which protects expandable sandcontrol screen assembly84 from damage during drilling.
• During the drilling operation, information may be recorded or may be sent to the surface in real-time from tool[0046]60 that may be sensing one or more parameters relating to the drilling operation. In fact, tool60 may be used to determine when the drilling operation should cease such that completing whiledrilling apparatus50 will be properly positioned relative toformation14.
• Once completing while[0047]drilling apparatus50 has reached the desired depth, as depicted in FIG. 2, the drilling portion of the completing while drilling operation ceases. Importantly, completing whiledrilling apparatus50 is positioned withinwellbore32 during the drilling operation. Accordingly, using completing whiledrilling apparatus50 assures that the completion equipment is placed withinwellbore32 before wellbore32 has an opportunity to cave in.
• At this point, suspension tool[0048]76 may be hydraulically actuated, as discussed in more detail below, to help support completing whiledrilling apparatus50. Alternatively, suspension tool76 may be mechanically or hydraulically actuated after disconnecting and retrieving drill string52 fromdrill bit30 and completing whiledrilling apparatus50. In either case, drill string52 may now be disconnected fromdrill bit30 and completing whiledrilling apparatus50.
• In those embodiments wherein the valving mechanism within float subassembly[0049]66 is a one-way valve, no operation is required to prevent fluid flow up throughdrill bit30. In those embodiments wherein the valving mechanism within float subassembly66 requires shifting to prevent fluid flow up throughdrill bit30, the closing operation may be achieved by appropriate upward or downward jarring on float subassembly66 or other suitable technique such as dropping a ball to shift a sleeve, which may also be used to in the disconnection process.
• Drill string[0050]52 is disconnected fromdrill bit30 and completing whiledrilling apparatus50 atsplined subassembly64. As explained above,splined subassembly64 includes a pair of mating members that are initially coupled together using shear pins or other suitable means. Accordingly, suitable upward jarring onsplined subassembly64 causes the shear pins to shear allowing for the disconnection of drill string52 fromdrill bit30 and completing whiledrilling apparatus50.
• Once drill string[0051]52 is disconnected fromdrill bit30 and completing whiledrilling apparatus50, drill string52 may be raised uphole until lugs62 are received within receiver72 of upper latch70. When lugs62 are received, this causes the release of upper latch70 from seal bore74 leavingdrill bit30 and completing whiledrilling apparatus50 in the hole, as best seen in FIG. 3.
• In the illustrated embodiment, the next step is to run an expansion tool[0052]100 downhole on acoiled tubing string102. Specifically, expansion tool100 has a small diameter running configuration such that it may be run throughtubular members78 and at least partially intocone launcher80. Once in this position, expansion tool100 can be shifted into its larger diameter expansion configuration suitable for expanding expandabletubular members82 and expandable sandcontrol screen assembly84, as best seen in FIG. 4. Expansion tool100 includes a tapered cone section104, apiston106 and ananchor section108.Anchor section108 includes a receiver portion that is coupled to the lower end of coiledtubing string102.
• In operation, a downward force is placed on expansion tool[0053]100 by applying the weight of coiledtubing string102 on expansion tool100. This downward force operates tostroke piston106 to its compressed position. Oncepiston106 completes its downward stroke, fluid is pumped down coiledtubing string102 which setsanchor section108 creating a friction grip betweenanchor section108 and the interior of the surrounding tubular which prevents upward movement ofanchor section108. As more fluid is pumped down coiledtubing string102,piston106 operates to urge tapered cone section104 downwardly such that tapered cone section104 places a radially outward force against the wall of expandabletubular members82 and expandable sandcontrol screen assembly84 causing these expandable products to plastically deform increasing the diameter thereof.
• This process continues in a step wise fashion wherein each stroke of expansion tool[0054]100 expands a section of expandabletubular members82 or expandable sandcontrol screen assembly84. When expansion tool100 contacts seal bore92, the expansion process is complete, as best seen in FIG. 5. Expansion tool100 is then returned to its running configuration such thatcoiled tubing string102 and expansion tool100 may be retrieved to the surface.
• Following the expansion process, a tubing string[0055]112 may be run downhole to provide a conduit for formation fluids to travel fromformation14 to the surface, as best seen in FIG. 6. In the illustrated embodiment, aseal assembly114 is carried on tubing string112 and is installed against the interior of seal bore74 in a known manner to prevent production fluids from flowing around the exterior of tubing string112.
• Referring now to FIG. 7, therein is depicted another embodiment of an apparatus for completing an interval of a wellbore while drilling that is generally designated[0056]150. As illustrated, completing whiledrilling apparatus150 is being used to lengthenwellbore132 beyond an upper section ofwellbore132 that includes casing134 that is cemented therein bycement136. Completing whiledrilling apparatus150 includes aconventional drill string152 that is used to apply weight ondrill bit130 asdrill bit130 rotates such thatwellbore132 may be extended. In the illustrated embodiment,drill bit130 is rotated using adownhole mud motor154 which utilizes drilling fluid, indicated asarrows156, to impart rotation to drillbit130. The drilling fluid, including the cuttings created bydrill bit130, is then returned to the surface around the exterior of completing whiledrilling apparatus150 as indicated byarrows158.
• Between[0057]drill string152 andmud motor154, completing whiledrilling apparatus150 may include a variety ofother tools160 such as measurement while drilling tools, logging while drilling tools or the like.Mud motor154 is coupled to drillbit130 via asplined subassembly164. As described above,splined subassembly164 includes mating members that transfer rotation frommud motor154 to drillbit130 and allow the flow of drilling mud therethrough. The mating members ofsplined subassembly164 are initially coupled together using shear pins or other suitable means that allow for the transfer of rotation between the mating members and initially prevent relative translational movement therebetween.
• Positioned between[0058]splined subassembly164 anddrill bit130 is afloat subassembly166.Float subassembly166 includes a valving mechanism that allows drilling mud to travel fromdrill string152 intodrill bit130 but prevents return fluid flow through fluid communication paths indrill bit130 during subsequent operations such as gravel packing and production.
• Completing while[0059]drilling apparatus150 is positioned arounddrill string152. Completing whiledrilling apparatus150 includes aseal bore174. Seal bore174 is designed to provide a receiving surface for various sealing mechanisms as explained below. Next, completing whiledrilling apparatus150 has asuspension tool176 that is designed to support completing whiledrilling apparatus150 withinwellbore132 and prevent the flow of fluids between completing whiledrilling apparatus150 andcasing string134 acrosssuspension tool176. In the illustrated embodiment,suspension tool176 is hydraulically actuated as described below. Completing whiledrilling apparatus150 also includesseal bore178. Seal bore178 is designed to provide a receiving surface for various sealing mechanisms as explained below.
• In the illustrated embodiment, completing while[0060]drilling apparatus150 includescrossover ports180.Crossover ports180 are initially in a closed position during the drilling operation to prevent fluid flow between the interior and exterior of completing whiledrilling apparatus150. As described below,crossover ports180 are opened prior to a gravel packing operation to allow a gravel packing slurry to travel from the interior to the exterior of completing whiledrilling apparatus150.
• Next, completing while[0061]drilling apparatus150 has one or more sections oftubular members182.Tubular members182 are designed to linewellbore132 between the lower end ofcasing134 andformation114.
• Coupled to the lower end of[0062]tubular members182 is a sandcontrol screen assembly184. Sandcontrol screen assembly184 may be of any suitable construction but it preferably includes aperforated base pipe186. Positioned aroundbase pipe186 is afilter media188 such as a wire wrapped screen jacket that may include a screen wire wrapped around a plurality of ribs such that the screen wire forms a plurality of turns with gaps therebetween through which formation fluids flow but which prevent the flow of particulate materials of a predetermined size from passing therethrough. Positioned exteriorly offilter media188 is a perforatedouter shroud190 that serves as a gravel packing apparatus. Specifically,outer shroud190 is designed to improve the gravel pack by allowing for any sand bridges that form in the annulus between the sand control screen and the borehole during a gravel packing operation to be bypassed. In addition, one or more channels may be positioned betweenouter shroud190 and filtermedia188 to form slurry passageways. In either case, the sand bridges are bypassed by the fluid slurry by passing throughouter shroud190 into the annulus betweenouter shroud190 and filtermedia188 or into the channels. After bypassing the sand bridge, the fluid slurry passes back throughouter shroud190 to reenter the annulus betweenouter shroud190 and the borehole to complete the gravel packing process.
• While a single section of sand[0063]control screen assembly184 is depicted, it should be understood by those skilled in the art that any number of section of sandcontrol screen assemblies184 includingouter shrouds190 may be used as part of completing whiledrilling apparatus150. The number of sections of sandcontrol screen assemblies184 will be determined based upon the length offormation114.
• Below the lower end of sand[0064]control screen assemblies184 there may be additional sections oftubular members192. At the lower end of completing whiledrilling apparatus150 there is asplined subassembly housing194.Splined subassembly housing194 provides support betweensplined subassembly164 and completing whiledrilling apparatus150.Splined subassembly housing194 includes a dynamic seal that prevents the flow of fluids betweensplined subassembly housing194 andsplined subassembly164, such as a bearing seal. The dynamic seal allows for relatively rotational movement betweensplined subassembly housing194 andsplined subassembly164 so that the torsional force placed onsplined subassembly164 during drilling operations whereindrill bit130 is rotated is not transferred to completing whiledrilling apparatus150.
• Positioned between[0065]drill string152 and completing whiledrilling apparatus150 is a pair ofseal members196,198 such as cup seals. As explained below,seal members196,198 allow for the hydraulic operation ofsuspension tool176. Also positioned betweendrill string152 and completing whiledrilling apparatus150 is arelease nut200.Release nut200 helps to support completing whiledrilling apparatus150 ondrill string152 then is operated to releasedrill string152 from completing whiledrilling apparatus150.
• The operation of completing while[0066]drilling apparatus150 will now be described with reference to FIGS.7-10. After the upper section ofwellbore132 has been drilled and cased, the lower section ofwellbore132 that traversesformation114 may now be drilled and completed. First,drill bit130,float subassembly166,splined subassembly164 includingsplined subassembly housing194,mud motor154 and measurement whiledrilling tool160 are assembled at the surface and coupled todrill string152. Thereafter, the remainder of completing whiledrilling apparatus150 is assembled and attached todrill string152. Specifically, the required number oftubular members192 are threadably attached to splinesubassembly housing194 and the required number of sections of sandcontrol screen assemblies184 withouter shrouds190 are threadably attached together in a conventional manner arounddrill string152 asdrill string152 is threadably assembled and lowered into the well as necessary.
• Once the required length of sand[0067]control screen assemblies184 are in place arounddrill string152, the required length oftubular members182 is then attached to the outer string as additional sections ofdrill string152 are threadably assembled and lowered into the well. To finish the assembly of completing whiledrilling apparatus150, seal bore178,suspension tool176 and seal bore174 are assembled.
• The entire completing while[0068]drilling apparatus150 is then lowered downhole ondrill string152 untildrill bit130 reaches the bottom ofwellbore132.Wellbore132 can them be extended by rotatingdrill bit130 and advancingdrill string152. In the illustrated embodiment, this is achieved by pumping drilling fluid, represented byarrows156, downdrill string152 and throughmud motor154. This creates a rotation inmud motor154 that in turn rotates the mating members ofsplined subassembly164 anddrill bit130. After rotatingmud motor154, the drilling fluid passes throughsplined subassembly164,float subassembly166 anddrill bit130. The drilling fluid then carries the cuttings created bydrill bit130 back to the surface as indicated byarrows158.
• As[0069]splined subassembly164 andsplined subassembly housing194 are coupled together via a dynamic bearing type seal, the rotation ofsplined subassembly164 is not transferred to completing whiledrilling apparatus150. Accordingly, no torque is transferred to completing whiledrilling apparatus150 due to the rotation ofdrill bit130 which protects sandcontrol screen assembly184 from damage during drilling.
• During the drilling operation, information may be recorded or may be sent to the surface in real-time from[0070]tool160 that may be sensing one or more parameters relating to the drilling operation. In fact,tool160 may be used to determine when the drilling operation should cease such that completing whiledrilling apparatus150 will be properly positioned relative toformation114.
• Once completing while[0071]drilling apparatus150 has reached the desired depth, as depicted in FIG. 7, the drilling portion of the completing while drilling operation ceases. Importantly, completing whiledrilling apparatus150 is positioned withinwellbore132 during the drilling operation. Accordingly, using completing whiledrilling apparatus150 assures that the completion equipment is placed withinwellbore132 before wellbore132 has an opportunity to cave in.
• At this point,[0072]suspension tool176 may be hydraulically actuated. Specifically, as best seen in FIG. 8, this is achieved by dropping aball202 downdrill string152. Onceball202contacts sleeve204,drill string152 is pressurized to shiftsleeve204 andopen ports206. Onceports206 are open, the fluid pressure withindrill string152 may be communicated tosuspension tool176 betweenseals196,198 to hydraulicallyactuate suspension tool176 which helps to support completing whiledrilling apparatus150.
• As discussed above, in those embodiments wherein the valving mechanism within[0073]float subassembly166 is a one-way valve, no operation is required to prevent fluid flow up throughdrill bit130. In those embodiments wherein the valving mechanism withinfloat subassembly166 requires shifting to prevent fluid flow up throughdrill bit130, the closing operation may be achieved by appropriate upward or downward jarring onfloat subassembly166 or other suitable technique such as dropping a ball to shift a sleeve, which may also be used to in the disconnection process.
• [0074]Drill string152 is now ready to be disconnected fromdrill bit130 and completing whiledrilling apparatus150. Specifically,drill string152 is disconnected fromdrill bit130 and completing whiledrilling apparatus150 atsplined subassembly164. As explained above,splined subassembly164 includes a pair of mating members that are initially coupled together using shear pins or other suitable means. Accordingly, suitable upward jarring onsplined subassembly164 causes the shear pins to shear allowing for the disconnection ofdrill string152 fromdrill bit130 and completing whiledrilling apparatus150.
• Once[0075]drill string152 is disconnected fromdrill bit130 and completing whiledrilling apparatus150,drill string152 is rotated atrelease nut200 to complete the disconnection such thatdrill string152 may be raised uphole leavingdrill bit130 and completing whiledrilling apparatus150 in the hole.
• In the illustrated embodiment, the next step is to run a[0076]service tool210 downhole to perform a gravel pack operation, as best seen in FIG. 9. Specifically,service tool210 includes acrossover assembly212 and a pair ofseal members214,216 that are positioned on opposite sides ofcrossover ports180, which are now open. Once in place, a fluid slurry containing gravel, sand or proppants is pumped downhole withinservice tool210 and throughcrossover assembly212, as indicated byarrows218. The fluid slurry then enters the annulus between completing whiledrilling apparatus150 and the borehole as indicted byarrows220.
• As stated above,[0077]outer shroud190 forms a gravel packing apparatus aroundfilter media188.Outer shroud190 is used to allow the fluid slurry to bypass any sand bridges that form during the gravel packing operation such that the fluid slurry is distributed to various locations within the interval to be gravel packed. In the illustrated embodiment, the fluid slurry is injected into the annulus then entersouter shroud190 if sand bridging occurs. Alternatively, the fluid slurry could be injected directly into the annulus betweenouter shroud190 andfilter media188. Additionally, as stated above, one or more channels may be disposed in the annulus betweenouter shroud190 and filtermedia188 to form slurry passageways. In these embodiments, three independent paths are established for the fluid slurry. Specifically, the annulus betweenouter shroud190 and the borehole, the area betweenouter shroud190 and filtermedia188 defined by the channels and the area betweenouter shroud190 and filtermedia188 not defined by the channels.
• In any of these embodiments, when the fluid slurry travels from the interior to the exterior of[0078]outer shroud190, a portion of the gravel in the fluid slurry is deposited aroundouter shroud190. This process progresses along the entire length ofouter shroud190 as required until the annulus aroundouter shroud190 becomes completely packed with the gravel. In addition, some of the fluid slurry enters and remains inside in the portions ofouter shroud190 that surroundfilter media188. The fluid portion of the slurry is allowed to pass throughfilter media188, as indicated byarrows222, which leaves the gravel from the fluid slurry in this region. Again, this process progresses along the entire length ofouter shroud190 such that this region becomes completely packed with the gravel. The fluid portion that travels throughfilter media188 then enterswash pipe224 and travels throughcrossover assembly212 as indicated byarrows226. The fluid then enters the annulus betweenservice tool210 and completing whiledrilling apparatus150, as indicated byarrows228, for return to the surface. This process continues until the entire production interval is completely packed with the gravel.
• Following the gravel packing process,[0079]service tool210 is retrieved to the surface and atubing string230 may be run downhole to provide a conduit for formation fluids to travel fromformation114 to the surface, as best seen in FIG. 10. In the illustrated embodiment, aseal assembly232 is carried ontubing string230 and is expanded against the interior of seal bore174 to prevent production fluids from flowing around the exterior oftubing string230.
• While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.[0080]

Claims (41)

What is claimed is:

1. A method of completing a wellbore while drilling comprising the steps of:

disposing a drill bit on an end of a drill string;

positioning a completion assembly around a section of the drill string;

extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly; and

ceasing the advancement of the drill string when the completion assembly has reached a desired depth.

2. The method as recited inclaim 1 further comprising the steps of disconnecting the drill string from the drill bit and retrieving the drill string to the surface leaving the completion assembly and the drill bit downhole.

3. The method as recited inclaim 1 wherein the step of positioning a completion assembly around a section of the drill string further comprises positioning an expandable screen around the section of the drill string.

4. The method as recited inclaim 3 further comprising the step of expanding the expandable screen after the completion assembly has reached the desired depth.

5. The method as recited inclaim 1 wherein the step of positioning a completion assembly around a section of the drill string further comprises positioning a sand control screen and a gravel packing assembly around the section of the drill string.

6. The method as recited inclaim 5 further comprising the step of gravel packing the wellbore around the sand control screen and the gravel packing apparatus.

7. The method as recited inclaim 1 wherein the step of positioning a completion assembly around a section of the drill string further comprises establishing a fluid seal between the completion assembly and the drill string to prevent fluid migration therebetween.

8. The method as recited inclaim 1 wherein the step of positioning a completion assembly around a section of the drill string further comprises rotatably coupling the completion assembly to the drill string to prevent torque transfer therebetween.

9. The method as recited inclaim 1 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises rotating the drill bit by operating a downhole motor.

10. The method as recited inclaim 1 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises rotating the drill bit by rotating the drill string.

11. The method as recited inclaim 1 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises extending the wellbore beyond the end of a casing in the wellbore.

12. The method as recited inclaim 11 further comprising the step of supportably coupling the completion assembly to the casing with a suspension tool.

13. The method as recited inclaim 1 further comprising the step of installing a production tubing relative to the completion assembly providing for fluid communication therebetween.

14. A method of completing a wellbore while drilling comprising the steps of:

disposing a drill bit on an end of a drill string;

positioning a completion assembly including an expandable screen around a section of the drill string;

extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly;

ceasing the advancement of the drill string when the completion assembly has reached a desired depth; and

expanding the expandable screen.

15. The method as recited inclaim 14 further comprising the steps of disconnecting the drill string from the drill bit and retrieving the drill string to the surface leaving the completion assembly and the drill bit downhole.

16. The method as recited inclaim 14 wherein the step of positioning a completion assembly around a section of the drill string further comprises establishing a fluid seal between the completion assembly and the drill string to prevent fluid migration therebetween.

17. The method as recited inclaim 14 wherein the step of positioning a completion assembly around a section of the drill string further comprises rotatably coupling the completion assembly to the drill string to prevent torque transfer therebetween.

18. The method as recited inclaim 14 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises rotating the drill bit by operating a downhole motor.

19. The method as recited inclaim 14 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises rotating the drill bit by rotating the drill string.

20. The method as recited inclaim 14 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises extending the wellbore beyond the end of a casing in the wellbore.

21. The method as recited inclaim 20 further comprising the step of supportably coupling the completion assembly to the casing with a suspension tool.

22. The method as recited inclaim 14 further comprising the step of installing a production tubing relative to the completion assembly providing for fluid communication therebetween.

23. A method of completing a wellbore while drilling comprising the steps of:

disposing a drill bit on an end of a drill string;

positioning a completion assembly including a sand control screen and a gravel packing assembly around a section of the drill string;

extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly;

ceasing the advancement of the drill string when the completion assembly has reached a desired depth; and

gravel packing the wellbore around the sand control screen and the gravel packing apparatus.

24. The method as recited inclaim 23 further comprising the steps of disconnecting the drill string from the drill bit and retrieving the drill string to the surface leaving the completion assembly and the drill bit downhole.

25. The method as recited inclaim 23 wherein the step of positioning a completion assembly around a section of the drill string further comprises establishing a fluid seal between the completion assembly and the drill string to prevent fluid migration therebetween.

26. The method as recited inclaim 23 wherein the step of positioning a completion assembly around a section of the drill string further comprises rotatably coupling the completion assembly to the drill string to prevent torque transfer therebetween.

27. The method as recited inclaim 23 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises rotating the drill bit by operating a downhole motor.

28. The method as recited inclaim 23 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises rotating the drill bit by rotating the drill string.

29. The method as recited inclaim 23 wherein the step of extending the wellbore by rotating the drill bit and advancing the drill string without rotating the completion assembly further comprises extending the wellbore beyond the end of a casing in the wellbore.

30. The method as recited inclaim 29 further comprising the step of supportably coupling the completion assembly to the casing with a suspension tool.

31. The method as recited inclaim 23 further comprising the step of installing a production tubing relative to the completion assembly providing for fluid communication therebetween.

32. A method of completing a wellbore while drilling comprising the steps of:

disposing a drill bit on an end of a drill string;

positioning a completion assembly including an expandable screen around a section of the drill string;

establishing a fluid seal and a rotatable coupling between the completion assembly and the drill string to prevent fluid migration and torque transfer therebetween;

extending the wellbore by rotating the drill bit and advancing the drill string beyond the end of a casing in the wellbore without rotating the completion assembly;

ceasing the advancement of the drill string when the completion assembly has reached a desired depth;

supportably coupling the completion assembly to the casing with a suspension tool;

disconnecting the drill string from the drill bit;

retrieving the drill string to the surface leaving the completion assembly and the drill bit downhole; and

expanding the expandable screen.

33. A method of completing a wellbore while drilling comprising the steps of:

disposing a drill bit on an end of a drill string;

positioning a completion assembly including a sand control screen and a gravel packing apparatus around a section of the drill string;

establishing a fluid seal and a rotatable coupling between the completion assembly and the drill string to prevent fluid migration and torque transfer therebetween;

extending the wellbore by rotating the drill bit and advancing the drill string beyond the end of a casing in the wellbore without rotating the completion assembly;

ceasing the advancement of the drill string when the completion assembly has reached a desired depth;

supportably coupling the completion assembly to the casing with a suspension tool;

disconnecting the drill string from the drill bit;

retrieving the drill string to the surface leaving the completion assembly and the drill bit downhole; and

gravel packing the wellbore around the sand control screen and the gravel packing apparatus.

34. An apparatus for completing a wellbore while drilling comprising:

a drill string;

a drill bit mounted on an end of the drill string; and

a completion assembly positioned around a section of the drill string, whereby the wellbore is extended by rotating the drill bit and advancing the drill string without rotating the completion assembly and the advancement of the drill string is ceased when the completion assembly has reached a desired depth.

35. The apparatus as recited inclaim 34 wherein the drill string is removable from the completion assembly and the drill bit such that the drill string is retrievable to the surface leaving the completion assembly and the drill bit downhole.

36. The apparatus as recited inclaim 34 wherein the completion assembly further comprises an expandable screen and wherein the expandable screen is expanded after the completion assembly has reached the desired depth.

37. The apparatus as recited inclaim 34 wherein the completion assembly further comprises a sand control screen and a gravel packing assembly and wherein the wellbore around the sand control screen and the gravel packing apparatus is gravel packed after the completion assembly has reached the desired depth.

38. The apparatus as recited inclaim 34 wherein the completion assembly further comprises a seal member that is coupled to the drill string to prevent fluid migration therebetween.

39. The apparatus as recited inclaim 34 wherein the completion assembly further comprises a rotatable coupling that is coupled to the drill string to prevent torque transfer therebetween.

40. The apparatus as recited inclaim 34 further comprising a downhole motor that drives the rotation of the drill bit.

41. The apparatus as recited inclaim 34 further comprising a suspension tool that supportably couples the completion assembly to a casing within the wellbore.

Images