DEVICE

BACKGROUND

[0001] The present disclosure relates generally to a system for running an expandable patch within a well, and more particularly to a wireline tractor system capable of installing the expandable patch in a horizontal portion of the well.

[0002] When a flow control device in a horizontal well produces an unwanted fluid, such as water or gas, it may be desirable for an operator to install a patch over the flow control device to limit leakage of the unwanted fluid into the horizontal well. When a patch is installed within a wellbore, a logging run may be performed to identify a location of the leak and a subsequent run is performed to place a patch within the well at the leak location. This may result in high time costs, uncertain placement of the patch in relation to the leak location, and an inability of a wireline system to perform additional runs to additional locations downhole from a previously installed patch.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Illustrative embodiments of the present invention are described in detail below with reference to the attached figures, which are incorporated by reference herein, wherein: [0004] FIG. 1 is a schematic view of a system for running an expandable patch within a well;

[0005] FIG. 2A is a perspective view of a bistable rigid sealing device in a collapsed state;

[0006] FIG. 2B is a perspective view of the bistable rigid sealing device of FIG. 2A in an expanded state;

[0007] FIG. 3 is a schematic view of the system of FIG. 1 while installing the expandable patch within the well; and

[0008] FIG. 4 is a schematic view of the system of FIG. 1 after installing the expandable patch within the well while the system is removed from the well.

[0009] The illustrated figures are only exemplary and are not intended to assert or imply any limitation with regard to the environment, architecture, design, or process in which different embodiments may be implemented.

DETAILED DESCRIPTION

[0010] In the following detailed description of several illustrative embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the embodiments described herein may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments described herein, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the invention. To avoid detail not necessary to enable those skilled in the art to practice the embodiments described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative embodiments are defined only by the appended claims.

[0011] Unless otherwise specified, any use of any form of the terms "connect," "engage," "couple," "attach," or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. Further, any use of any form of the terms "connect," "engage," "couple," "attach," or any other term describing an interaction between elements includes items integrally formed together without the aid of extraneous fasteners or joining devices. In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to". Unless otherwise indicated, as used throughout this document, "or" does not require mutual exclusivity.

[0012] The subject matter disclosed in the present application provides a system that enables high precision installation of one or more patches within a horizontal well. As referenced herein, a horizontal wellbore is intended to include wellbores having segments of bore that are horizontal, or in which an uphole portion of a well segment is below a downhole portion of the well segment. In the foregoing context, "uphole" means closer to the surface of the well when traveling along the path of the wellbore. In specific applications, the system includes a wireline tractor system capable of determining a location in the well that is producing an unwanted fluid and installing an expandable patch at the determined location. In this manner, the system is able to prevent or limit flow of unwanted fluids into the horizontal wellbore. rnmn via i i _{s a} schematic view of a system 100 for running an expandable patch 102 within a well 104. The system 100 includes a group of tools used to block flow from a flow control device 106A in a horizontal portion 108 of the well 104. The flow control device 106A (and flow control device 106B) is shown as a representative point of ingress of an unwanted wellbore fluid, such as water or gas, into the well 104. The system may alternatively be used to block flow into a ruptured tubing segment or casing, failed joint or other permeation that allows unwanted fluid to enter a production string 124 or wellbore casing 122. Additionally, the system may be used to bridge a damaged section of the tubing, such as damage from excessive corrosion. To that end, it is noted that the embodiments described herein are generally described as operable to prevent the ingress of unwanted fluid into the production string, but the embodiments and methods may alternatively be employed to seal an unwanted point of ingress into any tubular segment in which a wireline may be deployed, such as a wellbore casing, a completion string, or other type of tubing string.

[0014] Referring again to the embodiment of FIG. 1 , the system 100 provides the ability to block flow of the unwanted fluid from the flow control device 106A into the well 104. Multiple flow control devices 106A and 106B may also be located in a zone, and the system 100 may be operable to block flow of unwanted fluid from both of the flow control devices 106A and 106B in a single trip. Moreover, in addition to blocking the flow of unwanted fluid, the system may be deployed to partially block production from a wellbore zone by blocking some of the flow control devices 106A and 106B within the zone. As such, the system 100 may also be deployed to reduce flow within a zone in the interests of achieving more even drainage of a reservoir 1 10.

[0015] The system 100 in the illustrated embodiment includes a tractor 112, hydraulic pump 1 14, a setting tool 116 (e.g., a hydraulic setting tool, a mechanical setting tool, or an inflatable packer), the expandable patch 102, a locator 1 18 (e.g., a casing-collar locator (CCL), gamma ray detector, or a magnetic field detector), all run on an electric wireline (E-line) 120. The tractor 1 12 is operable to pull the wireline 120 through an open hole or casing 122 into the horizontal portion 108 of the well 104, and the locator 118 is operable to determine the location of a location of ingress of an unwanted fluid or other ruptured component of the production string 124. In some embodiments, the locator 1 18 is a casing-collar locator operable to determine the location of a leaking flow control device 106A or 106B. [0016] In response to the locator 118 determining the location of the leaking flow control device 106A or 106B, a controller coupled to the tractor and the locator instructs the tractor 112 to provide a locomotive force to position the expandable patch 102 adjacent to the leaking flow

06A or 106B. Once appropriately positioned, the controller is operable to actuate the setting tool 116 to induce expansion of the expandable patch 102, which in turn is operable to seal the leaking flow control device 106A or 106B upon expansion. The expandable patch 102 may be used to block flow from a variety of types flow control devices 106, such as inflow control devices (ICDs), autonomous inflow control devices (AICDs), inflow control valves (ICVs), autonomous inflow control valves (AICVs), injection ports, sliding sleeve doors (SSDs), screen joints, or any other device that creates a flow path from an outer diameter of well tubing (e.g., the production string 124) to an inner diameter of the well tubing. Power may be provided downhole to the foregoing system components, and other components of the system by the wireline 120. [0017] In some embodiments, the expandable patch 102 includes an expandable rigid sealing device 200, as described in detail with respect to FIGS. 2A and 2B. An elastomer sealing layer may be molded, glued, or mechanically attached to an outer diameter of the expandable rigid sealing device 200 on either end, or over an entire length of the expandable rigid sealing device 200. The expandable rigid sealing device 200 may be a high expansion tubular member, as described with respect to FIGS. 2A and 2B, or a solid tubular member having an expansion ratio of up to approximately 20%. The elastomer sealing layer surrounding the expandable rigid sealing device 200 may be formed from any number of conformable, closed cell materials such as simple HNBR (hydrogenated nitrile butadiene rubber) or swellable rubber. An outer diameter of the elastomer may be smooth or have ribs, in some examples, the expandable rigid sealing device may have a bistable property (e.g., FIGs. 2A and 2B illustrated and discussed below). The term "bistable" as used herein, refers to a change in the expansion force relative to the amount of expansion. As an example, the expansion force needed to expand a bistable device may decrease once a certain expansion distance is reached. As another example, the rate of increase of the expansion force needed to expand a bistable device may decrease once a certain expansion distance is reached.

[0018] The expandable patch 102 may also be a two part system with a truss or mesh support structure that is expandable to provide mechanical support to the elastomer sealing layer. In some embodiments, the setting tool 116, which may be an inflatable packer, is operable to expand the expandable patch 102 upon being actuated by an actuator (e.g., hydraulic pump 114). In another embodiment, the setting tool used to expand the expandable patch 102 is a downhole power unit (DPU) with a cone that is pulled through the expandable patch 102 to mechanically expand the expandable patch 102. In additional embodiments, the expandable patch 102 is expanded using a combination of mechanical and hydraulic actuation. Such expansion may be g a hydraulic section that pulls and/or pushes a mechanical cone through the expandable patch 102, or a DPU that pulls and/or pushes an inflatable device through the expandable patch 102.

[0019] Although a hydraulic pump 114 is illustrated as the actuator, it is to be understood that any sufficient actuator may be used to actuate the setting tool, for example, an electric linear actuator. As discussed above, actuators may be hydraulic pumps, electric linear actuators (e.g., the DPU discussed above), electro-mechanical actuators, or any sufficient actuator for actuation of the setting tool 1 16 as would be readily apparent to one of ordinary skill in the art.

[0020] Flow control devices 106, such as ICDs, are mounted on an exterior of a perforated base pipe (e.g., a perforated segment of the production string 124). Locating the flow control devices 106 may be accomplished using a variety of tools and methods. For example, a casing-collar locator (CCL) may be used as the locator 1 18 to locate masses of housings of the flow control devices 106 or a physical location from each coupling of the flow control devices 106. A mechanical caliper tool may also be used as the locator 1 18 to locate perforations on the inner diameter of the casing 122. An additional embodiment uses cup seals that seal against the inner diameter of the tubing as the system 100 is run down the well 104. Location at the perforations within the well 104 are verified by loss of pressure between the cup seals of the locator 1 18.

[0021] Turning to FIG. 2A, a perspective view of the bistable rigid sealing device 200 of the expandable patch 102 in a collapsed state is depicted. The bistable rigid sealing device 200 is surrounded by an elastomeric sealing layer 204 and is insertable into the well 104 at a desired depth within the well 104. For example, the bistable rigid sealing device 200 is positioned in line with the flow control device 106 that is experiencing a leak. Upon expansion of the bistable rigid sealing device 200, the bistable rigid sealing device 200 is able to stop or reduce flow from the leak at the flow control device 106.

[0022] FIG. 2B is a perspective view of the bistable rigid sealing device 200 in an expanded state, with the elastomeric sealing layer 204 hidden. As the bistable rigid sealing device 200 expands, gaps 202 are formed in the sealing device 200. The elastomeric properties of the elastomeric sealing layer 204 allow the elastomeric sealing layer 204 to expand within rupturing to form a seal against the applicable flow control device or other leak within the well 104. The elastomeric sealing layer 204 thereby covers the gaps 202 with a reinforced elastomeric material that does not extrude through the gaps 202 when experiencing the pressure from the leak within the well. While FIGS. 2A and 2B illustrate a specific example of the bistable rigid sealing device 200. the bistable rigid sealing device 200 used in the system 100 may also include a tubular device made of a solid material (e.g., without generating the gaps 202 upon expansion). The tubular device made of a solid material, however, may not provide as great of an expansion ratio as an expansion ratio available to the illustrated bistable rigid sealing device 200.

[0023] FIG. 3 is a schematic view of the system 100 in operation while installing the expandable patch 102 is deployed within the well 104. In the illustrated embodiment, the locator 1 18 locates the leaking flow control device 106B, and the tractor 1 12 positions the expandable patch 102 in an appropriate position to seal the leaking flow control device 106B. As illustrated, the hydraulic pump 114 inflates the setting tool 1 16 (here, an inflatable packer) to force the expandable patch 102 into a sealing contact with the tubing of the production string 124 and/or with the leaking flow control device 106B. Once in contact with the tubing segment and/or with the leaking flow control device 106B, the expandable patch 102 blocks flow of fluids from the flow control device 106B.

[0024] FIG. 4 is a schematic view of the system 100 after installing the expandable patch 102 within the well 104 while the system 100 is removed from the well 104. Upon installation of the expandable patch 102, the hydraulic pump 114 deflates the inflatable packer 116 to remove contact between the inflatable packer 1 16 and the expandable patch 102. As the system 100 is removed from the well 104 using an application of uphole force on the E-line 120, the expandable patch 102 remains in sealing contact with the flow control device 106B.

[0025] When the system 100 returns to the surface, an additional expandable patch 102 may be positioned around the inflatable packer 116 for another run downhole within the well 104. In another embodiment, the system 100 may include several inflatable packers 116 and expandable patches 102. In such an embodiment, the system 100 is deployed downhole within the well 104, and each of the expandable patches 102 may be installed within the well 104 at different flow control devices 106 or casing leak locations all in a single run within the well 104. [0026] Further, when the expandable patches 102 are installed within the well 104, the expansion of the expandable patches 102 may be sufficient to allow passage of the system 100 in an unexpanded state. For example, when the flow control device 106B is patched with the expandable patch 102, a subsequent run into the well to a flow control device 106 further downhole from the flow control device 106B is enabled without restricting passage of the system 100. In other embodiments, the system 100 may provide an expandable patch 102 that also plugs the well 104 at the location of the expandable patch 102. In such an embodiment, the expandable packer 116 mav be positioned on a downhole end of the system 100 such that the expandable packer 116 is positioned and maintained in a desired downhole location to provide a plugging mechanism within the well 104. Such an embodiment may be accomplished with or without the addition of the expandable patch 102 surrounding the expandable packer 116.

[0027] It is also to be recognized that the disclosed systems and methods of use may also directly or indirectly affect the various downhole equipment and tools that may contact the components of the disclosed systems and methods of use. Such equipment and tools may include, but are not limited to, wellbore casing, wellbore liner, completion string, insert strings, drill string, coiled tubing, slickline, wireline, drill pipe, drill collars, mud motors, downhole motors and/or pumps, surface-mounted motors and/or pumps, centralizers, turbolizers, scratchers, floats (e.g., shoes, collars, valves, etc.), logging tools and related telemetry equipment, actuators (e.g., electromechanical devices, hydromechanical devices, etc.), sliding sleeves, production sleeves, plugs, screens, filters, flow control devices (e.g., inflow control devices, autonomous inflow control devices, outflow control devices, etc.), couplings (e.g., electro-hydraulic wet connect, dry connect, inductive coupler, etc.), control lines (e.g., electrical, fiber optic, hydraulic, etc.), surveillance lines, drill bits and reamers, sensors or distributed sensors, downhole heat exchangers, valves and corresponding actuation devices, tool seals, packers, cement plugs, bridge plugs, and other wellbore isolation devices, or components, and the like. Any of these components may be included in the systems generally described above and depicted in FIGs. 1- 4. [0028] Provided are systems to seal a portion of a well in accordance with the disclosure and the illustrated FIGs. An example system comprises an electric wireline; a position locator powered by the electric wireline; a setting tool; an expandable patch positioned adjacent the setting tool, wherein the expandable patch is configured to restrict the flow of fluid into a tubing segment at a determined location upon installation within a deviated wellbore; an actuator configured to actuate the setting tool to install the expandable patch at the determined location within the non- vertical well, wherein the actuator is controlled by the electric wireline; and a tractor configured to transport the system along the horizontal well, wherein the tractor is powered by the electric wireline.

[0029] Additionally or alternatively, the system may include one or more of the following features individually or in combination. The position locator may be operable to provide the determined location, and wherein the determined location corresponds to the position of a flow control device within a wellbore. The setting tool may be selected from the group consisting of ng tool, a mechanical setting tool, and an inflatable packer. The expandable patch may comprise a bistable rigid sealing device surrounded by an elastomer sealing layer. The flow control device locator may be a casing-collar locator. The system may comprise a second inflatable packer and a second expandable patch. The system may be configured to decrease the flow of fluid from at least two of the flow control devices in a single run into the non-vertical well.

[0030] Provided are methods of forming a seal within a wellbore in accordance with the disclosure and the illustrated FIGs. An example method comprises deploying a wireline to the wellbore using a tractor, the tractor being coupled to and powered by the wireline; operating a position locator of the wireline to locate a position within the wellbore; operating the tractor to position an expandable patch and a setting tool at the located position; and actuating the setting tool to cause expansion of the expandable patch, wherein expansion of the expandable patch causes the expandable patch to seal the wellbore at the location.

[0031] Additionally or alternatively, the system may include one or more of the following features individually or in combination. The position locator may be operable to provide the determined location, and wherein the determined location corresponds to the position of a flow control device within a wellbore. The setting tool may be selected from the group consisting of a hydraulic setting tool, a mechanical setting tool, and an inflatable packer. The expandable patch may comprise a bistable rigid sealing device surrounded by an elastomer sealing layer. The flow control device locator may be a casing-collar locator. The system may comprise a second inflatable packer and a second expandable patch. The system may be configured to decrease the flow of fluid from at least two of the flow control devices in a single run into the non-vertical well. The method may further comprise operating an actuator to actuate the setting tool to install the expandable patch within the non-vertical well, wherein the actuator is controlled by the electric wireline. The locating the position may comprise locating the position of a flow control device within a wellbore. The setting tool may be selected from the group consisting of a hydraulic setting tool, a mechanical setting tool, and an inflatable packer. The expandable patch may comprise a bistable rigid sealing device surrounded by an elastomer sealing layer. The position locator may be a casing-collar locator. The expandable patch may comprise a first expandable patch and a second expandable patch, and wherein the setting tool comprises a first setting tool and a second setting tool, and wherein the second setting tool is operable to actuate the second expandable patch. The method may further comprise operating the position locator to locate a second position within the wellbore; operating the tractor to position the second expandable patch at the second position without withdrawing the wireline from the wellbore; and

;cond setting tool to cause expansion of the second expandable patch, wherein expansion of the second expandable patch causes the second expandable patch to seal the wellbore at the second location.

[0032] Provided are systems to seal a portion of a production string in accordance with the disclosure and the illustrated FIGs. An example system comprises an electric wireline; a position locator powered by the electric wireline; a setting tool; an expandable patch positioned adjacent the setting tool, wherein the expandable patch is configured to restrict the flow of fluid into a tubing segment of the production string at a determined location upon installation downhole from a horizontal portion of the production string; an actuator configured to actuate the setting tool to install the expandable patch at the determined location within the production string, wherein the actuator is controlled by the electric wireline; and a tractor configured to transport the system along the horizontal well, wherein the tractor is powered by the electric wireline.

[0033] Additionally or alternatively, the system may include one or more of the following features individually or in combination. The position locator may be operable to provide the determined location, and wherein the determined location corresponds to the position of a flow control device within a wellbore. The setting tool may be selected from the group consisting of a hydraulic setting tool, a mechanical setting tool, and an inflatable packer. The expandable patch may comprise a bistable rigid sealing device surrounded by an elastomer sealing layer. The flow control device locator may be a casing-collar locator. The system may comprise a second inflatable packer and a second expandable patch. The system may be configured to decrease the flow of fluid from at least two of the flow control devices in a single run into the non-vertical well. The position locator may be operable to provide the determined location, and wherein the determined location corresponds to the position of a flow control device within the production string. The setting tool may be selected from the group consisting of a hydraulic setting tool, a mechanical setting tool, and an inflatable packer. The expandable patch may comprise a bistable rigid sealing device surrounded by an elastomeric sealing layer. The system may comprise a second inflatable packer and a second expandable patch, wherein the system is configured to decrease the flow of fluid from at least two of the flow control devices in a single run into the production string.

[0034] The preceding description provides various embodiments of the apparatuses, systems, and methods disclosed herein which may contain different method steps and alternative combinations of components. It should be understood that, although individual embodiments may be discussed herein, the present disclosure covers all combinations of the disclosed deluding, without limitation, the different component combinations, method step combinations, and properties of the system.

[0035] It should be understood that the compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps. The compositions and methods can also "consist essentially of or "consist of the various components and steps. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the element that it introduces.

[0036] Therefore, the present embodiments are well adapted to attain the ends and advantages mentioned, as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, the invention covers all combinations of all those embodiments. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the present invention.