This invention relates to cleaning of screens, gravel packs and formations in producing well having installed production tubing. In particular, this invention relates to methods that provide downhole acoustic cleaning.
In any typical hydrocarbon well, damage to the surrounding formation can impede fluid flow and cause production levels to drop. While many damage mechanisms plague wells, one of the most pervasive problems is particles clogging the formation pores that usually allow hydrocarbon flow. These clogging particles can also obstruct fluid pathways in screens; preslotted, predrilled, or cemented and perforated liners; and gravel packs that may line a well. Clogging particles may even restrict fluid flow in open-hole wells. Drilling mud, drilled solid invasion, or even the porous formation medium itself may be sources for these particles. In particular, in situ fines mobilized during production can lodge themselves in the formation pores, preslotted liners, screens and gravel packs, sealing them to fluid flow. Referred to as the “skin effect,” this damage is often unavoidable and can arise at any stage in the life of a typical hydrocarbon well. The hydrocarbon production industry has thus developed well-stimulation techniques to repair affected wells or at least mitigate skin-effect damage.
The two classic stimulation techniques for formation damage, matrix acidizing and hydraulic fracturing, suffer from limitations that often make them impractical. Both techniques require the operator to pump customized fluids into the well, a process that is expensive, invasive and difficult to control. In matrix acidizing, pumps inject thousands of gallons of acid into the well to dissolve away precipitates, fines, or scale on the inside of tubulars, in the pores of a screen or gravel pack, or inside the formation. Any tool, screen, liner or casing that comes into contact with the acid must be protected from its corrosive effects. A corrosion inhibitor must be used to prevent tubulars from corrosion. Also, the acid must be removed from the well. Often, the well must also be flushed with pre- and post-acid solutions. Aside from the difficulties of determining the proper chemical composition for these fluids and pumping them down the well, the environmental costs of matrix acidizing can render the process undesirable. Screens, preslotted liners and gravel packs may also be flushed with a brine solution to remove solid particles. While this brine treatment is cheap and relatively easy to complete, it offers only a temporary and localized respite from the skin effect. Moreover, frequent flushing can damage the formation and further decrease production. In hydraulic fracturing, a customized fluid is ejected at extremely high pressure against the well bore walls to force the surrounding formation to fracture. The customized gel-based fluid contains a proppant to hold the fractures open to fluid flow. While this procedure is highly effective at overcoming near-borehole skin effects, it requires both specialized equipment and specialized fluids and therefore can be costly. Fracturing can also result in particle deposition in the formation because the gels involved may leave residue in the vicinity of the fractures.
The hydrocarbon production industry developed acoustic stimulation as an alternative to the classic stimulation techniques. In acoustic stimulation used for near-well bore cleaning, high-intensity acoustic waves transfer vibrational energy to the solid particles clogging formation pores. The ensuing vibrations of the solid particles loosen them from the pores. Production-fluid flow out of the formation in producing wells causes the solid particles to migrate out of the pores, clearing the way for greater production-fluid flow. In injection wells, either injection-fluid flow or production-fluid flow can flush the loosened solid particles from the pores. Acoustic stimulation may also be used to clean preslotted and predrilled liners, screens and gravel packs. Near-well bore cleaning by acoustic stimulation has shown great promise in laboratory experiments, and the industry has developed several tools using this technique for use in real-world wells.
One type of acoustic tool that has been described employs an oval configuration. In an oval configuration, the tool has a cylindrical housing with a set of piezoelectric drivers mounted a various locations around the side walls of the housing. Separate control signals are used to activate the individual piezoelectric drivers according to a desired mode of operation. According to one exemplary oval mode configuration, four divers are position equidistant around the circumference of the housing. A four divers make up two sets with two drivers in each set. In each set of drivers, the drivers are positioned exactly opposite from each other on the housing. During operation, a first set of drivers is activated to pull outwardly on the sidewall of the housing, while the second set of drivers is activated to push inwardly on the housing. According to separate control signals, the drivers are then activated to push/pull in the opposite directions. In particular, the first set of drivers is activated to push inwardly on the sidewall of the housing, while the second set of drivers is activated to pull outwardly on the housing. As the piezoelectric drivers vibrate, the housing flexes between an oval having its major axis along the first set of drivers and an oval having its major axis along the second set of drivers. The radiated energy is strongest at the antinodes (the wall locations intersected by the diameters having maximum deflection. Midway between the antinodes on the wall are locations that remain stationary during vibration. The stationary points are nodes. Depending on the wall thickness and the material properties of the housing and the size of the piezoelectric drivers, the drivers may be activated at a frequency equal to a harmonic frequency of the housing so that the amplitude of deflection is maximized.
The lowest frequency oval mode has four antinodes and four nodes. Higher-order oval modes have even integer numbers of antinodes and nodes (six, eight, etc.). While it is theoretically possible to operate a tool with any order of oval mode resonance by driving the tool at the resonant frequency of that order of mode, practical limits on electrical impedance matching and driver placement constrain the number of useful driving frequencies.
This invention relates to cleaning of screens, gravel packs and formations in producing well having installed production tubing. In particular, this invention relates to methods and apparatuses that provide downhole acoustic cleaning.
The invention provides a method for generating acoustic waves, the method having the following steps: extending a tine from a support structure so that a proximal end of the tine is attached to the support structure and a distal end of the tine is uninhibited; positioning an oscillator so as to be supported by the support structure and to mechanically communicate with the tine; and oscillating the tine with the oscillator.
According to a further aspect of the invention, there is provided a method for generating acoustic waves, the method having: extending two tines from a support structure so that proximal ends of the two tines are attached to the support structure and distal ends of the two tines are uninhibited; positioning an oscillator so as to be supported by the support structure and to mechanically communicate with the two tines; and oscillating the two tines with the oscillator.
The invention also provides a system for generating acoustic waves, the system having the following components: a support structure; a tine extending from the support structure so that a proximal end of the tine is attached to the support structure and a distal end of the tine is uninhibited; and an oscillator in mechanical communication with the tine.
According to another aspect of the invention, there is provided a system for generating acoustic waves, the system having: a support structure; two tines extending from the support structure so that proximal ends of the two tines are attached to the support structure and distal ends of the two tines are uninhibited; and an oscillator in mechanical communication with the two tines.
According to yet another aspect of the invention, there is provided a system for generating acoustic waves, the system having: a support structure; a tine extending from the support structure so that a proximal end of the tine is attached to the support structure and a distal end of the tine is uninhibited; and a means for oscillating the tine, wherein the means for oscillating is in mechanical communication with the tine.
The objects, features, and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the exemplary embodiments which follows.
The present invention may be better understood by reading the following description of non-limitative embodiments with reference to the attached drawings wherein like parts of each of the several figures are identified by the same referenced characters, and which are briefly described as follows.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, as the invention may admit to other equally effective embodiments.
This invention relates to cleaning of screens, gravel packs and formations in producing well having installed production tubing. In particular, this invention relates to methods and apparatuses that provide downhole acoustic cleaning.
Referring to
The activator housing 2 contains a piezoelectric stack 5 and a temperature compensated backing mass 6. In alternative embodiments, magnetostrictive devices are used to stimulate the tool. The piezoelectric stack 5 and backing mass 6 are sandwiched between a force plate 7 and a Bellville washer 8. A preloaded bolt 9 extends through the Bellville washer 8, the backing mass 6, the piezoelectric stack 5, and into the force plate 7. In the embodiment illustrated, the preloaded bolt 9 also extends through a hole in the side of the activator housing 2. The interior of the activator housing 2 is also filled with a pressure balanced fluid 10. The activator housing 2 also has two seals 11 to retain the pressure balanced fluid 10, wherein the seals 11 are near the position where the activator housing 2 is connected to the shaft 4. Tuning fork tines 12 are also attached to the activator housing 2 near the seals 11. In the illustrated embodiment, the acoustic stimulation tool 1 has two tuning fork tines 12. The tuning fork tines 12 and seals 11 are positioned on opposite sides of the shaft 4. Two force rods 13 extend from the force plate 7 and through the seals 11. The force rods 13 engage moment arms 14, which extend from the tuning fork tines 12 towards the shaft 4. The tuning fork tines 12 are mounted to the activator housing 2 like cantilever beams so that the distal ends of the tuning fork tines 12 are free to deflect or move.
The outside diameter of the activator housing 2 is approximately equal to the outside diameter of the tool body 3. The tuning fork tines 12 are attached to the activator housing 2 at a position radially inward from the outside diameter of the activator housing 2. In embodiments of the invention where the tuning fork tines 12 are parallel to the longitudinal central axis of the acoustic stimulation tool 1, the position of the attachment of the tuning fork tines 12 relative to the activator housing 2 provides a tool wall standoff 15. The tool wall standoff provides room for the tuning fork tines 12 to vibrate when the acoustic stimulation tool 1 is pressed firmly against the inside diameter of a production tubing or other surface, not shown. In one embodiment of the invention, the outside diameters of the activator housing 2 and the tool body 3 is about 2.5 inches and the tool wall standoff 15 is about 0.2 inches. The tuning fork tines 12 extend from the activator housing 2 toward the tool body 3 but may stop short of contact therewith. In certain embodiments, a tool body standoff 16 exists between the distal ends of the tuning fork tines 12 and the tool body 3. In one embodiment of the invention, the tool body standoff 16 is 0.05 inches.
The acoustic stimulation tool 1 is operated by applying power and/or a control signal to the piezoelectric stack 5. The piezoelectric stack 5 expands and contracts according to the period of the control signal. The periodic movement of the piezoelectric stack 5 applies a periodic force to the force rods, which in turn apply a periodic force to the moment arms of the tines 12. The tines 12 are thereby excited and vibrate periodically to acoustically radiate a pressure wave pattern from the tool to the surroundings.
Referring to
A further embodiment of the invention is illustrated with reference to
In certain alternative embodiments, one of the tines illustrated in
A perspective view of a dual tine embodiment of the invention is shown in
A perspective view of a single tine embodiment of the invention is shown in
Referring to
In alternative embodiments of the invention, a single tine extends from the support housing and the piezoelectric stack is oriented transversely between the tine and a portion of the support housing. In certain embodiments of the invention, the piezoelectric stack oscillates the tines by pushing the tines transversely to cause the tine to vibrate or oscillate.
The illustrated embodiments are described herein as employing piezoelectric devices. However, in alternative embodiments of the invention, magnetostrictive devices are used.
Because the tines 12 are attached at their proximal ends to the housing and are free to move at their distal ends, the tines behave like cantilevers. The shape, size, weight, etc. of the tine define how the tine vibrates in response to forces applied to the moment arm of the tine by the force rod. This vibrational motion of the tine imparts momentum to the acoustic stimulation tool and may result in relatively small amplitude for the tine. Thus, care should be taken to ensure that the vibrational motion of the tine(s) is not dampened significantly by the other structures of the acoustic stimulation tool.
Certain dual tine configurations of the present invention have two lowest order modes of vibration. The conventional (symmetric) mode moves both tines radially outward together and radially inward together. This symmetric motion balances momentum imparted to the remaining structures of the acoustic stimulation tool and gives relatively little tool vibration. An unconventional (asymmetric) mode moves one tine inwardly while it moves the other tine outwardly and visa versa. Tine displacement for the symmetric mode has one of the tines move as the mirror image relative to the motion of the same tine in the asymmetric mode (assuming the motions for the other tines are controlled to be identical for symmetric and asymmetric modes). If one tuning fork tine moves radially outward then the other tine moves radially inward, the asymmetric mode may impart momentum to the remaining portions of the tool. Depending on the tine configuration, the asymmetric and symmetric modes may have slightly different frequencies.
Depending on the configuration of the tine, the tine may also have modes of vibration according to harmonic frequencies. The first three order modes of an exemplary tine are shown with reference to
In
In
A third order mode of oscillation is illustrated in
Higher order modes of oscillation may also be achieved by these and other tine configurations.
The axial length of the antinodes in
One embodiment of the invention uses axial piezoelectric stacks and moment arms to actuate the tines. The tine thickness and length are selected to obtain large axial length of antinodes, comparable to the width of the tine. The tool configuration has a maximum outside diameter that passes through any constriction in the candidate production tubing. The tine has a standoff of at least 0.2 inches from the formation wall during cleaning.
Therefore, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those that are inherent therein. While the invention has been depicted and described with reference to embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alternation, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.