Embodiments usable within the scope of the present disclosure relate, generally, to systems and methods usable to penetrate and/or otherwise overcome a downhole target and/or obstruction in a wellbore, and more specifically, to devices and methods for projecting a medium in a direction generally parallel to the axis of a wellbore (e.g., in an uphole or downhole direction) to remove, reduce, and/or otherwise affect debris, a downhole tool, or other similar obstructions and/or restrictions, and to subsequently retrieve debris resulting from such operations when desired.
When drilling, completing, and/or otherwise forming or operating on a wellbore, it is often necessary to install and/or set devices that block, seal, restrict, or isolate a portion of the wellbore. For example, sub surface safety valves (which typically include a flapper valve), are deployed to restrict the egress of lower zoned material (e.g., oil and gas); however, it is common for flapper valves to become blocked or otherwise hindered or prevented from opening, preventing production or other operations. In other situations, foreign objects (e.g., “fish”), debris, and/or other objects, can become lodged within a wellbore, especially at restrictions in a wellbore. Such items can often present difficulties in their removal due to the lack of fixation of the object in the wellbore and/or the material of the object (e.g., Inconel, Hastalloy, etc.)
Conventional methods for removing downhole obstructions include use of jars to apply a physical/mechanical force to such obstructions, pigs or similar fluid jetting systems typically used to clean a conduit (e.g., to remove paraffin or similar substances), and other similar systems that generally rely on physical/mechanical force to forcibly move an obstruction.
Prior-filed U.S. application Ser. No. 13/815,614 relates to apparatus and methods for at least partially removing an obstruction (e.g., a downhole target) from a wellbore, e.g., by penetrating the downhole target with a medium, such as molten fuel, a perforating jet or object, a blade, a corrosive medium, or other similar means for eroding, penetrating, perforating, and/or otherwise overcoming a blockage or restriction. The nozzle geometry of such a device can be varied depending on the nature of the wellbore, the medium used, and the downhole target, to facilitate overcoming the obstruction, and when desired and/or necessary, an operation may include multiple trips in which each successive trip utilizes an apparatus having a different nozzle geometry to progressively remove an obstacle and/or enlarge an opening.
A need exists for apparatus and methods for removing certain types of obstructions, such as flapper valves and other types of downhole tools, using a reduced number of trips. For example, certain types of obstructions, such as flapper valves, could be penetrated and/or otherwise affected in a manner that allows the resulting pieces to fall into the wellbore, rather than progressively enlarging a flowpath through the center of the flapper value.
Many downhole tools, including flapper valves, are conventionally formed from inconel, stainless steel, and/or other generally non-ferromagnetic materials, due primarily to the fact that ferromagnetic materials can interfere with the operation of various downhole equipment, while attracting wellbore debris (e.g., filings, cuttings, etc.) that can cause deposits, occlusions, and/or build-up within a flowpath and eventually hinder or prevent proper operation of one or more tools. Fishing and/or other methods to recover debris and/or pieces of such downhole tools are often time consuming, cumbersome, and difficult.
A need also exists for apparatus and methods usable to facilitate removal of debris and/or pieces from downhole tools, e.g., using magnetic means.
Embodiments usable within the scope of the present disclosure meet these needs.
Embodiments of the present disclosure relate generally to apparatus and methods usable for penetrating a downhole target (e.g., a flapper valve, a packer, a setting tool, or a similar sealing/isolating device, a safety valve, or any other type of restriction, obstruction, debris, etc.) within a wellbore. The apparatus can include a body having a longitudinal axis, a medium (e.g., a fuel load, such as thermite, a linear shaped charge, other types of explosive devices, blades, solid, fluid, and/or molten perforating materials, corrosive materials, or combinations thereof) associated with the body, and a nozzle at an end of the body. The nozzle can be adapted to project the medium in a direction generally parallel to the longitudinal axis of the body. An actuator can be provided in communication with the medium, such that actuation of the actuator causes projection of the medium through the nozzle. As such, embodiments usable within the scope of the present disclosure can project a medium in a downhole and/or uphole (e.g., axial) direction within a wellbore, enabling the apparatus to be placed above a blockage in a wellbore, beneath a safety valve or similar sealing device, and/or otherwise in association with a blockage or other type of obstruction that may later be overcome or removed.
The nozzle can be provided with a geometry that is configured to separate a downhole target into at least two portions, e.g., by projecting the medium in a pattern capable of separating the downhole target. For example, in an embodiment, the nozzle can have at least two slots therein, oriented such that projection of the medium separates the downhole target into a plurality of wedge-shaped portions. Such an embodiment can be used, e.g., to remove a flapper valve from a wellbore, using a smaller number of trips than other methods of removing and/or overcoming a flapper valve. For example, separation of a flapper valve into multiple, wedge-shaped portions can cause the separated portions to fall into the wellbore, thereby overcoming the obstruction in a manner that liberates the full diameter of the wellbore, in a smaller number of trips than other alternatives.
In situations where it is desirable to retrieve the separated portions of a downhole target, embodiments usable within the scope of the present disclosure can include methods for doing so. For example, if an obstruction (e.g., a downhole tool) formed from non-ferromagnetic materials must be overcome, embodiments usable within the scope of the present disclosure can include the use of a device that projects molten thermite or a similar type of fuel that can include iron or other ferromagnetic materials. Projecting of a medium containing ferromagnetic material can adhere, coat, fuse, and/or bond the ferromagnetic material to the downhole target, e.g., by forming a ferromagnetic matrix with the material of the downhole target. The resulting association between the ferromagnetic material of the medium and the downhole target can enable the target and/or separated portions thereof to be recovered using a magnetic tool.
In an embodiment, the apparatus for penetrating a downhole target can comprise a stand-off member that can be associated with the first end of the body, wherein the stand-off member can have a dimension that provides a space between the nozzle and the downhole target. The stand-off member can be adapted to be at least partially eroded by the medium.
In an embodiment, the apparatus for penetrating a downhole target can comprise a connector that can be associated with the second end of the body, wherein the connector, a device attached to the connector, or combinations thereof, can be usable to anchor the body in a generally fixed orientation relative to the wellbore to prevent movement of the body due to actuation of the actuator, projection of the medium, or combinations thereof.
In an embodiment, a cap can be associated with the first end of the body of the apparatus and can be configured to seal the nozzle to prevent entry of contaminants. The cap can be adapted to be at least partially eroded by the medium.
Embodiments of the present invention include a method for at least partially removing an obstruction from a wellbore having an axis. The method steps include positioning a body in the wellbore at a distance from the obstruction, wherein the body can comprise a nozzle having a geometry for projecting a medium in a direction generally parallel to the axis of the wellbore, and wherein the geometry can be configured for projecting the medium in a pattern adapted to separate the obstruction into at least two portions. The method steps can continue with projecting the medium through the nozzle in the direction generally parallel to the axis of the wellbore, wherein the medium affects at least one portion of the obstruction, thereby at least partially removing the obstruction from the wellbore.
In an embodiment, the method step of positioning the body at the distance from the obstruction can comprise providing the body with a stand-off member having a dimension that provides a space between the nozzle and the obstruction.
In an embodiment, the step of consuming the fuel load to cause projection of the medium through the nozzle can cause the medium to at least partially erode the stand-off member.
The method can further comprise the step of providing a cap into association with the body, wherein the cap can be configured to seal the nozzle to prevent entry of contaminants, and wherein projecting the medium through the nozzle can at least partially erode the cap.
In an embodiment, the steps of the method can further include anchoring the body in a generally fixed orientation relative to the wellbore to prevent any movement of the body due to projection of the medium. The step of anchoring the body can comprise providing a counterforce apparatus associated with the body, wherein the step of projecting the medium through the nozzle applies a force to the body, and wherein the counterforce apparatus produces a counterforce that opposes the force such that the body remains in the generally fixed orientation relative to the wellbore. The counterforce apparatus can be provided with an output, a duration, or combinations thereof, that corresponds to the geometry of the nozzle, the force, or combinations thereof.
In an embodiment of the method, the pattern of the nozzle can comprise at least two slots, and the step of projecting the medium can separate the obstruction into a plurality of wedge-shaped portions. The medium can comprise ferromagnetic material, and the step of projecting the medium can include associating the ferromagnetic material with the obstruction, such that said at least two portions of the obstruction can be magnetically retrieved.
The embodiments of the present invention can further include a method for removing and retrieving a downhole object from a wellbore, wherein the method can comprise the steps of: contacting the downhole object with a medium comprising a ferromagnetic material, thereby associating the downhole object with the ferromagnetic material; and contacting the ferromagnetic material with a retrieval device comprising a magnetic element, thereby associating the downhole object with the retrieval device. The medium can comprise thermite, and the step of contacting the downhole object with the medium can comprise projecting molten thermite into contact with the downhole object, thereby at least partially fusing the ferromagnetic material to the downhole object.
The steps of the method can further comprise positioning a body in the wellbore at a distance from the downhole object, wherein the body comprises a nozzle having a geometry adapted to project the medium in a direction generally parallel to an axis of the wellbore, and projecting the medium through the nozzle in the direction generally parallel to the axis of the wellbore.
In an embodiment, the nozzle can comprise a geometry for projecting the medium in a pattern adapted to separate the downhole target into at least two portions associated with the ferromagnetic material. The geometry of the nozzle can comprise at least two slots, wherein the step of projecting the medium can separate the downhole object into a plurality of wedge-shaped portions associated with the ferromagnetic material. In an embodiment, the step of contacting the downhole object with the medium separates the downhole object into at least two portions associated with the ferromagnetic material.
In the detailed description of various embodiments usable within the scope of the present disclosure, presented below, reference is made to the accompanying drawings, in which:
One or more embodiments are described below with reference to the listed Figures.
Before describing selected embodiments of the present disclosure in detail, it is to be understood that the present invention is not limited to the particular embodiments described herein. The disclosure and description herein is illustrative and explanatory of one or more presently preferred embodiments and variations thereof, and it will be appreciated by those skilled in the art that various changes in the design, organization, means of operation, structures and location, methodology, and use of mechanical equivalents may be made without departing from the spirit of the invention.
As well, it should be understood that the drawings are intended to illustrate and plainly disclose presently preferred embodiments to one of skill in the art, but are not intended to be manufacturing level drawings or renditions of final products and may include simplified conceptual views to facilitate understanding or explanation. As well, the relative size and arrangement of the components may differ from that shown and still operate within the spirit of the invention.
Moreover, it will be understood that various directions such as “upper”, “lower”, “bottom”, “top”, “left”, “right”, and so forth are made only with respect to explanation in conjunction with the drawings, and that components may be oriented differently, for instance, during transportation and manufacturing as well as operation. Because many varying and different embodiments may be made within the scope of the concept(s) herein taught, and because many modifications may be made in the embodiments described herein, it is to be understood that the details herein are to be interpreted as illustrative and non-limiting.
Referring now to
Specifically, the depicted apparatus (10) is shown having an elongate, tubular body (12) having a box end (14) and a pin end (16). The pin end (16) is depicted having sealing elements (18) (e.g., O-rings or similar elastomeric and/or sealing members) associated therewith. A fuel load (20) is shown disposed within and substantially filling the central bore of the body (12). In an embodiment, the fuel load (20) can include thermite and/or a mixture of thermite and one or more polymers adapted to produce a gas and/or force as the thermite combusts, such as the power source described in U.S. Pat. No. 8,196,515 and U.S. Pat. No. 8,474,381, which are incorporated herein by reference in their entireties.
In operation, the box end (14) and/or the pin end (16) of the depicted apparatus (10) can be configured to function as a nozzle, such that when the fuel load (20) is consumed (e.g., through actuation of a thermal generator or other type of ignition source or actuator), a medium (e.g., molten thermite) is projected through the nozzle, generally parallel to the axis of the body (12). The medium can subsequently affect an obstruction within a wellbore (e.g., a flapper valve, debris, a setting tool, a restriction, or other similar types of obstacles) located in an axial direction (e.g., uphole or downhole) relative to the apparatus (10), e.g., by at least partially degrading, perforating, penetrating, and/or eroding the obstruction.
As described above, however, the depicted apparatus (10) can be used in conjunction with additional containers and/or apparatus containing additional fuel, or the depicted apparatus (10) can function as a carrier for a fuel load (20) for use by an associated apparatus. Similarly, an initiation apparatus can be threaded to and/or otherwise engaged with either end (14, 16) of the apparatus (10), and/or other attachments and/or components can be engaged with the depicted apparatus (10), such as a stand-off member, an anchor and/or attachment/latching mechanism, or other similar components, as described above and below.
Referring now to
The depicted embodiment of the apparatus (26) is shown having an insert (40) disposed within the body (28) proximate to the second end (32), which in an embodiment, can be formed from graphite or a similar material that will remain generally unaffected by the consumption of a fuel load and the projection of a medium. The insert (40) is shown having an internal bore, which is continuous with a bore through the stand-off member (36), defining a nozzle (42) at the second end (32) of the body (28). The stand-off member (26) is depicted having a seal and/or plug (44) engaged therewith, over the nozzle (42), with an associated O-ring or similar sealing member (46), such that the seal and/or plug (44) blocks the opening of the nozzle (42) while the apparatus (26) is lowered and/or otherwise positioned within the wellbore. The seal and/or plug (44) thereby prevent(s) the entry of contaminants into the nozzle (42) and body (28), until the apparatus (26) is actuated. Consumption of the fuel load (48), which in an embodiment, can include thermite and/or a thermite-polymer mixture, causes projection of a medium (e.g., molten thermite and/or gas) through the nozzle (42), which can remove and/or penetrate and/or otherwise degrade the seal and/or plug (44), and further affect an obstruction located external to the apparatus (26) (e.g., located in an axial direction proximate to the second end (32) thereof.)
It should be understood that the nozzle (42), the fuel load (48), the stand-off member (36), and other components of the apparatus (26) can be readily varied and/or provided having other dimensions, shapes, and/or forms without departing from the scope of the present disclosure. For example,
Referring now to
It should be understood that various components of the depicted apparatus (58) can be readily modified without departing from the scope of the present disclosure. For example,
Each of the embodiments shown in
In use, any of the above-described embodiments, and/or another similar apparatus configured to project a medium in an axial direction can be positioned within a wellbore (e.g., by lowering the apparatus via a conduit engaged with the upper end/top connector thereof). The apparatus can be anchored in place, such as through use of a positioning and latching system, such as that described in U.S. Pat. No. 8,616,293, which is incorporated herein by reference in its entirety. For example, a latching member can be engaged to an embodiment of the present apparatus via a connection to the upper end/top connector thereof. In other embodiments, various other types of anchors, setting tools, and/or securing devices can be used to retain the apparatus in a generally fixed position within a wellbore without departing from the scope of the present disclosure.
In a further embodiment, any of the above-described embodiments, and/or another similar apparatus can be positioned within a wellbore, facing a first direction (either uphole or downhole), while a second identical or similar apparatus can be provided, facing the opposite direction. The two apparatus can be actuated simultaneously, such that the force produced by the second apparatus (e.g., a counterforce apparatus), counteracts and/or otherwise opposes the force applied to the first apparatus by consumption of the fuel load and projection of the medium, thereby retaining both apparatus in a generally fixed position within the wellbore during use. The nozzle geometry, fuel load, and/or other characteristics of the second/counterforce apparatus can be selected based on the nozzle geometry, fuel load, and/or other expected forces associated with the first apparatus.
As described above, depending on the nature of an obstruction in a wellbore, it may be desirable to use multiple apparatus in succession, each having a differing nozzle geometry. For example,
A first apparatus (Al), such as an apparatus similar to that shown in
Following use of the first apparatus (A1), a second apparatus (A2), such as an apparatus similar to that shown in
Following use of the second apparatus (A2), a third apparatus (A3), such as an apparatus similar to that shown in
Referring now to
The apparatus (100) is shown having a generally tubular body (102) with a bore and/or cavity (104) therein, usable to contain a medium (e.g., a thermite-based fuel load or other types of media) for affecting a downhole target, such as a flapper valve. The body (102) includes a first end (104) having a nozzle (110) engaged therewith, and a second end (108) usable to engage the apparatus (100) to an adjacent component, connector, conduit, and/or other type of object.
The nozzle (110) is shown having a geometry adapted to separate a flapper valve or similar downhole object and/or obstruction into portions (e.g., wedge-shaped pieces). Specifically, the depicted nozzle (110) includes four slots (112A, 112B, 112C, 112D) extending in a radial direction and spaced generally equally about the face of the nozzle (110). A diverter (114) is positioned adjacent to the nozzle (110), toward the interior of the body (102).
In use, a medium (e.g., molten thermite) can be projected from the interior of the body (102) toward the nozzle (110), guided by the diverter (114) through the slots (112A, 112B, 112C, 112D), such that the molten thermite or similar medium that exits the apparatus (110) is projected in a pattern corresponding the position of the slots (112A, 112B, 112C, 112D), thereby affecting a downhole target by separating and/or severing the downhole target into wedge-shaped pieces generally corresponding to the portions of the nozzle (110) unoccupied by slots. For example, during typical use, projection of molten thermite through the depicted nozzle (110) would sever a flapper valve into four wedge-shaped pieces by cutting generally perpendicular slots through the valve.
For example,
Embodiments usable within the scope of the present disclosure thereby provide apparatus and methods usable to penetrate, perforate, and/or erode a target that presents a blockage, hindrance to travel, and/or inadequate flow path in a wellbore, through the projection of a medium to affect the obstruction. Embodiments can include use of nozzles having geometries adapted for separating a downhole target, such as a flapper valve, into multiple portions, and can further include methods for applying a ferromagnetic property to previously non-ferromagnetic objects to facilitate retrieval of the objects.
While various embodiments usable within the scope of the present disclosure have been described with emphasis, it should be understood that within the scope of the appended claims, the present invention can be practiced other than as specifically described herein.
The present application is a continuation-in-part application that claims the priority benefit of the prior-filed, co-pending United States patent application having U.S. patent application Ser. No. 13/815,694, filed Mar. 14, 2013, which is incorporated by reference herein in its entirety.
Number | Date | Country | |
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Parent | 13815694 | Mar 2013 | US |
Child | 15444099 | US |